Abstract: Methods and apparatus for plasma-assisted joining of one or more parts together are provided. The joining process may include, for example, placing at least first and second joining areas in proximity to one another in a cavity, forming a plasma in the cavity by subjecting a gas to electromagnetic radiation in the presence of a plasma catalyst, and sustaining the plasma at least until the first and second joining areas are joined. Plasma catalysts, and methods and apparatus for igniting, modulating, and sustaining a joining plasma, are provided. Additional cavity shapes, and methods and apparatus for selective plasma-joining, are also provided.

Abstract: A suspension for coupling a steer axle assembly to a vehicle frame is provided that moves one or more of the spring reaction points outboard to increase roll stiffness and enable the use of a lighter axle. In one embodiment of the invention, the suspension includes a spring coupled to the vehicle frame and a shock absorber having a first end coupled to the spring and a second end coupled to a component of the steer axle assembly, such as the kingpin, at a location outboard of a longitudinal frame rail of the vehicle frame.

Abstract: A method of inflating a tire, or vehicle tire, that minimizes the amount of time needed for same is disclosed. The method of inflating a tire with a tire pressure management system includes introducing continuous fluid flow of a fluid into the tire, ascertaining the dynamic pressure of the fluid during said introducing continuous fluid flow, terminating continuous fluid flow when the dynamic pressure exceeds or equals a predetermined amount, and introducing pulsed fluid flow of the fluid into the tire.

Abstract: A suspension and steering subassembly for a heavy truck is provided including a subframe. The subframe includes first and second side members extending substantially in the direction of vehicle travel and first and second cross members extending substantially perpendicular to the direction of vehicle travel. The first and second cross members are integral with the first and second side members such that the subframe is a unitary member. The first and second side members and the first and second cross members are further configured to receive first and second lower suspension control arms, first and second upper suspension control arms, and a portion of the steering linkage for the vehicle. The subframe may further be configured to receive a steering gear and one or more strut rods to provide fore/aft support to the subframe.

Abstract: A tandem axle assembly capable of accommodating variations in driveline length is provided. The tandem axle assembly includes forward and rear axle assemblies each having a wheel differential with the forward axle assembly further including an inter-axle differential for dividing power between the two wheel differentials. A male-female slip connection is formed between two members at one or more of the following intersections: the connection between a power input shaft driving the inter-axle differential and a power transmission shaft for transferring power from a vehicle driveshaft to the power input shaft; the connection between an output shaft driven by the inter-axle differential and an output yoke of an intermediate drive shaft assembly extending between the forward and rear axle assemblies; and the connection between an input yoke of the intermediate drive shaft assembly and a pinion shaft in the rear axle assembly drivingly coupled to the rear wheel differential.

Abstract: A method of joining two vehicle suspension components made from the same or dissimilar materials includes providing a first suspension component, and providing a second suspension component made from a material which is same/dissimilar to the material used to make the first suspension component, where one of the first and second suspension components is a metallic component made of a metallic material. A portion of one of the first and second suspension components is positioned within a portion of the other of the suspension components in an overlapping manner, thereby forming an overlapping portion. A metallic band may be disposed around the overlapping portion. An inductor is positioned around the overlapping portion. The inductor is energized to generate a magnetic field for collapsing at least one of the overlapping portion and the metallic band at a velocity sufficient to magnetic pulse weld the components to each other, thereby securing the first and second suspension components together.

Abstract: The present invention minimizes variations in torque due to cogging in a permanent magnet brushless electric motor and, among other things, specifies a topology of a rotor and a stator in relation to one another. According to one embodiment, a permanent magnetic motor includes a housing surrounding a stator that in turn surrounds a rotor rotatably mounted to the housing. The stator has a stator cross section including a plurality of uniformly distributed and spaced apart stator poles separated by slots. The stator poles extend radially inward from the inner surface and terminate at an end defined by an inner pole face. Each end is separated from an adjacent end by a distance defined as a stator slot width W. The rotor cross section includes a plurality of spaced apart permanent magnets carried by the shaft and angularly and uniformly distributed about the shaft.

Abstract: An inter-axle differential assembly comprises an input shaft, an output shaft arranged coaxially with respect to each other, a differential gearing and a dedicated reversible lubrication pump disposed between the input and output shafts. The reversible gerotor type lubrication pump includes a rotor driven by the input shaft, and an impeller, both disposed within a pump body coupled to a side gear drivingly connected to the output shaft. Thus, the lubrication pump generates lubricant flow only during the differential action between the input shaft and the output shaft, i.e. when needed. An oil flow generated by the lubrication pump is supplied to various components of the inter-axle differential gearing through a gallery of fluid passages.

Abstract: A weld between a tube yoke and a driveshaft tube can accommodate a greater amount of torsional shear stresses and, therefore, increase the load carrying capacity of a driveshaft assembly. The driveshaft assembly includes a yoke having a sleeve portion and a driveshaft tube having an end that extends about the sleeve portion of the yoke. The end of the tube is secured to the sleeve portion of the yoke by a weld having a shape that traverses multiple planes, such as a sinusoidal, saw-tooth, or square tooth shape. The weld occupies a greater area and, thus, has a greater surface contact between the sleeve portion of the yoke and the end of the driveshaft tube. The force vectors of the torsional shear stress sustained by the weld are in multiple planes. As a result, the force vectors of the torsional shear stress impinge the welds at different angles, and the weld has a greater load carrying capacity.

