Abstract: The present invention is directed to a constant velocity joint (“CV joint”) and, more particularly, to a Rzeppa CV joint and method of forming the same. The method generally includes the steps of forming a bell shaped outer bearing race and separating the bell shaped outer bearing race into a disc shaped outer bearing race and a stub shaft. The method may further include the step of machining the bell shaped outer bearing race to create the stub shaft integrally connected to the disc shaped outer bearing race, before separating the bell shaped outer bearing race into the disc shaped outer bearing race and the stub shaft.

Abstract: A starter motor for an internal combustion engine having an integral one-way roller clutch and epicycle gear train unit is provided. The integrated unit includes an integrated gear support/clutch barrel which, on one side, houses the roller and spring elements of the clutch and, on the other side, supports the planetary gears of the epicycle gear assembly. The invention is of simple construction and provides reduced overall starter motor dimension while demonstrating improved noise, vibration and harshness characteristics.

Abstract: The toothed rack steering gear has an adjusting nut and a housing. An opening with internal thread of the housing is adapted to the adjusting nut and receives the adjusting nut in the assembled state. In the housing at least one recess is provided in direct proximity of the opening. A retainer is provided; it has a ring shaped body and at least one finger. The finger protrudes from this ring shaped body and can engage into the recess. The retainer has a back surface and the adjusting nut has a front surface. In the assembled state both are in contact. A connecting device is provided and secures the connection between the back surface and the front surface.

Abstract: A method of making a windshield having first and second outer layers and a conductive bar, an electrical connector, and an intermediate layer positioned between the outer layers. The method includes the step of sinking the conductive bar and the electrical connector into a surface of the intermediate layer so as to be at least substantially flush with the surface. After sinking the conductive bar and the electrical connector into the surface, the first outer layer is engaged with the surface of the intermediate layer. Additionally, the second outer layer is engaged with a second surface of the intermediate layer.

Abstract: The present invention is directed to a flange attached to a window panel with an opening. The flange prevents an object from contacting the bottom edge of the opening as the object is passed through the opening. Moreover, the cargo rests on the flange rather than the bottom edge to prevent the cargo from damaging the window panel.

Abstract: A sliding window panel assembly for a motor vehicle. The assembly includes a stationary window panel having an opening formed therein, at least one guide rail coupled to the stationary window panel below the opening and above a bottom edge of the stationary window panel, a shoe slidably received within the guide rail and configured to slidably move within the guide rail, a movable window panel mounted onto the shoe such that the movable window panel slidably moves with the shoe. The movable window panel can slidably move with respect to the stationary panel along a movable panel path. The lead screw drive unit engages the shoe and is adapted to move the shoe and the movable panel along the movable panel path within the guide rail.

Abstract: A power connection apparatus of a vehicle is provided that includes a pair of substantially flat electrical conductor strips each having a first end and a second end. The first ends are adapted to be electrically coupled to integrated heater conductors in an automobile glazing. A film forms a protective coating over an intermediate section of the pair of electrical conductor strips. The film insulates and maintains a spaced relationship between the pair of substantially flat electrical conductors. A pair of wires is electrically coupled to the second ends. A first protective overmold seal is formed over the second ends of the pair of substantially flat electrical conductor strips for sealing the electric coupling of the second ends of electrical conductor strips and the wires.

Abstract: A stabilizer bar for an automotive vehicle is provided having an end link mounted to at least one end thereof. One end of the end link includes a bore in which is received a spherical bearing, such that forces transferred directly from the stabilizer bar to the end link are transferred through the spherical bearing. The second end of the end link is adapted to connect to a component of the vehicle's suspension system.

Abstract: A closure panel assembly (10) includes a fixed panel (12) defining an opening (14), a pair of guide rails (16,18) disposed on opposite sides of the opening, and a sliding panel (26) supported by the guide rails for movement between a closed position over the opening and an open position. Cooperating surface features (46,48) on at least one guide rail and the sliding panel engage one another when the sliding panel is moved to the closed position, to laterally displace the sliding panel toward the fixed panel and thereby compress a seal (44) disposed therebetween. Additional surface features (54) on the guide rail similarly engage the sliding panel's surface features to displace the sliding panel toward the fixed panel when the sliding panel is in a partially-open position, to thereby at least partially compress the seal and create a frictional drag on the sliding panel resisting further movement.

Abstract: A method for lapping the gears of a gear set as well as a gear lapping system. The gear set generally includes a first gear in meshed engagement with a second gear, each of the first and second gears having a plurality of gear teeth each with drive and coast flank surfaces. The method includes the steps of lapping the gear set by rotating the first gear in a first direction while the first gear is in mesh with the second gear. The method further includes sensing the vibrations occurring in the gear mesh during rotation and controlling the step of lapping based on the sensed vibrations. The gear lapping system includes an automated lapping machine that is adapted to lap the gear set including a ring gear and a pinion gear. The automated lapping machine is adapted to lap the gear set by rotating at least one of the ring and pinion gears while in mesh, in the presence of a lapping compound, and while translating the gear mesh back and forth across the gear flank surfaces for a plurality of cycles.

Abstract: The invention relates to a fuel charging system having pressure pulsation damping. The fuel charging system includes a first side rail connected to a second side rail by a crossover tube. Defined within the crossover tube are first and second passageways; the first passageway including a restricted flow section therein.

