Abstract: A ground vehicle radar system includes a windshield of the ground vehicle and a radar device installed behind the windshield. The windshield includes a metallization layer configured to inhibit propagation of infrared radiation through the windshield that also inhibits the propagation of radar signals. The metallization layer defines an opening in the metallization layer for radar signals emitted and detected by a radar device to pass through. An antenna of the radar device is installed behind the windshield and aligned with the opening. A lower portion of the antenna has a first field of view through the opening characterized as being directed horizontal toward a horizon forward of the vehicle. An upper portion of the antenna has a second field of view through the opening characterized as being directed downward toward an area of the ground forward of the vehicle.

Abstract: The disclosure relates to a unitary heat pump air conditioner (Unitary HPAC) having a plate type exchanger assembly, an electrically driven compressor, and coolant pumps. The plate heat exchanger assembly includes a plurality of plates stacked and hermetically sealed between an upstream end plate and a downstream end plate. The stacked plates define a condenser/chiller portion adjacent the upstream end plate, an accumulator portion adjacent the downstream end plate, and an evaporator/chiller portion sandwiched between the condenser/chiller portion and the accumulator portion. A refrigerant passageway extends through the plate type heat exchanger assembly, a hot coolant passageway extends through the condenser/chiller portion, and a cold coolant passageway extends through the evaporator/chiller portion. The cold coolant passageway and the hot coolant passageway are in non-contact thermal communication with the refrigerant passageway.

Abstract: A multi-stack fuel cell system is disclosed where multiple fuel cell stacks can be efficiently connected together. The fuel cell system includes a plurality of fuel cell modules include a sealed planar fuel cell stack that has internal manifold channels for transport of fuel and air to fuel cells within the stack and transport of tail gas and spent air away from fuel cells within the stack. Each of the fuel cell stacks is mounted on a base manifold, and the base manifold has side openings in fluid communication with the stack internal manifold channels. The side openings on the base manifold are configured so that the modules can be efficiently connected together.

Abstract: An electrical connector having one or more pairs of opposing contact arms extending from a body portion and configured to receive a mating connector. A spring clamp member is positioned over the opposing contact arms to increase a compressive force of the contact arms on the mating connector. The contact arms include stabilizing features to limit lateral, longitudinal, and/or rotational movement of the spring clamp member relative to the contact arms. The contact arms may be formed of a material having a high electrical connectivity and the spring clamp member may be formed of a different material having a higher relaxation temperature than the contact arm material. The mating connector may include be a male blade type terminal.

Abstract: A vehicle seat occupant detection device configured to indicate if a seat of a vehicle is occupied based on a weight of an occupant occupying the seat is provided. The device includes a spring and a sensor. The spring is configured to urge the device toward an unoccupied state. The sensor is configured to cooperate with the spring in order to determine an amount of deflection of the spring. In this way, the spring operates both as a return spring and an object that the sensor can detect and thereby determine the relative proximity of the spring.

Abstract: A low insertion force female terminal that is configured to make electrical contact with a male pin. The terminal includes a spring portion configured to be deflected by the pin as the pin is inserted into the terminal. The spring portion is also configured to urge a contact feature formed into the spring portion toward the pin to make electrical contact with the pin. The contact feature is characterized by an asymmetrical shape configured so a leading-edge ramp angle of the contact feature is less than a trailing-edge ramp angle of the contact feature. The asymmetrical shape reduces the peak insertion force for the terminal when compared to terminal designs that have symmetrically shaped contact features with similar dimensions.

Abstract: A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.

Abstract: An ignition coil assembly and a method of assembling the ignition coil assembly including a first spool, a first coil, and a second spool. The first coil is wound around a first spool outer surface. The first spool and the first coil are disposed within a cavity of the second spool and an electrically insulating material injected into an annular space defined between a first coil outer surface and a second spool inner surface. The first spool is configured to allow a decrease of a circumference of the first spool when the first coil is wound around an outer surface of the first spool. Decreasing the circumference of the first spool increases the annular space sufficient to inject the electrically insulating material into the annular space without creating substantial voids in the electrically insulating material.

Abstract: A connector system including a first connector having a longitudinally extending lock arm defining a lock nib and attached to the first connector. The lock nib is configured to engage a primary lock tab of a second connector when the first and second connectors are in a fully mated position and the lock arm is in a resting position. The lock nib is configured to disengage the primary lock tab and engage a secondary lock tab of the second connector when the lock arm is moved from a resting to an activated position and the first and second connectors are moved to a partially mated position while the lock arm is in the activated position. The connector system generates an audible or tactile click only when the first connector is fully mated with the second connector. The connectors can be disconnected with bare hands, no tools are required.

Abstract: A system for conditioning the intake air to an internal combustion engine includes a means to boost the pressure of the intake air to the engine and a liquid cooled charge air cooler disposed between the output of the boost means and the charge air intake of the engine. Valves in the coolant system can be actuated so as to define a first configuration in which engine cooling is performed by coolant circulating in a first coolant loop at one temperature, and charge air cooling is performed by coolant flowing in a second coolant loop at a lower temperature. The valves can be actuated so as to define a second configuration in which coolant that has flowed through the engine can be routed through the charge air cooler. The temperature of intake air to the engine can be controlled over a wide range of engine operation.

Abstract: A method for fault identification of gas sensors exposed to a gas mixture is disclosed for gas sensors having an output that depends on concentrations of two gas species in the gas mixture. The method includes receiving output signals from two such sensors, processing the output signals in a controller that implements a model of the sensors so as to identify a fault in the first gas sensor or the second gas sensor; and providing an indication of any identified faults.

