Abstract: A hose assembly includes a brake hose and a hose bracket integrally molded around the brake hose. The hose bracket attaches the hose to a frame of a vehicle. The bracket may be made of at least one polyolefin material selected from the group consisting of polypropylene, thermoplastic olefin (TPO), thermoplastic polyolefin elastomer (TPE), polypelene, santoprene, or other similar low temperature materials suitable for automotive applications. The bracket may be molded using a low pressure molding operation. Other conventional components of the hose assembly, such as rub rings and clips, can also be integrally molded to the brake hose in conjunction with the hose bracket.

Abstract: In order to prevent the formation of flash and air bubbles on a gasket used to seal a filter element when the filter element is mounted in a housing to filter a fluid, a molding apparatus comprises first and second mold components cooperating to define a mold cavity positioned around the filter media formed by their respective mold surfaces and adapted to receive an expandable material forming the sealing gasket. The mold cavity includes a substantially semi-spherical ridge portion having an apex. The ridge portion of the mold cavity is formed by both the first and second mold components abutting each other at the apex of the ridge portion of the mold cavity along a mold line oriented at an angle to a central axis of symmetry of the mold apparatus. Moreover, mold surfaces of the mold components have upwardly sloping ramp surfaces for preventing trapped air bubbles.

Abstract: A dual spring valve stem seal module utilizes an inner retention spring to incorporate a valve stem seal assembly, a valve spring and a spring retainer. The dual spring valve stem seal module reduces the inventory and simplifies the assembly required for the valve stem seal assembly, the valve spring and the spring retainer, thereby reducing the costs associated therewith.

Abstract: A filter/oil pan assembly for use in devices such as transmissions for vehicles and for use as oil pans in internal combustion engines includes a housing having an upper chamber and a sump, wherein a filter element is disposed between the upper chamber and the sump. The filter element includes a filter media having pleats which extend in the direction parallel to the direction of movement of the vehicle utilizing the filter element. In order to facilitate flow through the filter element, all interior surfaces of the housing slope toward a well in which the filter element is positioned and the filter element itself has laterally projecting flanges which slope downwardly toward the filter media.

Abstract: Multiple cutting heads are provided in a single cutting cell whereby vibrations created in one cutting head is isolated from the other cutting head(s). Each cutting head is supported by separate support structures to prevent the transfer of vibration from one cutting head to another. The multi-head laser cell includes a series of support structures that are staggered with respect to each other so that the lasers are isolated from each other. In the preferred embodiment, each laser cutting head has a dynamic pre-programmed operating zone to prevent collisions with other cutting heads. The control system will have the proper communications needed to coordinate motion used to develop the dynamic pre-programmed operating zone. Furthermore, the laser cutting heads preferably have multi-axes motion control; e.g., five axis motion control.

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 nitrile 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 panel filter element has a pleated filter media having peaks and valleys arranged in pleated sets of first and second panels. The pleated sets are adhered along side edges to form clean-side pockets which open adjacent to the valleys. The first and second panels have elongated embossments projecting both into and away from the pockets to keep the pockets open and to keep the pleated sets separate. Dirty air flows into the filter media both transverse to the peaks and laterally between the pleated sets of first and second panels. By having dirty air to be filtered flowing both transversly and laterally, the dirt holding capacity of the filter is increased while increases in restriction are minimized.

Abstract: A method and apparatus for preserving a starter/alternator in an I.C. engine system installation from repeated operation in the starter mode by detecting and preventing an I.C. engine stall by disabling the generator function of the starter/alternator. The system describes a method of comparing the detected rotational speed of the starter/alternator in generator mode with a reference rotational incipient stall speed of the system I.C. engine. If the I.C. engine speed falls below a threshold stall speed, the generator function of the starter/alternator is disabled. In addition, a second detected speed of the I.C. engine is detected following the disabling of the generator function to determine if the I.C. engine has resumed an engine speed above a second threshold speed, whereupon the generating function is restored.

Abstract: A test system is provided for primary and secondary brakes in a vehicle. The test system includes a two-position combination first valve having a first inlet coupled to a primary air supply, a second inlet coupled to a test air supply, and an outlet coupled to the primary brakes. The test system also includes a two-position combination second valve having a first inlet coupled to a secondary air supply, a second inlet coupled to the test air supply, and an outlet coupled to the secondary brakes. A system selector switch is provided for selectively applying current to one or both of the first and second valves responsive to a test signal input wherein each of the first and second valves directs fluid flow from one of the first and second inlets to the outlet.

Abstract: A method for operating a switched reluctance electrical generator in a manner that is highly efficient involves initially performing a mapping technique to obtain data relating to all of the possible operating conditions of the generator system that generate the desired output power. This mapping technique can be performed empirically or by computer simulation. Then, the effective phase currents supplied to the windings on the stator are measured or calculated. Next, the optimum conduction angles can be selected as those turn-on angles and turn-off angles that occur using the smallest effective phase currents supplied to the windings on the stator. Lastly, the generator system is operated using the selected optimum turn-on and turn-off angles. If desired, a feedback loop can be provided for comparing the actual output power that is generated by the generator system with a desired reference output power level to insure that such actual output power is maintained at or near the desired output power.

