Abstract: A circuit-carrying automotive component and a method of manufacturing the same are provided. In a preferred embodiment of the invention, the component includes a substrate made from a polymer that is molten at a predetermined elevated temperature. The component further includes a circuit board which defines an aperture therethrough adapted to receive the molten polymer at the elevated temperature and a fastener formed from the molten polymer through the aperture. The fastener is integral with the substrate and mechanically secures the circuit board to the substrate. The circuit board is made from a material that is resistant to fusing with the molten polymer at the elevated temperature.

Abstract: A heat exchanger acting as a condenser having a plurality of tubes for cooling a refrigerant flowing through the tubes to condense the vapor phase of the refrigerant to a liquid is shown wherein the condenser has a plurality of headers having baffles and/or phase separators positioned therein. The refrigerant strikes a side wall of one of the headers and respective phases are separated by gravity. Additionally, phase separators may be used to selectively route the vapor and liquid phases to specific locations in the heat exchanger. By-pass lines are used to transfer the non-productive phase to a specific location in the heat exchanger.

Abstract: A microcontroller-based fuzzy logic processing module for generating control signal values in response to variable input signal values in accordance with constraints imposed by propositions or "rules" stored in memory in a standardized format. Each rule consists of one or more input conditions and an output directive. The input conditions and the output directive for a given rule are "fuzzified" by determining the degree of membership of each in fuzzy sets defined by membership functions. Fuzzy logic processing is accomplished by determining the extent to which the input conditions are satisfied by the current values of the input signals in order to develop a rule strength value, and then performing a "center-of-gravity" determination based on the rule strength values assigned to the output membership functions.

Abstract: There is disclosed herein an apparatus for manufacturing a manifold for a heat exchanger. The apparatus includes a mechanism for forming a generally planar sheet of material into a generally cylindrical member having a seam along the longitudinal length thereof. The apparatus further includes a tool for forming a plurality of tube receiving slots in the cylindrical member and a device for applying a pressure against the seam so as to flatten the seam to provide good sealing contact at the seam.

Abstract: In a tube connection, an axial end region of a first tube is inserted into an axial end region of a second tube having an internal diameter greater than the external diameter of the first tube. Elastic sealing elements are disposed between the outside of the inserted end region and the inside of the receiving end region. A safety clip which holds the tubes in place in the axial direction is at the same time so formed that misalignment of the tubes in the region of the tube connection is prevented. The safety clip has first and second contact regions, in the form of clamps, which are provided for preferably area contact with the outsides of the end regions of the tubes to be connected. The contact regions each extend over an axial length such that when the safety clip is in the clamped position the tubes are held in the region of the tube connection non-tiltably in a mutually axially aligned position.

Abstract: A conductive fin for a heat exchanger includes an elongated fin member having two rows of tube receiving apertures extending through the fin member. The fin member includes two rows of raised members located on either side of a centerline bisecting the fin member so as to form a series of closely spaced pairs of raised members located between any two tube receiving apertures and being symmetrical about the centerline and defining two openings with one opening being larger than the other. Each of the raised members defines a pair of legs extending from the plane of the fin member and is positioned to channel air into the space between each respective pair of tube receiving apertures so as to increase the coefficient of heat transfer therebetween without increasing air pressure drop across the heat exchanger.

Abstract: An air vent for use in a motor vehicle passenger compartment, and in particular to an air vent with an air grill that can be rotated to a closed position. A housing has a first pivot bearing to which is connected a carrier with a second pivot bearing. An air grill with vanes has generally spherical peripheral surfaces and is connected to the second pivot bearing. The air grill may then be rotated about two orthogonal axes within the housing to vary the direction of the air flow entering the passenger compartment. The central vane has a circular periphery, and the air grill may also be rotated to a position in which this vane makes a seal with a compliant sealing section within the housing to close off the flow of air through the air vent.

Abstract: A heat shield for an accumulator used in automotive air conditioning systems is disclosed. The heat shield prevents overheating of the interior components of the accumulator while the accumulator is being manufactured.

Abstract: A protective sleeve for a fluid pipe is disclosed. The sleeve includes an inner and outer member which provide heat, sound and abrasion resistance. The inner member includes a pair of terminal edges which are spaced apart a predetermined distance. This distance is greater than the distance between the terminal edges of the outer member. A method of making such a protective sleeve is also disclosed.

