Abstract: A substrate assembly for use with a high power switching module includes at least one power block having a base plate for providing mechanical rigidity for the power block. The power block also includes at least one silicon die mounted onto the base plate and configured to form at least one high power switching transistor having leads extending away therefrom. The power blocks are then supportably mounted into corresponding apertures in a rigid frame which mounts the power switching module onto a heat dissipating surface and tested independently before mounting into the frame at full load current and power, which cannot be performed at the bare die level.

Abstract: There is disclosed herein an accumulator for an air conditioning system. The accumulator includes a sump for collecting oil to be provided to the air conditioning compressor. There is also disclosed an outlet tube in the accumulator, the tube having a flange opening and a necked-down portion a predetermined distance from the flange opening.

Abstract: There is disclosed herein a method for forming a manifold for a heat exchanger. The method includes the steps of the forming a generally planar sheet of material into a generally cylindrical member having a seam along the longitudinal length thereof. The method further includes forming a plurality of tube receiving slots in the cylindrical member and applying a pressure against the seam so as to flatten the seam.

Abstract: A cooling module for an automotive vehicle is disclosed. The module includes a pair of bypass doors for directing a flow of air around either of the condenser or radiator in the module depending upon the demands for engine cooling, air conditioning, and any other cooling requirements. Under suitable conditions, the radiator bypass feature or the condenser bypass feature will open, providing additional cooling for the condenser or radiator respectively, in order to satisfy given cooling requirements more efficiently.

Abstract: An isolated gate driver device for a power switching device having a plurality of transistors includes a primary circuit having a voltage source of a first voltage potential. The primary circuit constantly switches the voltage source to generate first and second load signals based on control signals received from a microcontroller. The first load signal is modulated at a first frequency for enabling the transistors, and the second load signal is modulated at a second frequency, different from the first frequency, for disabling the transistors. A plurality of high frequency transformers corresponding to each of the transistors is coupled to the primary circuit. The transformers have a primary side for receiving one of the first and second load signals and a secondary side for transforming the one of the first and second load signals into corresponding signals at a second voltage potential.

Abstract: An apparatus for alignment and delivery of tubing for use in manufacture and assembly of heat exchangers used for controlling temperature conditions. The apparatus includes a drum into which bulk tubes are loaded. The drum aligns and deposits the tubes onto a conveyor which transports the tubes to a feed magazine. An alignment mechanism aligns the tubes within the feed magazine for use in the process of the assembly of the heat exchanger.

Abstract: A steering gear rack (14) for a steering system (12) of a vehicle (10) is positioned in a housing (52) with its end portions (24, 26) protruding from the housing (52) to be connected by ball joints (32) and tie rods (16) to the front wheels of the vehicle (10). The hollow steering gear rack shaft (20) defines an air passageway (22) that extends between the end portions (24, 26). Each of the end portions (24, 26) has an end face (30) and internal threads (28) on the end portion (24) extending inward from the end face (30), and a longitudinal groove (34) extending inward from the end face (30) through and past the internal threads (28) and radially outward past the internal threads (28) extending the air passageway (22) to the end face (30). The end portions of the housing (52) are fitted with rubber boots (54, 56) to protect the ball joints (32) from the environment that are connected by the air passageway (22) and longitudinal grooves (34).

Abstract: A method for making a heat exchanger tube having an elongated, generally rectangular member including a planar base, a top, and pair of arcuate opposed side portions interposed between the base and the top. A partition extends from the top to the base to define a pair of fluid passageways, the partition including a pair of opposing, contacting shoulder portions and a leg portion depending from each of the shoulder portions which contact the base. A first braze receiving of predetermined size is defined between the shoulder portions and the manifold of the heat exchanger. The size of the braze receiving area is controlled by minimizing the curvature of the shoulder portions.

Abstract: A method for forming a heat exchanger tube is disclosed. The method includes the steps of forming a pair of identical, asymmetric upper and lower members which and joining them together to form a tube. A plurality of longitudinally extending walls are also formed in the tube members. The walls form a plurality of flow paths in each tube.

