Abstract: A heat exchanger (20) includes an inlet connector (22) having a flat joint surface (23) and an outlet connector (24) having a flat joint surface (25). The heat exchanger (20) also includes a round tube (26). The round tube (26) includes an inlet aperture (28), an outlet aperture (30) and flat surfaces (32, 34) adjacent each of the inlet aperture (28) and the outlet aperture (30). The flat joint surface (23) of the inlet connector (22) is coupled to the flat surface (32) adjacent the inlet aperture (28) and the flat joint surface (25) of the outlet connector (24) is coupled to the flat surface (34) adjacent the outlet connector (24).

Abstract: Two components necessary to make up a heat exchanger assembly generally need to be brazed. Two components may be secured which do not contain a cladded alloy. Staking or crimping is used to hold the two components together while securing a braze ring captured between the two components which acts as a brazing mechanism.

Abstract: A heat exchanger assembly is provided. The heat exchanger assembly comprises a core body, a plate fixedly coupled to the core body, the plate defining an aperture therein, and a tank having a foot thereon, wherein under the condition that the plate and the tank are coupled to one another, the aperture functionally engages the foot. The plate sidewall comprises the aperture and further comprises a crimping member in a distal end of the sidewall. The foot further comprises a securing surface and an engagement surface, the engagement surface being configured to engage the aperture and the crimping member being configured to be bent about the foot to engage the securing surface. A sealing member is placed between the tank and the plate to fluidicly seal the tank and the plate once coupled together. Such a configuration provides two means of coupling the plate to the tank.

Abstract: A heat exchanger (20) includes an inlet connector (22) having a flat joint surface (23) and an outlet connector (24) having a flat joint surface (25). The heat exchanger (20) also includes a round tube (26). The round tube (26) includes an inlet aperture (28), an outlet aperture (30) and flat surfaces (32, 34) adjacent each of the inlet aperture (28) and the outlet aperture (30). The flat joint surface (23) of the inlet connector (22) is coupled to the flat surface (32) adjacent the inlet aperture (28) and the flat joint surface (25) of the outlet connector (24) is coupled to the flat surface (34) adjacent the outlet connector (24).

Abstract: A sensor system (24) for controlling a ventilation unit (22) of a vehicle (20) includes a sensitivity selector (70) for enabling a user to select a setting (76) corresponding to an air quality threshold (94, 98), and an air quality sensor (62) proximate an exterior of the vehicle (20) for detecting an air quality parameter (71). A controller (66) is responsive to the selector (70) and the sensor (62), and is in communication with an inlet air valve (32) of the ventilation unit (22). A method (118) of operating the sensor system (24) entails receiving a current value of the air quality parameter (71) at the controller (66) for comparison with the air quality threshold (94, 98). The controller (66) generates a switch signal (74) in response to the comparison for adjusting the inlet air valve (32) between an outside air mode (44) and a recirculation mode (46).

Abstract: A tube interface (53) includes a first tube (28) and a second tube (34). The first tube (28) has an oblong opening (54) exhibiting a first major dimension (58), and the second tube (34) has an oblong end (52) exhibiting a second major dimension (72). The oblong end (52) of the second tube (34) is inserted into the oblong opening (54) so that the second major dimension (72) is aligned with the first major dimension (58). The second tube (34) is turned in the oblong opening (54) to move the second major dimension (72) out of alignment with the first major dimension (58) of the oblong opening (54) to secure the second tube (34) to the first tube (28) prior to brazing.

Abstract: A motor assembly (20) includes a motor (22) and an end cap (26). The end cap (26) includes an electrically insulating body (28) having a peripheral edge (30) that interfaces with a conductive housing (24) of the motor (22). Motor terminals (94, 102) and an electromagnetic suppression (EMD) chip device (54) are located within the body (28). The chip device (54) has an input terminal (74) in electrical communication with the motor terminal (94), an input terminal (76) in electrical communication with the motor terminal (102), and an earth terminal (78). A conductive ground strap (56) is in electrical communication with the earth terminal (78). The ground strap (56) encapsulates and retains the chip device (54) in the end cap (26) and has an end (60) fitted onto the peripheral edge (30) of the end cap (26) between the end cap (26) and the conductive housing (24) of the motor (22).

