Abstract: The isolator core cooperates with companion core elements in a casting operation to form a short coolant jacket surrounding the upper portion of each engine cylinder adjacent the air/fuel combustion chamber and an air pocket that surrounds the lower region of the cylinder. Drainback passage core elements may be formed integrally with the isolator core thereby reducing the total number of cores in the casting mold package during a casting operation, the finished casting thereby eliminating dividing walls between the isolator and the oil drain cores thus reducing the number of core elements and reducing the cost and complexity of the casting operation as well as reducing the weight of the finished casting. The isolator core may be used independently of cylinder liners during the casting operation.

Abstract: The invention is a method of treating exhaust gases generated by an internal combustion engine using a NOx trap in the exhaust gas system. The method comprises locating a nitrogen oxide trap in the exhaust gas passage and cycling the air/fuel ratio of the exhaust gases entering the trap between lean and rich, such that the trap absorbs nitrogen oxides during the lean cycle and desorbs the nitrogen oxides when the concentration of the oxygen in the exhaust gas is lowered as during a rich cycle. The trap comprises: (a) a tri-metal oxides made of aluminum-manganese-zirconium and (b) at least 0.1 wt. % platinum, the wt. % being based on the weight of said tri-metal oxide material. The desorbed nitrogen oxides may be converted over the precious metal to N.sub.2 and O.sub.2 by reductants like hydrocarbons present in the exhaust gas. The invention is also the catalyst trap material.

Abstract: A coordinated engine and transmission traction control method is disclosed for reducing driven wheel speed transients related to transmission shifting during a traction control event. The method includes sensing a driven wheel speed, and estimating a driving surface coefficient of friction based on the sensed wheel speed. The method also includes prolonging a transmission upshift by reducing a rate of change of a commanded speed ratio in proportion to the estimated driving surface coefficient of friction, and decreasing engine torque during the transmission upshift. A system including a wheel speed sensor and control logic is also disclosed for performing the method.

Abstract: A method of reclaiming foundry sand by (a) providing a treatment tower having a plurality of heat conductive tubes extending across the interior of the treatment tower, the tubes being arranged in rows and staggered with respect to tubes in adjacent rows to create close spacing therebetween sufficient to permit the sand to flow continuously and non-turbulently along the contours of the exterior under the influence of gravity before dropping to the next adjacent tube to thereby again flow continuously and non-turbulently in successive sequence downwardly of the tower; (b) quiescently heating the interior tower space and tubes to a temperature in excess of 1300.degree. F.

Abstract: A control valve system for a multiple ratio transmission with a high ratio clutch and an intermediate ratio brake servo including a first solenoid operated valve that generates a control pressure for intermediate servo apply and a second solenoid operated valve that generates a control pressure for intermediate servo release and for the high clutch. The second and the first solenoid valves control the intermediate servo stroke phase and the second solenoid valve controls, either closed or open loop, the deceleration of a high clutch drum. Pressures electronically controlled by the solenoid valves are distributed to the clutch and brake servo pressure chambers by a shift valve configuration, whereby high quality upshifts and downshifts are achieved.

Abstract: A system and method for reducing speed of a vehicle to maintain a target vehicle speed include determining an actual vehicle speed, comparing the target vehicle speed to the actual vehicle speed to generate a speed error, determining a continuously variable braking torque as a function of the speed error when the actual vehicle speed exceeds the target vehicle speed, and applying the continuously variable braking torque to at least one wheel of the vehicle to reduce the speed error toward zero and control the speed of the vehicle. The present invention is applicable to vehicles powered by an internal combustion engine, electric vehicles, fuel cell vehicles, and hybrid vehicles. The continuously variable braking torque may be applied using regenerative braking to improve fuel efficiency. Friction brakes may also be utilized either alone, or in combination with regenerative braking, for vehicles capable of brake-by-wire control strategies.

Abstract: A polymer-electrolyte-membrane fuel cell assembly comprising an ionomeric, conducting polymer membrane, an anode on a first face of the polymer membrane, a cathode on a second face of the polymer membrane, at least one of the anode and the cathode each comprising catalyst support material comprising conductive zeolite particulate material, and noble metal catalysts supported on the catalyst support material.

Abstract: A system and method for controlling an internal combustion engine using a controller to implement at least two control modes having corresponding first and second mode controllers with disparate control parameters include comparing output of the first and second mode controllers to generate an error, generating a correction value based on the error, and providing the correction value to one of the mode controllers to provide a smooth transition of control between the mode controllers. In one embodiment, the first controller is a torque controller which determines a desired air flow to achieve a desired torque and the second mode controller is an idle speed controller which determines a desired air flow to maintain a desired engine speed. The invention is advantageous in that it provides for smooth transitions between control modes, such as between idle mode and a normal driving mode, by harmonizing the outputs of the controllers.

Abstract: A two-stage temperature gauge for a vehicle indicates whether engine temperature is normal or overheated. The gauge registers "normal" when the vehicle engine temperature is at or below a threshold value and registers "hot" when the vehicle engine temperature exceeds the threshold value. A circuit (10) for operating the gauge has an input terminal (12) for receiving a signal from an electronic engine controller (14) representative of engine temperature for causing the gauge register either "normal" or "hot". An indicating lamp (28) connected to the input terminal (12) illuminates to also indicated an overheated engine condition.