Abstract: An apparatus for selectively orienting consecutive fin strips relative to one another as a preliminary step in the manufacture of a heat exchanger includes a sensor for sensing the presence of each of a series of fin strips all having a common orientation relative to one another. The apparatus includes an orienting member which receives signals from the sensor as to the presence of each fin strip and rotates each consecutive fin strips in alternating clockwise and counter-clockwise directions to orient consecutive fin strips 180.degree. relative to each adjacent fin strip.

Abstract: A method for making a manifold for a tube and fin type heat exchanger is disclosed wherein the manifold includes a solder strip. The manifold includes a channel having a base member and a pair of vertical walls, a plurality of fluid conducting passageways in the base member, and a solder strip disposed in the channel. The strip is secured in place by bending a portion of the wall over a longitudinal edge of the solder strip.

Abstract: There is provided herein a refrigerant receiver for use in an automotive air conditioning system. The receiver includes a generally cylindrical body, a circular closure member secured at one end of the body and a manifold member configured to engage the closure member. The manifold includes a bottom surface having a stepped configuration which sealingly engages a corresponding stepped surface on the closure member. A single threaded fastener is utilized to secure the manifold to the closure member.

Abstract: An accumulator assembly having an accumulator surrounded by a heat insulating layer on the outer side thereof. The container includes mounting devices formed on the exterior thereof for mounting the accumulator assembly in place.

Abstract: A tube expanding assembly expands a plurality of tubes used in combination with a plurality of fins and end sheets to form a heat exchanger, the tube expanding assembly includes a nest plate secured to the base wherein the nest plate holds the tubes thereon, a bolster cylinder extendable between the base and the nest plate for moving the nest plate relative to the base, a ram support disposed above the base, a ram plate secured to the ram support, a ram cylinder depending from the ram support and secured to the ram plate wherein the ram cylinder moves the ram plate relative to ram support, a plurality of expansion rods depending from the ram plate wherein each of expansion rods is extendable through each of the tubes such that the tubes engage the fins and end sheets, and a plurality of transducers, each of the transducers are associated with each of the bolster cylinder and the ram cylinder such that the transducers create signals identifying position of each of the ram plate and the nest plate.

Abstract: A door assembly for controlling air flow through a motor vehicle climate control system includes a door panel having a pair of opposed faces and a terminal edge. A seal member is attached to at least one of the pair of opposed faces and has a terminal edge generally disposed along the terminal edge of the panel. A film member overlies the seal member and also has a terminal edge generally disposed along the terminal edge of the panel. The terminal edge of the film member is substantially non-linear such that noise produced by air flow passing around the terminal edge of the panel is minimized.

Abstract: There is disclosed herein an accumulator for an automotive 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: A method of controlling a crimp press for crimping a hose assembly includes the steps of placing a hose 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: A cooling system for an automotive vehicle is disclosed including a heat exchanger assembly, a rotatable axial flow fan and a shroud member at least partially surrounding the fan and the heat exchanger assembly. The cooling system further includes a first ejector disposed between the heat exchanger and the engine and a pair of second ejectors disposed on the inner fender members of the vehicle for drawing ambient air from under the heat exchanger and pumping the air toward the engine and for preventing recirculation of the air exiting the shroud member back to the fan while the vehicle is at idle.

Abstract: A method for making a plate-tube heat exchanger 10 is disclosed. The method includes the steps of forming a generally planar plate blank 36 from a deformable sheet of material, forming an aperture 38 at one end of the plate blank and forming a plurality of generally elongate bead preforms 40 in a predetermined configuration by drawing the material from the bottom surface of the plate blank towards the top surface. Next, a plurality of individual beads 34 are formed from each of the plurality of bead preforms by reverse drawing the bead preforms in a direction from the top surface of the plate towards the bottom surface of the plate. The method of the present invention concludes by forming the finish edges 46 of the plate.

Abstract: A fuel tank assembly is provided. The fuel tank assembly includes a plastic fuel tank having a wall defining an outer surface and an interior volume for storing fuel therein. A portion of the fuel tank wall further defines a generally cylindrical opening therethrough. The fuel tank assembly also includes an instrument having a generally cylindrical piece extending through the opening in the fuel tank wall such that the instrument communicates with the interior volume of the fuel tank. A retainer assembly is attached to the outer surface of the fuel tank wall for releasably securing the instrument to the fuel tank. The retainer assembly includes a plastic ring-like member having a generally cylindrical inner wall disposed around the generally cylindrical piece of the instrument, the inner wall defining a circumferentially extending sealing surface. The retainer assembly also includes a reinforcing member carried within the ring-like member adjacent to and generally concentric with the sealing surface.