Abstract: A method of forming an invisible frangible tear seam in a multi-layered vehicle trim panel for deployment of an air bag therethrough. The method involves the use of a jig or mask that is configured in the desired shape of the tear seam. The tear seam is produced by providing a first polymeric layer on a trim panel mold surface and then positioning the jig or mask on the first polymeric layer. Next a second polymeric layer is applied to the first polymeric layer using a spray process. After the second polymeric layer has been applied the jig or mask is removed, leaving a foot-print of the jig or mask which defines the tear seam. The resulting bi-layered structure is joined to a support panel using an adhesive foam to form a multi-layered vehicle trim panel.

Abstract: A motor assembly (20) includes a motor (22) and an end cap (26). The end cap (26) includes an electrically insulating body (28) having a peripheral edge (30) that interfaces with a conductive housing (24) of the motor (22). Motor terminals (94, 102) and an electromagnetic suppression (EMD) chip device (54) are located within the body (28). The chip device (54) has an input terminal (74) in electrical communication with the motor terminal (94), an input terminal (76) in electrical communication with the motor terminal (102), and an earth terminal (78). A conductive ground strap (56) is in electrical communication with the earth terminal (78). The ground strap (56) encapsulates and retains the chip device (54) in the end cap (26) and has an end (60) fitted onto the peripheral edge (30) of the end cap (26) between the end cap (26) and the conductive housing (24) of the motor (22).

Abstract: A heat exchanger (40) includes first and second headers (44, 46). Multiple flat core tubes (54) are arranged spaced apart from one another and connected between the headers (44, 46). A fin pack (56) has multiple rows (58) of fins (60) and multiple tabular portions (62, 64). Pairs (70, 72) of adjacent multiple rows (58) are interconnected by the tabular portions (62, 64). The tabular portions (62, 64) define channels (78) between each of the rows (58) of fins (60). A method (90) for producing the heat exchanger (40) entails concurrently inserting multiple core tubes (54) into the channels (78), with one row of fins (60) being disposed between each pair of the core tubes (54).

Abstract: A tube interface (53) includes a first tube (28) and a second tube (34). The first tube (28) has an oblong opening (54) exhibiting a first major dimension (58), and the second tube (34) has an oblong end (52) exhibiting a second major dimension (72). The oblong end (52) of the second tube (34) is inserted into the oblong opening (54) so that the second major dimension (72) is aligned with the first major dimension (58). The second tube (34) is turned in the oblong opening (54) to move the second major dimension (72) out of alignment with the first major dimension (58) of the oblong opening (54) to secure the second tube (34) to the first tube (28) prior to brazing.

Abstract: A tube interface (53) includes a first tube (28) and a second tube (34). The first tube (28) has an oblong opening (54) exhibiting a first major dimension (58), and the second tube (34) has an oblong end (52) exhibiting a second major dimension (72). The oblong end (52) of the second tube (34) is inserted into the oblong opening (54) so that the second major dimension (72) is aligned with the first major dimension (58). The second tube (34) is turned in the oblong opening (54) to move the second major dimension (72) out of alignment with the first major dimension (58) of the oblong opening (54) to secure the second tube (34) to the first tube (28) prior to brazing.

Abstract: A heat exchanger evaluation system (84) includes a refrigeration subsystem (126) and a platform (94) in communication with the subsystem (126) for attachment of a heat exchanger (32). The system (84) further includes a thermal imaging camera (168) and a monitor (100). A method (180) entails routing a fluid (38) through the heat exchanger (32) via the refrigeration subsystem (126). The camera (168) detects the temperature variation across the heat exchanger (32) as the fluid (38) flows through the heat exchanger, and provides successive thermal images representing the temperature variation responsive to the flow of the fluid (38). The thermal images are utilized to determine an efficacy of the flow through the heat exchanger (32). In particular, a determination can be made as to whether the flow deviates from a pre-determined flow path (79) of the fluid (38) through the heat exchanger.

Abstract: A receiver (24) for a condenser system (20) includes a body (32) in fluid communication with a header (28) of the condenser system (20). A first cap (38) is coupled to an end (34) of the body (32) and has a saddle portion (40) coupled to the header (28). The receiver (24) further includes a tube section (42) coupled to a second end (36) of the body. A second cap (50) is removably interconnected with the tube section (42) following insertion of a service cartridge (76) into the body (32). The service cartridge (76) includes a substantially-rigid tubular member (78) having rib members (84) radially extending from an outer surface (86) of the tubular member (78). Covers (90, 92), each having openings (94, 96), are coupled to opposing ends of the tubular member (78). The service cartridge (76) includes multiple features for drying, filtering, and/or leak detection.

