Abstract: Thermoplastic elastomeric compositions and processes for preparing the compositions comprising a blend of polypropylene, styrene-ethylene butylene-styrene copolymer, ethylene-propylene-diene monomer elastomer, linear low density polyethylene, peroxide crosslinking agent and a crosslinking coagent. The peroxide crosslinking agent and crosslinking coagent provide a crosslinking system. The compositions improve melt strength and increase resistance to flow and tear. The composition may further comprise mineral oil, antioxidant, colorant, a processing aid and stabilizer and mixtures thereof. The processes for preparing thermoplastic elastomeric compositions are particularly useful in microcellular injection molding to form articles with improved surface characteristics.

Abstract: A cable drive assembly for opening and closing a sliding vehicle door has first and second drums that are drivingly connected to each other via a tension spring that biases the drums in opposite directions. The drums include a catch that holds the first and second drums in a cocked condition where the spring is tensioned to provide slack in a closed loop cable to facilitate inserting a traveler attached to the cable into a track. The cocked drums are manually rotated in a drum housing in one direction to move the traveler and insert it into the track. After the traveler is inserted, the cocked drums are manually rotated in the opposite direction. This releases the catch so that the tensioned spring takes up the slack in the closed loop cable.

Abstract: Disclosed is a method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a thermal spray process. The process can be utilized to apply a base metal such as copper to a substrate and the base metal becomes the catalytically active oxide during and following application to the substrate. This system replaces a multi-step process within a single step process to provide a catalytically active surface that can be utilized to reduce ground level ozone and other atmospheric pollutants.

Abstract: An instrument panel cover arrangement used for covering an airbag module mounted beneath an instrument panel cover in a vehicle and method of making the same is disclosed. The arrangement includes a rigid substrate forming the instrument panel cover and having inner and outer surfaces and a hidden door configured in the substrate aligned with the underlying airbag module. The hidden door is removably securely to the substrate so as to be flushly aligned with the outer surface of the substrate and is defined by a thinned portion relative to the substrate outlining a perimeter of the hidden door. The thinned portion defines a first relief in the inner surface of the substrate. A plurality of cut lines generally define an airbag deployment opening and extend entirely through the substrate at a location corresponding to the first relief.

Abstract: An elongated housing for use with an airbag module is provided. The housing comprises a first wall, a second wall, a bottom wall joining the first and second walls such that a first width is defined by the housing, and a cushion deployment opening opposite the bottom wall. The cushion deployment opening is between a first edge of the first wall and a second edge of the second wall. The cushion deployment opening has a second width that is between about 90 percent of the first width and about 30 percent of the first width.

Abstract: An air bag pressure control system for use in a vehicle is provided. The system comprises a housing, an inflatable cushion, and a dual stage inflator. The inflator generates a quantity of inflation gas to deploy the inflatable cushion from the housing. A vent opening is formed in the housing to selectively direct a portion of the inflation gas towards or away from the inflatable cushion. A sensing and diagnostic module detects an activation event level. A control algorithm tailors an inflation level of the inflatable cushion during deployment according to the activation event level.

Abstract: An assembly of efficient construction and operation to hold restraining air bag tethers to a shortened operative length under a first set of conditions and to extend such tethers under a second set of conditions. The extension of the restraining tethers is carried out in conjunction with the delivery of an increased volume of inflating gas to the air bag cushion. The air bag assembly may be operated using as few as two activatable initiators to activate inflation stages while simultaneously controlling tether length to effect delivery of a proper volume of inflation gas for a desired cushion profile.

Abstract: An acceleration sensor assembly for a restraint retractor of a seat restraint system in a vehicle includes an acceleration sprocket operatively connected to the restraint retractor. The acceleration sensor assembly also includes an acceleration pawl cooperating with the acceleration sprocket to operatively cause lock up of the restraint retractor. The acceleration sensor assembly includes an inertia member cooperating with the acceleration pawl to move the acceleration pawl when an acceleration force is present and a gimbal to support the inertia member. The acceleration sensor assembly further includes a non-contact damping mechanism cooperating with the gimbal to dampen movement of the gimbal until the acceleration force exceeds a predetermined value and the inertia member actuates the acceleration pawl to engage the acceleration sprocket to operatively cause lock up of the restraint retractor and prevent unwinding of a belt from the restraint retractor.

Abstract: A vehicle airbag system and method of removably securing the same is disclosed. The method and system include an instrument panel disposed within a passenger compartment of the vehicle having an opening to receive an airbag module and a cover removably secured thereto. The cover is configured to cover the opening and to flushly mount with a surface defining the instrument panel. A chute extends from a bottom surface of the cover and is configured to operably connect with the airbag module. A securement feature extends from one side wall defining the chute and is configured to slidingly engage one edge defining the opening of the instrument panel to mechanically wedge the one edge between the bottom surface of the cover and the securement feature. A plurality of apertures are configured in an opposite side of the cover that are configured to receive a mechanical fastener therethrough to secure the opposite side of the cover to the instrument panel.