Abstract: An engine starting apparatus comprises a starter/alternator assembly operatively coupled to the engine and is capable of being operated in a starter mode for starting the engine and in a generator mode for generating electric power when driven by the engine. The starter/alternator assembly includes a starter/alternator machine drivingly connected to the engine, an inverter provided for controlling an output of the starter/alternator machine to selectively choose either the starting mode or the generation mode, and an electronic controller provided for controlling the starter/alternator assembly. The starting apparatus further comprises an engine speed sensor for monitoring a rotational speed of the engine that is electrically connected to the electronic controller. A method of controlling the engine starting apparatus controls transition of the starter/alternator assembly from the starter mode to the generator mode in response to the rotational speed of the engine directly sensed by the engine speed sensor.

Abstract: Methods and materials for sealing and insulating a fuel cell plate are disclosed. The disclosed process includes applying a coating precursor on at least one surface of the fuel cell plate, and curing the coating precursor by exposure to radiation. Disclosed coating precursors include those containing an acrylated oligomer and a photoinitiator, which can polymerize in response to ultraviolet or electron beam radiation. Other disclosed coating precursors are those that can polymerize in response to exposure to infrared radiation or heating, and include epoxy nitrite resins and organopolysiloxane resins. The disclosed processes and coating precursors provide certain advantages over conventional methods and designs for insulating and sealing fuel cell plates since the disclosed coating precursors can be quickly and precisely applied to fuel cell plates by, for example, screening printing.

Abstract: A tuning cable assembly comprising a reinforced tube, a tuning cable placed within said reinforced tube, where the tuning cable is comprised of a thermoset material or a cross-linked thermoplastic material, and a narrow annular cavity formed between the inner surface of the reinforced tube and the outer surface of the tuning cable. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. This abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Abstract: A valve stem seal assembly includes several protrusions or bumps on the bottom of a spring seat flange or on a spring wear washer surrounding the seal. The protrusions can be either cast formed or machined in place. In described embodiments, the protrusions are adapted to engage corresponding depressions, holes, or receptors in a cylinder head deck surface against which the flange or wear washer abuts. A positive mechanical anchor is thereby created for resisting any torque applied to the flange or washer through mechanical vibration induced rotation of the valve spring. Sliding contact is thereby avoided at the interface between the flange or washer and the cylinder head, and wear is prevented. Use of one disclosed embodiment will require that the cylinder head manufacturer provides a cylinder head that includes several small depressions or apertures in the valve spring seat area that correspond with the disclosed protrusions or bumps.

Abstract: An end cap of a filter element has canted fins in an annular space between a filter element and filter housing for imparting a rotary motion to a fluid prior to the fluid passing through the filter element. The end cap includes a plurality of axially extending legs upstream of the fins, which legs engage a nutplate. Spaces between the legs provide an inlet allowing dirty fluid to flow to the outside surfaces of the filter element. The fins remove large particles from the fluid by centrifugal force so that large particles do not add to the contaminant load in the filter elements.

Abstract: A valve stem seal assembly includes a retainer and a sealing element disposed within the retainer. The retainer includes a step and one or more installation pads. The sealing element includes a first sealing lip for sealing a valve stem, and a second sealing lip for sealing a chamfer of a valve guide. The step of the retainer exerts a compression force, F, against the second sealing lip to seal the second sealing lip against the chamber of the valve guide. The one or more installation pads exerts a frictional force against the valve guide to prevent movement of said valve stem seal assembly. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A differential with an improved locking mechanism is provided. The differential includes first and second clutch members in the form of a differential case having a first set of teeth and a an axle shaft mounted clutch collar having a second set of teeth. A yoke urges the clutch into an out of engagement and is supported on a pivot shaft. The yoke is selectively urged in one direction by an actuator acting on a lever on the pivot shaft. The lever is coupled to the yoke by a spring. The yoke is urged in an opposite direction by one or more return springs mounted on the same pivot shaft. The compact nature of the locking mechanism and the balance of forces provided by the springs and actuator provide an inexpensive and reliable locking mechanism.

Abstract: The present invention is directed to determining and controlling the appropriate moment at which a combined starter/alternator should transition from start-up mode to alternator/generator mode following an IC engine start-up sequence. The method relies on either belt/chain tensioner position or the position of the belt/chain itself to determine when the IC engine has achieved self-sustaining operation and signal the starter/alternator to transition from start-up to generator mode.

Abstract: The invention pertains to a valve cover for internal combustion engines with at least one overhead camshaft, wherein bearings for the camshaft(s) are embedded in a polymeric plastic material constituting the valve cover.

Abstract: The present invention relates to a method including thermal spraying a chromium nitride or a chromium carbide and chromium silicide coating material on to an article. The coating material may be in a powder form before thermal spraying. In one aspect, the thermal spraying includes melting the coating material, propelling the molten coating material toward the article to be coated, and coating the article with the molten coating material. In another aspect, the coated article is one or more piston rings.

Abstract: A yaw management system for a vehicle with driveline torque control is comprised of sensors to determine the rate of change of yaw in the vehicle, a controller for receiving information from the sensors, and a means for using that information to selectively transfer torque from the inner half shaft axles of the vehicle to the outer half shaft axles of the vehicle for regulating the torque delivered to the drive wheels.