Abstract: An inductive battery charging system that uses heat conducting heat exchangers that shape electromagnetic fields produced by the windings of the charging system. The field shaping provided by the heat exchangers of the present invention improves the power handling capacity of the system. The charging system includes a charge probe that includes a primary winding of a transformer and a charge port that includes secondary windings of the transformer. The heat exchangers are heat sinks that are inserted between or are disposed adjacent turns of the windings and are used to remove heat from windings. In the present invention, the heat exchangers are also used to shape the leakage flux near the edges of the windings in such a manner that AC losses in the windings are considerably reduced. The present invention may be used to increase the inductive charging capacity of an electric vehicle battery pack to on the order of 120 KW and beyond.

Abstract: A multi-phase AC to DC harmonic neutralizing power converter. The power converter includes a plurality of inputs for respective phases of a multi-phase source of AC power and a plurality of first rectifiers connected respectively to the inputs. A multi-phase harmonic neutralizing converter includes a power switching inverter having an input connected to the outputs of each of the first rectifiers, the inverter including LC resonant circuits. A plurality of second rectifiers having respective inputs connected to the output of the inverter through a plurality of respective transformers having outputs that are connected in voltage additive relationship to the outputs of the respective individual phase first rectifiers. A single set of power switches is utilized to neutralize multiple input power phases.

Abstract: A pattern recognition system is utilized in a supplementary inflatable restraint (SIR) system to distinguish between deployment and non-deployment events. The pattern recognition system preferably includes dedicated hardware or a microprocessor programmed to perform a neural network simulation utilizing crash data in the form of vehicle acceleration data. Training and trial vectors are generated from the data to train and, subsequently, test the neural network.

Abstract: A high voltage cable system for use with a contactless battery charging system that charge propulsion batteries of an electric vehicle, and the like. The contactless battery charging system includes a primary power converter coupled to a power source and a secondary power converter located on the electric vehicle that is coupled propulsion batteries of the electric vehicle. The primary and secondary power converters are connected by way of a coaxial power cable. An isolation transformer is coupled between the output of the primary power converter and the coaxial power cable. This transformer allows one of the two outputs of the primary power converter to be connected to ground potential. The isolation transformer improves the safety and reduces electromagnetic interference (EMI) when coupling power to the secondary power converter.

Abstract: An internal combustion engine has a crankshaft sensor with an uneven tooth spacing to identify an index tooth corresponding in position to top dead center (TDC) of the number 1 cylinder. A microprocessor based engine controller determines from the sensor pulses each TDC event. During cranking, the number 1 cylinder compression stroke is detected from engine speed variations by measuring time periods over sample ranges before and after TDC. When a compression stroke occurs just before TDC, the period before TDC is greater than the period after TDC, whereas other TDC events are evidenced by the period before TDC being smaller than or equal to the period after TDC.

Abstract: A high power module containing high power, high frequency semiconductor switching devices and methods of operating the same that provide high power and low inductance. The module incorporates compositional, geometrical and electrical symmetry. The module also includes short internal leads, special IC chip substrates, trimmable gate lead resistances, a special composite metal/ceramic baseplate, and a special terminal conductor overlap.

Abstract: A flexible capacitor is provided which is suitable for use in conjunction with a magnetic core for forming a CLC or pi filter, such as the type used for electrical connectors in the engine control hardware for an automobile. The flexible capacitor is generally composed of a flexible substrate having a surface on which interleaved conductor layers are supported. The interleaved conductor layers include at least two conductor layers, a first of which is composed of a plurality of islands of electrically conductive material which are electrically isolated from each other, while a second layer is composed of an electrically conductive material. A dielectric layer is disposed intermediate each adjacent pair of conductor layers so as to form a capacitive structure. The first conductor layer serves as the signal capacitor plate, while the second conductor layer serves as the ground capacitor plate.

Abstract: Ignition events in a direct ignition system are sensed by capacitively coupling positive and negative ignition voltages generated by the secondary winding of the ignition transformer. A pair of planar conductive plates disposed remote from each of the secondary winding leads capacitively couple the ignition voltages to a common node to provide an input to a processing circuit for determination of absolute engine position. The secondary coil and leads are at least partially immersed in an epoxy potting material, which forms a dielectric through which the conductive plates are capacitively coupled to the respective coil leads. The plates are electrically coupled by a conductor to form a common node, which in turn is electrically coupled to a signal processing circuit. Conveniently, the plates and conductors are formed as a single leadframe element and insert molded in the polyester material.

Abstract: Heat exchanger that are also outer turns of secondary windings of a transformer for use in a charge port of battery charging apparatus. The outer turns may have any shape or thickness, may be air or liquid cooled, or may be vapor changers (heat pipes). Other turns of the secondary windings cannot be used in this manner because they cause excessive energy dissipation, due to proximity losses. When used to a liquid cooled turn, the present invention comprises porting liquid coolant from a cooling system including a pump, a compact heat exchanger, and a fan through the outer windings. Heat dissipation from the secondary windings of the transformer is efficiently removed by providing an internal coolant flow passage or passages formed or integrated at the center of the outer windings comprising the heat exchangers. The internal passages may be configured in several ways. One approach is to construct thin, flat, self-contained flexible coolant bladders made of metal, such as copper.