Abstract: An assembly provides metallic ends to a composite shaft and a method of fabricating such an assembly. The composite shaft is preferably comprised of reinforced fibers. A metallic inner sleeve is positioned in the cavity of one end of the shaft. A metallic outer sleeve is positioned around the end of the shaft having the inner sleeve therein. The outer sleeve may include structural features, such as dimples, that ensure a stable connection between the sleeve and the shaft. The sleeves are compressibly forced onto the shaft, thereby forming the assembly. Both sleeves are metallic, and therefore provide a surface onto which weld joints can be formed. A preferred method of assembly includes the steps of expanding the inner sleeve and compressing the outer sleeve against the shaft.

Abstract: A motor vehicle power transfer unit includes an input portion, an output portion, a non-parallel gear set and a parallel gear set. The input portion is adapted to connect to an output portion of a transmission assembly and the output portion is adapted to connect to an input portion of a rear wheel drive line. The parallel gear set is coupled to the input portion and transfers power to the non-parallel gear set, which is coupled to the output portion. The non-parallel gear set includes a ring gear having a front face with gear teeth formed therein and a rear face having a cavity formed therein. The ring gear is supported within the power transfer unit by a bearing mounted within the cavity.

Abstract: A motor vehicle power transfer unit for distributing torque from a transmission assembly between a front wheel drive line and rear wheel drive line. The power transfer unit includes a housing that encloses a parallel gear set and a non-parallel gear set, which are coupled between an input portion and an output portion of the power transfer unit. The parallel gear set includes a driving gear, and idler gear and a driven gear and the idler gear is rotatably supported on a non-rotating support member that extends through the idler gear. Constructed in this manner, reduced lateral compactness of the power transfer unit is achieved.

Abstract: A mechanical stop is adapted to be mounted onto a rigid bar and includes a single piece conically shaped body having a plurality of inwardly extending projections. Each of the inwardly extending projections have a distal end that is contoured to match an outer surface of the bar. The distal ends define an opening. The conically shaped body is adapted to be plastically deformed to a substantially flat shape after being placed onto the rigid bar. The opening includes a first dimension larger than the rigid bar prior to being plastically deformed and a second dimension smaller than the rigid bar after being plastically deformed. After the conically shaped body is plastically deformed into a substantially flat shape, the distal ends will frictionally engage the outer surface of the rigid bar to secure the mechanical stop thereon.

Abstract: Universal joints, and more particularly, an apparatus and method for servicing staked universal joints as well as a u-joint serviced with the method and the apparatus. The service kit includes a replacement bearing assembly, a retention assembly and a spacer sized to fit between the retention assembly and the replacement bearing assembly. The method generally includes the steps of removing the stakes from an aperture on a driveshaft, removing an original bearing assembly from the aperture, inserting the replacement bearing assembly into the aperture, inserting the spacer into the aperture and retaining the spacer and replacement bearing assembly within the aperture with the retention assembly.

Abstract: A steer-by-wire assembly 10 is provided, including a flexible polymer steering column shaft 12 having a fixed end 14 and a free rotational end 16, and a control feature 22 in communication with said free rotational end 16. The flexible polymer steering column shaft 12 provides mechanical feel to the steer-by-wire system where prior mechanically actuated or servomotor devices were required.

Abstract: The present invention is a green soda-lime-silica glass composition. The composition comprises 68 to 75% SiO2, 10 to 18% Na2O, 5 to 15% CaO, 0 to 10% MgO, 0 to 5% Al2O3, and 0 to 5% K20, where CaO+MgO is 6 to 15% and Na2O+K20 is 10 to 20%, and colorants comprising: 0.3 to 0.8 wt. % total iron as Fe2O3 wherein the ratio of FeO/total Fe as Fe2O3 is 0.35 to 0.62; 0.05 to 0.5 wt. % manganese compound as MnO2; 0 to 0.1 wt. % titanium oxide as TiO2; and 0 to 1 wt. % cerium oxide as CeO2. The colored glass has the following spectral properties at 4.0 mm. thickness: 65 to 81% light transmittance using Illuminant A (LTA) and using Illuminant C has a dominant wavelength of 494 to 555 nanometers with an excitation purity of 2 to 9%.

Abstract: A lightweight damper for reducing noise and vibration in torque transferring assemblies that is easily assembled and cost efficient. The damper may be formed from a foam material having a density less than 1.4 lb/ft3, and includes an outer surface that is resiliently biased against the inner surface of a tubular shaft when installed. In a second embodiment, the damper is formed from a sheet of material that dissipates energy such as noises and vibrations through movement of the layers relative to each other. In third embodiment, the dampening sheet and foam damper are combined to provide a damper that dampens noises and vibrations across a large frequency range.

Abstract: The present invention discloses a synchronizing revolute joint with an external joint member, an internal joint member and rolling bearings arranged between the external joint member and the internal joint member. Each rolling bearing includes an inner race with a rolling bearing inner surface and an outer race with a rolling bearing outer surface. Between the inner race and the outer race there is arranged a plurality of rollers enabling the outer race to roll on the inner race. One of the inner race and the outer race includes an axial guide that determines the position of the rollers in relation to that race in the axial direction. The inner race and outer race are also axially displaceable against each other.