Abstract: An electronic position sensor for use with a power operated vehicle accessory, such as a power liftgate. The position sensor includes an elongated resistive circuit that is mounted such that it is stationary and extends along the path of a track portion of the power operated accessory. The position sensor further includes a contact nub mounted to a link member that moves within the track portion such that the contact nub is slidingly biased against the elongated circuit. As the link member moves under the force of a motor-driven output gear, the contact nub slides along the surface of the resistive circuit, thereby affecting the overall resistance of the circuit. The position sensor uses the overall resistance to provide an electronic position signal to an ECU, wherein the signal is indicative of the absolute position of the power operated accessory.

Abstract: A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate.

Abstract: In an automotive steering wheel-airbag module assembly a gear system is coupled to a steering wheel and to a steering shaft or column for transferring torque applied to the steering wheel directly to the steering shaft or column. An airbag module is positioned within the diameter of the steering wheel, wherein the airbag module remains in a stationary position during rotation of the steering wheel.

Abstract: An airbag module for restraining an occupant of a vehicle, comprising: a housing; an inflatable cushion being capable of being stored in an un-deployed position in the housing, the inflatable cushion having at least one vent opening disposed on an inboard side and an outboard side of the inflatable cushion, the outboard side being positioned closer to an exterior portion of the vehicle than the inboard side; an inflator for inflating the inflatable cushion, the inflator being in fluid communication with the inflatable cushion; and a biasing device being configured to restrict the deployment of the inflatable cushion in a first direction while allowing for deployment of the inflatable cushion in an inboard direction and an outboard direction, the outboard direction being towards an exterior portion of the vehicle and the inboard direction being opposite to the outboard direction, the biasing device restricts the deployment of the inflatable cushion when a portion of the biasing device makes contact with the oc

Abstract: An apparatus and method for maintaining a uniform gap between the periphery of an airbag module and its surrounding structure, comprising: at least one bushing having a protrusion depending outwardly from a surface of the bushing; and at least one insulator having a first bushing opening being configured to allow a portion the bushing to be slidably received therein, the bushing opening being configured to define a limit of travel of the portion of the bushings within the bushing opening.

Abstract: This disclosure relates to transducers, methods of making transducers and methods of converting between electrical energy and mechanical energy. The transducers comprise an elastomeric film disposed between two electrodes wherein at least one electrode can be a compliant electrode. The elastomeric film comprises a polyphosphazene.

Abstract: A new kinetic spray process is disclosed that enables the coating to withstand severe bending and stress without delamination. The method includes use of a low pressure kinetic spray supersonic nozzle having a throat located between a converging region and a diverging region. A main gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and the coating particles are directly injected into the diverging region of the nozzle at a point after the throat. The particles are entrained in the flow of the gas and accelerated to a velocity sufficient to result in partial melting of the particles upon impact on a substrate positioned opposite the nozzle and adherence of the particles to the substrate. The coating also has a desirable shinny surface. The method finds special application in coating substrates for use in formation of electrical connections.

Abstract: In a preferred embodiment, an engine coolant crossover assembly includes a crossover conduit member carrying an integral liquid cooled alternator and liquid cooled exhaust gas recirculation valve. The integration of one or both of these parts into the coolant crossover eliminates many parts from the total assembly. These parts include; attachment brackets, coolant hoses, hose clamps, cast mounting blocks, coolant tubes and attachment bolts. Reduction of these parts reduces system costs, assembly time, mass and potential coolant leak paths. A temperature sensor and a thermostat housing may also be included in the crossover assembly. The assembly may also be made part of an intake manifold for an integrated air fuel module of a V-type engine.

Abstract: A torque sensing apparatus for picking up a magnetic field of a magnetostrictive material disposed on a shaft, the torque sensing apparatus having: a first integrating ring; a second integrating ring; a first fluxgate return strip and a second fluxgate return strip each being connected to the first integrating ring at one end and the second integrating ring at the other end; an excitation coil; and a feedback coil; wherein the first integrating ring and the second integrating ring are configured to be positioned to pick up flux signals along the entire periphery of the ends of the magnetostrictive material.

Abstract: A seat restraint buckle and tension sensing assembly for a seat restraint system in a vehicle includes a buckle assembly having a housing for receiving a portion of a latch plate of the seat restraint system. The buckle assembly senses latching of the latch plate. The seat restraint buckle and tension sensing assembly also includes a tension sensing assembly disposed in the housing and cooperating with belt webbing of the seat restraint system for sensing a tension level in the seat restraint system.

Abstract: An airbag module, having a housing; 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 tension device; a tether element being secured to the inflatable cushion at one end and the tension device at the other; the tension device applies tension to the tether after the inflatable cushion is inflated to a first configuration by the inflator.