Abstract: A method of joining two vehicle axle housing components made from the same or dissimilar materials includes providing a first axle housing component, and providing a second axle housing component made from a material which is same/dissimilar to the material used to make the first axle housing component, where one of the first and second axle housing components is a metallic component made of a metallic material. A portion of one of the first and second axle housing components is positioned within a portion of the other of the axle housing 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.

Abstract: A vehicular body and frame assembly includes a plurality of individual frame modules that can be selectively connected together to form customized assemblies. Each of the individual modules can be constructed in any desired manner. To connect the modules together, each module has cooperating first and second connecting structures provided thereon. The first connecting structures are designed to connect to the second connecting structures. For example, the first connecting structures may be formed as hooks provided on the lower portions of the frame modules, and the second connecting structures may be formed as pins provided on the lower portions of the frame modules upon which the hooks can be engaged. The frame modules can be connected together in this manner and pivoted to a mating position, wherein they can be positively retained together by bolts or other fasteners that extend between the mating frame modules.

Abstract: The present invention is directed to a resin ceramic composition that includes a ceramic filler in an amount effective for providing a single composition with a magnetic field of at least one gauss.

Abstract: A method for measuring irregularities on the outer surface of an article employs an apparatus to obtain qualitative information regarding a first portion of the outer surface of the article, which can be used to generate a visual representation of a first portion of the outer surface of the article. Then, the article is moved by a predetermined amount, and the apparatus is again used to generate a visual representation of a second portion of the surface of the article. This process is repeated to obtain a plurality of visual representations that together span across a predetermined amount of the surface of the article. Then, the plurality of visual representations are processed to generate a single comprehensive enlarged visual representation of a relatively large surface area of the article, which is preferably shaded, colored, or otherwise highlighted to illustrate the irregularities that are formed therein.

Abstract: A method for joining vehicle components together to form a vehicle frame assembly where the components are formed from dissimilar materials such as metallic and non-metallic materials. A composite body mount bracket may be attached to a structural component of a vehicle body and frame assembly by providing a body mount bracket having an opening formed therethrough and by providing a first structural component formed from a metallic material also having an opening formed therethrough. The body mount bracket is then positioned adjacent the first structural component such that the respective openings are aligned with one another. A second structural component formed of a metallic material is then inserted through the aligned openings. Next, the second structural component is welded first structural component through a magnetic pulse welding technique, and lastly, the second structural component is pulse formed or deformed so as to mechanically clamp the body mount bracket thereto.

Abstract: A floating and captured cage nut assembly includes a structural member that is U-shaped with a pair of rolled sides defining mounting legs and a rolled front end defining an anti-rotation flange. The rolled sides of the structural member are positioned on the component and are welded or otherwise secured thereto over the opening during manufacture. The floating and captured cage nut assembly further includes an anti-rotation plate having a hexagonal opening to receive a flange nut and a locking window. The anti-rotation plate and the flange nut are inserted within the structural member and the anti-rotation flange is received within the locking window with clearance to loosely secure the components together. The flange nut is retained on the component, and the anti-rotation plate prevents its rotation. The clearance between the anti-rotation flange and the locking window facilitates the threading of the fastener into the nut within a predetermined tolerance zone.

Abstract: A method for manufacturing a vehicle frame assembly includes the initial steps of providing first and second structural components, disposing portions of the first and second structural components in an overlapping relationship, and generating an electromagnetic field that causes at least one of the overlapping portions of the first and second structural components to move into contact with the other of the overlapping portions of the first and second structural components at a high velocity so as to be joined together to form a joint. Third and fourth structural components are provided. The third and fourth structural components are joined to the first and second structural components together to form a vehicle frame assembly.

Abstract: A system and method for protecting a component of an I.C. engine system by controlling a starter/alternator in response to the component's temperature. The system describes a method of comparing the temperature of the component to a predetermined threshold temperature and, if the temperature exceeds the threshold, disabling the starter/alternator. According to the present invention the temperature of the vehicle battery, starter/alternator motor and starter/alternator inverter may be protected. The starter/alternator is controlled/disabled according to mode of operation.

Abstract: A steer axle assembly is provided having an axle beam disposed about a longitudinal axis and an inverted knuckle yoke. The yoke includes a body portion that is affixed to an external surface of the axle beam by welding. The yoke further includes first and second arms extending from the body portion. Body the body portion and arms are disposed one side of the axis extending through the axle beam. The drop of the axle is varied by varying the length of the body portion of the knuckle yoke.

Abstract: A clamp for gripping a part or workpiece is provided in which the arms of the clamp securely engage the part before being locked in place relative to the body of the clamp. The clamp includes a body and first and second arms extending from the body. The clamp further includes a nut disposed in one of the two arms and a fastener extending through portions of both arms. Rotation of the fastener causes movement of the nut along a first axis which causes a corresponding movement in a pushrod disposed in the same arm as the nut along a second axis perpendicular to the first axis. The pushrod engages a plate disposed within the body of the clamp to lock the arms of the clamp relative to the clamp body.