Abstract: A process (100) and apparatus (20) for control of a deployment of an airbag (28) for a seat (30) in a motor vehicle (22). Upon issuance of a deployment request (RD) by a vehicular computer (24) intended for a deployment activator (26), a processor (36) intercepts the deployment request (RD). The processor (36) then receives a load mass (M), a load temperature (T), and a load height (H) from a mass sensor (38), a thermal-imaging sensor (52), and a proximity sensor (54), respectively. The processor (36) adjudicates the load mass (M), load temperature (T), and load height (H), to determine a deployment status (SD). A deployment status (SD) of pass (SP) is adjudicated when the load mass (M) is greater than or equal to a reference mass (MR), the load temperature (T) is greater than or equal to a reference temperature (TR), and the load height (H) is greater than or equal to a reference height (HR). A deployment status (SD) of inhibit (SI) is adjudicated otherwise.

Abstract: A heat exchanger (40) includes a first header (42), a second header (44), and a plurality of tubes (46) extending between the first and second headers (42, 44). First and second extension members (48, 52) project from and are longitudinally oriented along a frontward facing side (50) of the headers (42, 44). The first and second extension members (48, 52) serve as guides for facilitating airflow through the heat exchanger (40). Third and fourth extension members (54, 58) project from and are longitudinally oriented along a rearward facing side (56) of the headers (42, 44). The third and fourth extension members (54, 58) serve to seal a gap between the heat exchanger (40) and an adjacent radiator (26), and guide airflow from the heat exchanger (40) through the radiator (26).

Abstract: A tube interface (53) includes a first tube (28) and a second tube (34). The first tube (28) has an oblong opening (54) exhibiting a first major dimension (58), and the second tube (34) has an oblong end (52) exhibiting a second major dimension (72). The oblong end (52) of the second tube (34) is inserted into the oblong opening (54) so that the second major dimension (72) is aligned with the first major dimension (58). The second tube (34) is turned in the oblong opening (54) to move the second major dimension (72) out of alignment with the first major dimension (58) of the oblong opening (54) to secure the second tube (34) to the first tube (28) prior to brazing.

Abstract: A system and method for the manufacture of a laser-welded cone-shell catalytic converter (100) is provided. An unformed shell blank (111) is formed into a cylindroid shell (110) having overlapping edges (112), which are then resistance welded to produce a shell seam (116). The shell seam (116) is planished to a thickness (120) less than 125 percent of a thickness (119) of the unformed shell blank (111). A ceramic catalytic substrate (130) is wrapped in a ceramic-fiber mounting mat (131) and inserted into the shell (110). Ends (125) of the shell (110) are crimped to form a 1 mm turndown (134). A pair of endcones (140) is assembled, where for each endcone (140) an outer cone (141) is loaded with an endcone insulation (142), and an inner cone (143) is pressed into and spot-welded to the outer cone (141). The endcones (140) are fitted to the shell (110) so as to form an overlap zone (151). The endcones (140) and shell (110) are then laser welded by an Nd:YAG laser (253) in the overlap zone (151).

Abstract: A receiver (24) in a condenser system (20) includes a body (32) in fluid communication with a header (28) of the condenser system (20). A service cartridge (154) is insertable into an interior cavity (106) of the body (32). The service cartridge (154) includes a substantially-rigid tubular member (156). Covers (166, 168), each having openings (170, 172), are coupled to opposing ends of the tubular member (78). A spindle (179) is non-detachably coupled to each of the first cover (166) and a cap (180). The cap (180) is configured for threaded attachment to a service end of the body (32) of the receiver (24). Refrigerant 150 is received by the tubular member (156) via the first openings (170), and is discharged from the tubular member (156) via the second openings (172). The service cartridge (154) includes multiple features for drying, filtering, and/or leak detection.

Abstract: A receiver (24) for a condenser system (20) includes a body (32) in fluid communication with a header (28) of the condenser system (20). A first cap (38) is coupled to an end (34) of the body (32) and has a saddle portion (40) coupled to the header (28). The receiver (24) further includes a tube section (42) coupled to a second end (36) of the body. A second cap (50) is removably interconnected with the tube section (42) following insertion of a service cartridge (76) into the body (32). The service cartridge (76) includes a substantially-rigid tubular member (78) having rib members (84) radially extending from an outer surface (86) of the tubular member (78). Covers (90, 92), each having openings (94, 96), are coupled to opposing ends of the tubular member (78). The service cartridge (76) includes multiple features for drying, filtering, and/or leak detection.