Abstract: The present invention is directed to electrical contacts that comprise spaced electrically conductive particles embedded and bonded into the surface of conductors in which the particles have been kinetically sprayed onto the conductors with sufficient energy to form direct mechanical bonds between the particles and the conductors in a pre-selected location and particle number density that promotes high surface-to-surface contact and reduced contact resistance between the conductors.

Abstract: A tension sensing assembly for a seat restraint system in a vehicle includes a rigid frame of a seat restraint buckle of the seat restraint system. The tension sensing assembly also includes a movable member operatively supported by the rigid frame and adapted to be connected to vehicle structure. The movable member is movable relative to the rigid frame. The tension sensing assembly includes a strain member operatively supported by the moveable member and the rigid frame. The tension sensing assembly further includes a strain gage sensor operatively supported by the strain member to indicate a tension level in the seat restraint system when the strain member is displaced by the movable member.

Abstract: A thermally enhanced electronic module includes a thermally conductive case, a self-aligning thermally conductive heat sink and an integrated circuit (IC) package. The case includes an aperture sized for receiving a portion of the heat sink. The IC package includes a first surface and a second surface, opposite the first surface, and is mounted to a substrate with the first surface of the IC package facing the substrate. The second surface of the IC package is in thermal contact with the heat sink, when the heat sink is positioned in the aperture and secured to the case.

Abstract: A capacitive load cell apparatus includes upper and lower capacitor plates and an intermediate dielectric in the form of a synthetic knit spacer material having upper and lower fabric layers interconnected by an array of deflectable synthetic fibers. When occupant weight is applied to the seat, the synthetic fibers deflect to locally reduce the separation between the upper and lower capacitor plates, and the consequent change in capacitance is detected as a measure of the applied weight. The load cell or just the dielectric may be encased in a polymeric sheath to prevent intrusion of foreign matter, and a fluid such as silicone may be dispersed in woven dielectric.

Abstract: A frontal air bag system for a vehicle includes an air bag module having a housing for mounting to vehicle structure of the vehicle and an air bag operatively connected to the air bag module. The frontal air bag system also includes an inflator disposed in the housing for inflating the air bag with an inflation gas. The frontal air bag system further includes at least one tether interconnecting the air bag and either one of the housing and the inflator to cause some of the inflation gas to vent through the housing to atmosphere.

Abstract: An air bag system for cushioning restraint of a vehicle occupant during an impact event. The air bag assembly includes an inflatable air bag cushion adapted to be inflated from a storage chamber to an inflated deployed condition within an occupant compartment. A gas emitting inflator is housed in fluid communication with the air bag cushion. At least one drag-inducing member engages the air bag cushion as the air bag cushion is inflated from the stored condition to the inflated deployed condition such that the period of energy transfer between the air bag cushion and the occupant is increased relative to unrestrained deployment from the storage chamber.

Abstract: A gear system for coupling a steering wheel to a steering wheel shaft, comprising: a first gear rotatable about a first axis and connected to the steering wheel, wherein rotation of the steering wheel causes rotation of the first gear; a second gear engaged to the first gear and configured to rotate about another axis when the steering wheel is rotated, wherein the another axis is displaced from the first axis; and a housing disposed about the gear system, wherein the housing remains in a stationary position during rotation of the steering wheel.

Abstract: A vehicle door handle assembly is mounted on a support panel for operating a door latch. The door handle assembly has a D-shaped door handle that includes an integral pivot pin. A lock button has a part cylindrical socket that receives the pivot pin to mount the lock button pivotally on the door handle. The pivot pin is shaped to provide a cross section that has a minimum thickness to facilitate lateral insertion of the pivot pin into the part cylindrical socket via a loading slot. The door handle also includes integral trunnions for mounting the door handle pivotally on the support panel.

Abstract: A capacitive sensor (30) for use with a automotive vehicle (200) having a power sliding door (202) has a flexible housing (44). The housing (44) has a first set of electrodes (12) and a second set of electrodes (14) interdigitally spaced from each other and a ground electrode (15) made from a flexible metallic braid.

Abstract: The invention relates to granulated gas charges and their use. Said granulated gas charges, whose combustion fumes are nitrogen-free and low in carbon monoxide, contain a) between 5 and 50% by weight binders; b) between 0 and 90% by weight oxidizing agents; and/or c) between 0 and 75% of an organic, notably nitrogen-free, fuel.