Abstract: A system and method for monitoring catalytic converter efficiency monitor the switch ratio of upstream and downstream exhaust gas oxygen sensors based on an acceptable temperature range of the catalytic converter. In one embodiment, catalytic converter temperature is determined based on exhaust gas temperature. The exhaust gas temperature may be used to infer the temperature of the catalytic converter mid-bed. The efficiency may be determined based on a correspondence with a number of mass air flow ranges. The system and method may also use vehicle speed and EGR to assure that the monitor samples data during repeatable, robust load-speed-temperature conditions. Switch data is stored in keep-alive memory to increase the confidence of the efficiency determination due to a larger data collection phase. A filter having a cycle based constant may be used to filter a current switch ratio before incorporating it into an average switch ratio.

Abstract: In an automotive ignition system having ignition coil banks with at least one ignition coil for energizing a corresponding spark plug, input/output (I/O) devices are provided in electrical communication with the ignition coil banks for relaying ignition coil signals, each ignition coil bank having at least one set of corresponding I/O devices relaying similar signals. The similar signals relayed by sets of corresponding I/O devices are stored in memory at addresses having a constant offset from each other. Program routines are also stored in memory for processing and generating the similar signals relayed by sets of corresponding I/O devices. The similar signals are accessed by the program routines using an indexed addressing mode and the constant address offset such that a single program routine controls one set of corresponding I/O devices independent of the ignition coil bank involved.

Abstract: An electric vehicle battery tray includes a base having an inner surface and an outer surface, a front and back wall having outer and inner surfaces adapted to overlay the base outer surface and to create substantially planar, vertical front and back wall inner surfaces thereby, and a left and right side wall having outer and inner surfaces adapted to longitudinally overlay the base outer surface and to create substantially planar, vertical left and right side wall inner surfaces thereby.

Abstract: A paintable, reactor grade thermoplastic olefin (TPO) comprising a blend of elastomer and polypropylene. The elastomer is present in an amount of about 10 to 35% by weight, based on the weight of the TPO. The elastomer comprising about 40 to about 60% by weight polyethylene, based on the weight of the elastomer. The TPO has a viscosity ratio of polypropylene to elastomer of about 50:1 to about 700:1.

Abstract: A method of operating an oxygen sensor in the exhaust stream of an engine. The oxygen sensor includes a zirconia plate (14) mounted to two electrodes (16,18), covered with porous layers (20,22). The two porous layers (20,22) are designed to sense the two conditions of air/fuel mixture, lean and rich, by creating a delay in the sensing of the rate of transmission of oxygen through one of these layers (20,22). The method includes flowing exhaust gas over the sensor, maintaining essentially no flow of current through the leads when the exhaust gas maintains a state of rich or lean air/fuel ratio, and sensing induced emf spikes between the leads as the exhaust gas stream transitions between rich and lean air/fuel ratios.

Abstract: Vehicle model rattle detection method and system process vibration displacement data of elements of a vehicle CAE model to predict rattle of the vehicle. The rattle detection method and system includes dividing a vehicle model into a plurality of elements and grids. The displacement data for each element as a function of vibration is then provided. The element-grid pairs which contact due to vibration are then determined using the displacement data. Contact velocity for each contacting element-grid pair due to vibration is then estimated. Rattle for each contacting element pair as a function of contact velocity is then determined. The displacement data includes magnitude data and phase data for each element as a function of vibration over time. A rattle index for each contacting element pair is generated, the rattle index is indicative of rattle severity.

Abstract: A three-dimensional multi-layer electronic device and method for manufacturing same, wherein the device comprises a three-dimensional substrate including a conductive trace on at least one surface of the substrate, a thin layer of dielectric material substantially covering a desired portion of the conductive trace(s) on the substrate, the dielectric layer including vias at selected locations, and applying a coating of conductive material on the dielectric layer and in the vias, and defining a conductive trace in the material to thereby form a multi-layer, interconnected three-dimensional electronic device. Additional layers of dielectric material and conductive traces may be similarly applied to create the desired number of circuit layers. Molded-in structural features, and/or vias may be defined in the appropriate layers to accommodate the attachment and/or interconnection of other electronic devices to the device.

Abstract: A fuel tank support for supporting and protecting a plastic fuel tank is mounted to the vehicle with the plastic fuel tank supported therein. Integral mounting members are formed in the fuel tank support to provide structural integrity, thereby obviating the need for additional mounting hardware and straps. In addition, apertures formed on the walls of the support provide vent holes for venting stagnant hot air from the space between the fuel tank and the fuel tank support.

Abstract: A method of determining reflective optical quality of a reflective product includes reflecting a first gray-scale pattern off the product; obtaining a first image of the first pattern with an image pickup device after the first pattern has reflected off of the product; and determining optical quality of the product based on data obtained from the first image. An apparatus for determining reflective optical quality of such a product is also disclosed.

Abstract: A side impact sensor system is used in a vehicle having a side air-bag, a lower body component, and a body side with a front door belt line area. The system includes a body side impact sensor mounted to the body side at least as high as the front door belt-line area. A lower body side impact sensor is mounted to the lower body component inboard from the body side. A safing sensor is secured to the vehicle. Electronic control module is provided in the electrical communication with the side air-bag and with the sensors for sending firing signals to the side air-bag when the safing sensor and at least one of the body and lower body side impact sensors signal a sufficiently high lateral acceleration indicative of a side impact.

Abstract: An apparatus for directing conditioned air into a vehicle passenger compartment including an integrally formed attachment member for securing the apparatus to a vehicle support structure. The attachment member has a flexible free end, an elongated body, an aperture, and a plurality of living hinges. The elongated body is inserted into a vehicle support structure aperture. The elongated body is then folded onto itself until the flexible free end is able to be inserted into locked engagement with the aperture in the elongated body. Thus, the present invention minimizes the cost of the apparatus, the number of parts, assembly time and complexity.