Abstract: The present invention provides an improved boot guide for a caliper brake system. The improved boot guide includes a guide portion integrally formed with a boot portion, wherein the guide portion guides a brake piston and the boot portion seals the brake piston. The piston may be electrically driven. Alternatively, the piston may be hydraulically driven. The guide portion of the single piece boot guide may further include a radial support member that provides a radial retaining force. The radial support member may be manufactured utilizing material selected from a group consisting of mild steel and spring steel. The single piece boot guide may be manufactured from an elastomer. The elastomer may be selected from the group consisting of polyvinyl chloride, ethylene propylene terpolymer rubber, and nitrile rubber. The boot portion may form convolutions within a boot guide cavity. The guide portion may include an environmental seal portion.

Abstract: A fast-acting rotor-locking mechanism for a vane-type camshaft phaser. A straight-sided locking pin is disposed in a bushing in the rotor and is urged into a sprocket well by a return spring. A pad disposed at the bottom of the well is a travel stop for the pin. When the pin is fully seated against the pad, the pad covers a portion of the end of the pin. The uncovered portion of the pin end, exposed to oil pressure for unlocking the pin when it is fully seated, is decreased over the prior art pin, permitting use of a lighter locking spring having a lower spring rate. Because of the lighter locking spring, the pin accelerates more rapidly and unlocks significantly faster than in a comparable prior art phaser.

Abstract: A sensing assembly identifies detonations in a plurality of cylinders of an internal combustion engine. The internal combustion engine includes an engine block. The sensing assembly includes a base that is fixedly secured to the engine block of the internal combustion engine. The sensing assembly also includes a sleeve that is fixedly secured to the base and extends outwardly therefrom. A sensor element extends around a portion of the sleeve. The sensor element receives vibrations generated by the detonations of the internal combustion engine and converts those vibrations into an electrical current. The sensing assembly includes a first terminal abutting the sensor element. The first terminal includes a first terminal pad directed in a first direction. The sensing assembly also includes a second terminal abutting the sensor element.

Abstract: A durable magnetorheological fluid for use in a vibration dampening device is described. The MR fluid includes magnetizable particles having a particle size less than about 25 microns, a carrier fluid, a thixotropic agent, and a lubricative additive. The carrier fluid includes a polyalphaolefin and a plasticizer. The lubricative additive has a particle size equal to or less than 10 microns such that the ability of the additive to lubricate the magnetizable particles is optimized. The lubricative additive includes at least one of polytetrafluoroethylene, graphite, and molybdenum disulfide.

Abstract: A partial assembly process for a vane-type cam phaser. A pulley/sprocket is loaded onto a first camshaft-shaped fixture with a cam nose extending beyond the length of an actual cam nose such that a phaser rotor containing a locking bolt, when mounted onto the cam nose, is displaced axially from the pulley/sprocket by an amount sufficient to set the axial engagement of the bolt upon final assembly. A stator is loaded onto the pulley/sprocket and is rotated clockwise until it contacts the rotor, thereby removing all rotational and radial lash from the system. One or more axial holes are bored through the pulley/sprocket and stator and a locking pin such as a roll pin is inserted to permanently pin the stator to the pulley/sprocket.

Abstract: A steer-by-wire handwheel actuator in a vehicle is presented. The handwheel actuator comprises a driver input shaft; a gear train connected to the driver input shaft; a motor responsive to control signals from a controller and variably geared to the gear train; a electro-mechanical brake responsive to the control signals from the controller and geared to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train.

Abstract: A vehicle seat occupant classification system uses a pressure responsive, fluid filled bladder and pressure sensor adapted for engagement with an underside of a foam seat cushion so as to generate a pressure signal corresponding to the weight of an occupant on an upper side of the foam seat cushion. A humidity sensor responds to relative humidity of air adjacent the pressure sensor and/or foam seat cushion to generate a humidity signal that is used to compensate at least one of the pressure signal, a stored reference pressure value and a stored threshold value, from which at least in part; an occupant classification is determined.

Abstract: The subject invention improves the electrical connection in a clutch assembly for engaging a compressor in a vehicle air conditioning system. In accordance with the subject invention, a tab extends from the mounting plate and the second end of the ground lead is frictionally retained between the tab and the core winding housing. This is accomplished by turning a tab out of the plane of a mounting plate, placing the second end of the ground lead under the tab and bending the tab downwardly to clamp the second end of the ground lead between the tab and the core winding housing to frictionally retain the second end of the ground lead between the tab and the core winding housing.

Abstract: A hydraulic manifold assembly for variable actuation of engine valves. First and second plates have portions of flow passages integrally molded therein. The plates are formed preferably by injection molding of a suitable polymer, for example, glass-filled nylon, and are joined together as by cementing or preferably by fusion welding (vibration welding) along mating surfaces to form the full pattern of flow passages. This method of forming the manifold obviates the need for separate fasteners to connect the plates and for internal seals to form the flow passages. The assembly further comprises a retainer for retaining a plurality of individual solenoid-actuated valves in sockets formed in the plates. Preferably, the retainer is formed to function simultaneously as a positive crankcase ventilation (PCV) baffle that attaches to the plates via integrally molded releasable snap tabs.