Abstract: A sealed electronic module includes a housing having an open end for receiving a circuit board, and a slotted side wall for receiving a connector header mounted on the circuit board. The connector header fits snugly in the side wall slot and includes an integral trough that engages the interior face of the side wall to form a U-shaped channel that surrounds the sides and bottom of the slot. The housing is positioned with its open end upward, and potting material is dispensed onto the exposed surface of the circuit board in a single step to seal the circuit board to the housing. A portion of the potting material flows into and fills the U-shaped channel to seal the connector header to the housing.

Abstract: A tension sensing assembly for a seat restraint system in a vehicle includes a rigid frame of a seat restraint buckle of the seat rstraint system. The tension seensing assembly also includes a movable member mounted on the rigid frame and adapted to be connected to vehicle structure. The movable member is movable relative to the rigid frame. The tension sensing assembly furtheer includes a magnet mounted to the rigid frame and a Hall effect sensor mounted to the movable member and cooperable with the magnet to change an output of the Hall effect sensor to indicate a tension level in the seat restraint system.

Abstract: The present invention is directed to a process for preparing aluminum and aluminum alloy surfaces in heat exchangers for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits monolith or composite coatings that can include all braze materials and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.

Abstract: An apparatus and method for customizing the pressure within an inflatable cushion of an air bag module is provided. The method comprises determining whether additional venting of an air bag is required. A sensing and diagnostic module will receive its relative inputs from a plurality of sensors and will determine whether vents in an inflatable cushion should be opened to allow diffusion of an inflation gas. The apparatus allowing vents to open at specified times to allow for diffusion of the inflation gas.

Abstract: A pyromechanical battery pole disconnect element, includes a housing (1) in which an electrical conductor is located, a pyrotechnic active element (14) including a breaking piston with a disconnect element (7) to sever the electrical conductor at an isolating point (11), and a pyrotechnic charge to drive the disconnect element (7). All of the current-conducting components except the active element (14) are combined to form a one-piece battery terminal clamp element (5).

Abstract: A method and apparatus for reducing gap variation between an airbag module and a steering wheel insert while acting as a horn switch for a horn. The apparatus includes a contact spring disposed between the airbag module and the steering wheel insert. The spring has at least two raised locations having one side of each raised location biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite said first direction to actuate the horn. An insulative spring retainer has one surface disposed on the steering wheel insert and an opposite surface configured to retain the contact spring. The retainer is further configured to operably couple with the steering wheel insert and includes at least one contact aligned with a corresponding raised location to actuate the horn upon electrical contact therebetween.

Abstract: A deployment flap for use with an inflatable cushion is provided. The deployment flap includes a fabric or other flexible, foldable material; a plurality of securement tabs each having a weakened area; and a cover area defined in the fabric. The fabric is connectable to the inflatable cushion to cause the inflatable cushion to be biased in a selected direction upon inflation of the inflatable cushion. The cover area covers the inflatable cushion prior to inflation of the inflatable cushion. The securement tabs secure the fabric to a retainer. The weakened area releases the fabric from the retainer upon the inflation of the inflatable cushion.

Abstract: A frontal air bag system for a vehicle including an inflator mounted to vehicle structure and an air bag operatively connected to the inflator and mounted to a pillar of the vehicle. The frontal air bag system also includes a trim molding covering the air bag and mounted to the pillar. The air bag, inflated by the inflator, is extended downward and sideways in front of an occupant seated in the vehicle.

Abstract: An air bag module, having a housing with at least one vent opening; an inflatable cushion being stored in an un-deployed position in the housing; an inflator for inflating the inflatable cushion, the inflator being in fluid communication with the inflatable cushion; a deployable member being configured to cover the at least one vent opening; a tether element being secured to the inflatable cushion at one end and the deployable member at the other; an actuator adapted to restrain or release the tether element wherein the deployable member is pulled away from the at least one vent opening when the actuator releases the tether, the at least one vent opening is in fluid communication with the inflatable cushion when the deployable member is pulled away.

Abstract: An air bag safety system for cushioning restraint of a vehicle occupant during an impact event. The safety system includes a variable depth inflatable air bag cushion inflated by a gas emitting inflator within an inflator housing. A cover element of substantially pliable material is located in adjustable relation to a vent opening across a wall of the housing. The cover element is selectively displaceable relative to the vent opening in response to the inflation depth of the air bag cushion so as to adjust venting characteristics across the housing.