Abstract: A pushbutton for an automotive control panel has a button portion extending through a hole in a trim plate and an enlarged skirt portion behind the plate, and is spring loaded to push the skirt against the rear surface of the plate. A ledge surrounding the button opposes the rear surface. The pushbutton is painted and paint on the ledge causes the skirt to stick to the rear surface of the plate. To prevent sticking, pointed spacers are molded on the ledge so that only the spacer points engage the plate. Sticking from paint adhesion is minimized due to the small amount of paint on the spacer points. Alternatively, the pointed spacers are formed on the rear surface of the plate.

Abstract: A substrate subassembly for a high power module, and methods involving the same. The substrate subassembly contains only one switching transistor and has at least one integral short terminal lead tab. The substrate subassemblies can be pretested at significant operating current, to obtain enhanced characterization and matching of mounted switching transistors. Trimmable gate lead resistances can be incorporated in the substrate subassemblies. Enhanced compositional, geometrical and electrical module symmetry is available. New module structures and method are afforded.

Abstract: A transponder embedded in a key and a reader/exciter coil surrounding the lock cylinder are inductively linked to provide energization to the transponder, causing it to emit a digital identification code. A control circuit associated with the coil supplies energizing coil current and analyzes the emitted code to verify the authenticity of the key. The coil and control circuit are contained in a planar multi-layer hardboard printed circuit having high circuit integrity and being very thin for accommodation in the lock assembly. Alternatively, the coil and control circuit are contained in a flexible printed circuit. There the coil includes two opposed elongated legs which are positioned on opposite sides of the lock cylinder and folded in a way to conform to the cylinder surface, forming in effect a very thin cylindrical coil. An extension on the printed circuit form a path to the control circuit which is remote from the cylinder.

Abstract: A method and system for discriminating a target which presents a hazard to a motor vehicle moving in a first lane of traffic from a target moving in a second adjacent lane of traffic which does not present a hazard to the vehicle. The method includes the steps of utilizing an antenna mounted flush to a side of the vehicle to produce a radar beam having a beamwidth greater than 5-10 degrees to illuminate the target. At least a portion of the radar beam is produced along a first axis which is perpendicular to the direction of motion of the vehicle. The reflected signal is received from the illuminated target and a velocity of the illuminated target is estimated with a Kalman filter relative to the velocity of the vehicle in the direction of a second axis which is parallel to the direction of motion of the vehicle based on the reflected signal.

Abstract: A multilayer circuit is provided characterized by a multilayer conductor structure. The multilayer conductor structure is composed of at least two conductor layers, with each adjacent layer being separated by a dielectric material in the form of one or more dielectric layers. The multilayer circuit further includes electrically conductive members or features for electrically interconnecting the conductor layers at two or more locations along the lengths of the conductor layers. As a result, portions of the conductor layers between two or more locations are electrically in parallel with each other, such that the multilayer conductor is characterized by an electrical resistance between the locations which is less than the electrical resistance of the individual conductor layers between the locations. The multilayer conductor is therefore characterized by an augmented current-carrying capacity as compared to a single layer conductor of the same length and width.

Abstract: An ink composition is provided for forming an ultra-thick thick film which is suitable for conducting heat laterally from a heat generating device supported on a substrate. The ink composition is formulated to enable the ultra-thick thick film to be formed as a single layer, such that only a single print, dry and fire cycle is required to form the film. Advantageously, ultra-thick thick films having thicknesses of about 125 micrometers (about 0.005 inch) and greater can be formed by a single layer of the ink composition.

Abstract: Stable current control to an inductive load uses a digital driver having registers loaded with load control parameters from a microprocessor. The parameters, along with a counter responsive to clock pulses, control a pulse period and a pulse width which are used to operate an FET in series with the load to control load current. Current mode control develops a decreasing current limit voltage in each pulse period by decrementing a down counter at a rate and from an initial value commanded by the microprocessor, and converting the value to an analog current limit signal. The signal is compared to a load current feedback signal and the pulse width is truncated if the load current reaches the current limit signal.

Abstract: An inductive load energized by a variable duty cycle pulse signal contains ripple at steady state conditions, and the average current is used as feedback to a controller. The average current is obtained without filtering by synchronously sampling the local maxima and minima of the current and averaging the last two samples. The maxima and minima are detected by sampling at the falling and rising edges of the pulse signal. The method is implemented by software in a microprocessor or by hardware comprising a pulse generator, sample and hold circuits, and an averager. The resulting average value is then asynchronously sampled by a microprocessor.

Abstract: A low inductance coaxial semiconductor switching module and methods of operating the same. The module can contain high power, high frequency semiconductor switching devices, operated to provide high power at low inductance. The module incorporates compositional, geometrical and electrical symmetry in a coaxial configuration. The module also includes short internal leads, a special circumferential array of substrates, a special circular gate circuit, a special circular kelvin circuit, and special terminal subassembly and special module mounting features.

Abstract: A method and apparatus for electron or laser beam welding of semiconductor subassemblies to larger terminal members, without exposing semiconductor chips in such subassemblies to detrimental welding "flash".

Abstract: A serial communication bus for a motor vehicle subject to different ground voltages on the common line and a transmitting module has a compensation circuit to prevent mismatches which distort pulse current waveforms and cause radiated emissions. When line ground voltage is higher than the transmitter voltage an integrator is used to simulate the line ground voltage and apply that to the transmitter ground. The integrator has a small current source and a very large current sink to follow the line ground potential. The transmitter output is disabled between pulses to avoid increasing the line ground voltage. When line ground voltage is lower than the transmitter voltage, the transmitter is enabled between pulses to feed current to the line to increase its potential.