Abstract: An electronics module that includes a printed circuit board (PCB), a connector, a housing with a shroud, and an interposer. The PCB defines a plane of the PCB. The connector is coupled to the PCB to form a circuit board assembly (CBA). The connector includes a plurality of header pins oriented perpendicular to the plane. The housing is configured to receive the CBA. The housing is configured to define an opening in a wall of the housing proximate to the connector when the CBA is installed. The wall is characterized as perpendicular to the plane. The interposer is configured to couple to the housing. The interposer includes a plurality of mating pins oriented parallel to the plane. Each of the mating pins defines a forked end configured to make electrical contact with each of the header pins when the interposer is inserted into the opening.

Abstract: An electrical connector configured to retain an electrical terminal including a terminal lock nib that projects inward into a terminal cavity from a first cavity wall for retaining the electrical terminal in the connector body and a flexible cantilever beam that projects axially into the terminal cavity from a fixed end of the cantilever beam. The cantilever beam is located opposite the terminal lock nib and is configured to push the terminal against a second cavity wall and into retaining engagement with the terminal lock nib. The connector also includes a support ridge that projects into the terminal cavity and is configured to contact and restrict movement of a free end of the cantilever beam during insertion of the terminal into the terminal cavity. The terminal has a laterally spaced lock surface engageable with the lock nib and is configured to prevent withdrawal of the terminal from the cavity.

Abstract: A vehicle instrument panel assembly that includes a display surface and a pointer equipped with an electro-optical cell. The display surface is equipped with a graphical indicator. The graphical indicator is selectively operable to an off-state and an illuminated-state. The pointer is operable to move about an axis to point to indicia on the display surface. The pointer is operable to a position that obstructs the graphical indictor from view. The electro-optical cell is operable to a transparent-state and located on the pointer to overlay the graphical indicator when the pointer is at the position that obstructs the graphical indictor from view. The cell is operated to the transparent-state when the graphical indicator is operated to the illuminated-state.

Abstract: An occupant detection system and method that uses an isolation assembly to isolate electrically a power supply providing power to a heater element for heating a vehicle seat from a sensing circuit that uses the heater element as an electrode for electric field or capacitance type occupant detection. The isolation assembly includes a common mode choke that by itself provides sufficient isolation when the sensing circuit excitation signal frequency is high enough, and provides switches that infrequently interrupt electrical power to the heater element so a humidity level can be determined using a relatively low excitation signal frequency. Knowing the humidity level is desirable to adjust a threshold use to determine if the sensing circuit indicates that the seat is empty, or is occupied.

Abstract: A sensor module configured to be located behind a window of a vehicle to detect an object through the window and about the vehicle. The module includes a radar unit with an antenna and a controller. The antenna emits and/or receives a radar signal through the window with a selected or preferred polarization. The polarization determines a preferred angle of propagation of the radar signal through the window based on reflection characteristics of the window that vary with impingement angle and transmitted polarization. By varying the transmitted polarization vs. beam direction when a directional antenna is used, the signal propagating through the windshield can be maximized to enhance object detection over a range of signal directions. Also, by varying the transmitted polarization when an omnidirectional type antenna is used, the object can be ‘illuminated’ with variable intensity and detected with variable sensitivity.

Abstract: Arrangement for mounting an electronic display (30) at the centre of a rotary switch (12), including: a support board (18), an electrical connection device (74) which is arranged on the board (18) in order to connect the display (30) to an electronic control circuit, a cylindrical box (32) which is mounted on the board and which forms the fixed central body of the rotary switch (12), an annular body (34) forming a rotor which is mounted in rotation on the cylindrical box about an axis so as to form a turning part of the rotary switch (12), characterized by the fact that the cylindrical box (32) includes a container designed to receive the display (30) by transversal insertion, relative to the axis of the rotary switch (12).

Abstract: A case includes a first case section and a second case section defining an interior. The first case section includes a groove extending along the first case section. The second case section includes a tongue extending along the second case section into the groove. The groove includes a groove inner wall proximal to the interior of the case and a groove outer wall distal from the interior of the case. The tongue extends from a tongue base end to a tongue free end and includes a tongue inner wall proximal to the interior of the case and a tongue outer wall distal from the interior of the case. The tongue free end is in contact with the groove inner wall and spaced apart from the groove outer wall and the tongue base end is in contact with the groove outer wall and spaced apart from the groove inner wall.

Abstract: The invention relates to a head-up display device, including a projector for generating a light beam carrying information to be displayed, a combiner having a display position for displaying the information in the field of vision of a user, and an optical system defining an optical path between the projector and the combiner when the latter is in the display position thereof, for directing the light beam onto the combiner. The optical system includes a first and a second deflecting mirror. The first mirror is arranged for receiving the light beam from the projector and for sending said light beam to the second mirror, the latter being arranged for sending the light beam over the optical path toward the combiner. An actuation system is provided for adjusting the length of the optical path between the projector and the combiner by positioning the first and second deflecting mirrors.

Abstract: A system, controller, and method for aligning a stereo camera of a vehicle mounted object detection system that includes a first camera and a second camera mounted spaced apart on a vehicle. An image from each camera at two different times is used to determine an observed displacement of an object relative to the vehicle. A predicted displacement of the object relative to the vehicle is also determined using either a difference of vehicle position measured based on other vehicle measurements or GPS, or a difference of size of the object in images taken at the two different times. Alignment is provided by determining a triangulation correction based on a difference of the observed displacement and the predicted displacement to correct for misalignment of the cameras.