Abstract: An electric power assist steering system is controlled by sensing torque in a steering shaft at a point along said steering shaft between a hand wheel and a mechanical connection to an electric motor, wherein the sensing includes sensing a magnetic field direction and intensity.

Abstract: A lead-containing glass material of the type suitable for use in a wafer bonding process, wherein the moisture resistance of the glass material is increased by the presence of a lead phosphate coating on an outer exposed surface of the material, thereby acting as a barrier to reaction of moisture with the lead of the glass material. A source of reactive phosphate ions is applied to the glass material so as to spontaneously form the desired lead phosphate coating.

Abstract: A composite steering column jacket including a pair of composite sections joined along a flange area. The composite sections include outer and inner walls spaced coaxially from each other, that mate at first and second flanges. A cavity is defined by the space between the inner and outer walls and is filled with a foam material that is disposed within. The composite steering column jacket has an increased stiffness and reduced weight when compared to conventional metal steering column jackets.

Abstract: A method of making a heated steering wheel comprises depositing an electrically conductive layer on at least a portion of a steering wheel substrate to produce thereon a heating element for receiving an electrical current and providing a source of heat. Also disclosed is a heating element for a steering wheel and a heated steering wheel assembly formed using this method.

Abstract: A hydrocarbon scrubber including a monolith; a seal disposed concentrically around an end of the monolith, wherein the seal includes an inner surface having a diameter equal to or less than an outer diameter of the monolith, a shoulder member protruding from the seal and physically contacting at least a portion of an end face of the monolith, and a rib member disposed on an outer side of the seal and in physical contact with the shell.

Abstract: A ball nut and return liner assembly includes a ball nut having a tubular body having a longitudinal axis, the tubular body having an inner surface and an outer surface, a plurality of arcuate grooves defined on the inner surface. A longitudinal slot is defined on the inner surface parallel to the longitudinal axis, interrupting the plurality of arcuate grooves, and forming a pocket for receiving the return liner, the longitudinal slot having first curved walls. The return liner is provided with a first surface having a plurality of S-shaped return grooves extending from the first side to the second side to cooperate with the plurality of arcuate grooves in the ball nut. The return liner is further provided with a second surface for fitting within the longitudinal slot within the ball nut, the second surface having second curved walls.

Abstract: A deactivation valve lifter includes a lifter body. The body defines at least one annular pin chamber therein. The lifter body has a first end configured for engaging a cam of an engine. A pin housing includes a pin housing wall and pin housing bottom. The pin housing wall includes an outer surface. The pin housing bottom defines a radially directed pin bore. The pin housing is concentrically disposed within the lifter body such that the outer surface of the pin housing wall is adjacent to at least a portion of an inner wall of the lifter body. A deactivation pin assembly is disposed within the pin bore and includes pin members. A portion of each pin member is disposed within the annular pin chamber to thereby couple the lifter body to the pin housing. An external lost motion spring is coupled to the body and pin housing.

Abstract: An improved hydraulically assisted braking and steering system of a vehicle having a hydraulic pump communicating with a hydraulic steering assist device and including a hydraulic brake assist device coupled in series between the pump and the steering assist device includes the provision of a flow splitter which operates to reduce the interdependence of the hydraulic brake and steering assist devices on the flow of fluid from the pump. The flow splitter communicates with the outlet of the pump and the inlet of the brake assist device and is operative when the back pressure from the brake assist device exceeds a predetermined control value to divert a fraction of the flow of fluid around the brake assist device directly to the steering assist device, thereby providing sufficient flow to operate both the brake and steering assist devices within their normal design limits, rather than having the brake assist device starve the steering assist device when under heavy load.

Abstract: A ball-nut assembly includes a ball nut and a crossover member. The ball nut incudes a radial through slot and an outer surface. The outer surface has a first portion, has a ledge radially recessed from the first portion and at least partially bounding the through slot, and has an undercut wall connecting the ledge and the first portion. The crossover member has a flange and a crossover-grooved portion. A method for making a ball-nut assembly positions the crossover member from outside the ball nut to have the flange supported by the ledge and the crossover-grooved portion located in the through slot. The method also deforms the flange creating a staked portion of the flange which contacts the undercut wall of the outer surface of the ball nut.

Abstract: Staggered firing of first and second spark plugs in a dual-plug spark ignition engine is achieved by apparatus that fires the first spark plug based on an output signal produced by an engine control module and firing the second plug based on the output of a delay control circuit responsive to the output signal produced by the engine control module. The delay control circuit additionally detects engine speed based on the firing frequency of the first spark plug, and selects a delay time so that the firing of the second spark plug is delayed with respect to the firing of the first spark plug by a calibrated angle of engine rotation.

Abstract: Disclosed is a method and a nozzle for a kinetic spray system that uses much lower powder pressures than previously used in kinetic spray systems. The method permits one to significantly decrease the cost of the powder delivery portion of the system, to run the system at higher temperatures for increased deposition efficiency and to eliminate clogging of the nozzle. The nozzle is a supersonic nozzle having a throat located between a converging region and a diverging region, with the diverging region defined between the throat and an exit end. At least one injector is positioned between the throat and the exit end with the injector in direct communication with the diverging region. The powder particles to be sprayed are injected through the at least one injector and entrained in a gas flowing through the nozzle. The entrained particles are accelerated to a velocity sufficient to cause them to adhere to a substrate positioned opposite the nozzle.