Abstract: A pickup truck cab and box marrying and decking system for vehicle assembly plants is adapted to newer style pickup trucks in which portions of the box front end extend forwardly to wrap around the back corners of the cab to provide a flowing appearance. The disclosed system lifts the cab and box sections off skids on a first conveyor and transfers them to over a second conveyor bringing in a chassis frame. Measurement devices determine the position of locating fixtures on the frame. The cab and box sections are then brought together, or married, and are precisely aligned with the frame locating fixtures. The cab and box sections are then lowered to deck the married sections on the frame in precise alignment with the locating fixtures.

Abstract: A heat exchanger formed from a plurality of adjacent, contiguous plate members is disclosed. The plate members are joined together by a first and second set of tabs, the tabs being configured to bend at predefined locations. The plates are folded in a bellows-like fashion to form a heat exchanger core. The bend zones provide proper plate-to-plate contact when forming the plate tubes as well as proper fin height spacing between adjacent pairs of plate tubes.

Abstract: A ball joint assembly is disclosed which comprises a generally cylindrical housing having a recess at one end thereof with a circumferential lip, a ball element disposed in the housing, and a joint pin connected to the ball element and extending from the housing. The assembly further includes a polymeric bearing disposed over the ball element in the housing and a cover plate for sealing the ball element and bearing in the housing and preventing contaminants from entering the housing.

Abstract: The present invention is a tool for inserting an evaporator orifice tube check valve into an evaporator orifice tube. The tool uses a press pin comprising a pneumatically activated cylinder which forces the evaporator orifice tube check valve into the evaporator orifice tube a predetermined distance. The tool also includes a reciprocating cylinder which locates the valve to a proper seating depth, a signal generator which notifies the operator if the valve in a particular evaporator is not seated properly, and a marking device which creates a label on the evaporator orifice tube only if the evaporator orifice tube check valve is at the predetermined desired location.

Abstract: A method of controlling a crimp press for crimping an assembly includes the steps of placing an assembly in an open crimp die of a crimp press, advancing a ram of the crimp press to a predetermined position to close the crimp die, determining whether a pressure in the ram is within a predetermined range, and alerting an operator if the pressure in the ram is not within the predetermined range.

Abstract: There is disclosed herein a tubular coupling comprising a first tube, a cage disposed on an end portion of the first tube, a bead for retaining the cage on the end portion of the first tube and a second tube telescopically engageable with the first tube. The coupling further include a spring disposed around the cage for preventing telescopic disengagement of the second tube from the first tube as well as a plurality of o-rings disposed on the end of the first tube. One of the o-rings is disposed at the pivot point of the coupling, the pivot point being defined as the midpoint of the distance between a first contact point and a second contact point between the first tube and the second tube when the tubes are engaged.

Abstract: A heat exchanger tube is disclosed. The tube includes identical, asymmetric upper and lower members which are joined together to form a tube. A plurality of longitudinally extending walls are disposed in the tube members which form a plurality of flow paths.

Abstract: A method and system for automatically controlling a heating, ventilating, and air conditioning (HVAC) unit of a vehicle includes multiple electric motors for actuating multiple respective doors directing air flow through the HVAC unit and temperature of the air flow. A plurality of sensors sense a plurality of temperatures. A controller determines a desired temperature and desired direction of air flow based on the plurality of temperatures. The controller also controls the multiple electric motors so that their respective doors move at the same time while preventing preselected doors from operating at the same time based on the desired temperature and desired direction of air flow.

Abstract: An apparatus and a method for embedding conductors in a structure having a signal distribution function associated therewith such as a vehicle instrument panel are disclosed. The apparatus includes an embedding tool which can be positioned in three dimensional space to embed conductors in non-planar surfaces. A method for such embedding is also disclosed.

Abstract: A method for making a manifold for a tube and fin type heat exchanger wherein the manifold is a one piece aluminum extrusion. The manifold includes a U-shaped channel having a base member and a pair of vertical walls, a plurality of fluid conducting passageways in the base member, and a pair of hollow longitudinal fluid conduits. The conduits are then crimped at predetermined locations to form fluid baffles and the manifold is then sealed. The baffles include slits which allow a bonding agent to secure the baffle within the fluid conduit.

Abstract: There is disclosed a condenser for use in an air conditioning system. The condenser includes a receiver dryer fluidly communicating with it. The receiver dryer includes a fluid inlet for receiving a two-phase refrigerant mixture from the condenser and two outlets, both of which direct refrigerant back to the condenser after phase separation.