Abstract: The present invention provides a flexible slide mounting member for use with a battery package which is disposed on a top surface of a battery and is electrically connected to terminal posts extending outwardly from the battery. In one embodiment, the flexible slide mounting member comprises an elongated member having a central opening extending the length of the flexible slide mounting member and has a rectangular cross section, wherein the central opening receives and retains a portion of the battery package. The flexible slide mounting member has a predetermined number of raised, retaining rails formed on an outer surface thereof, wherein the retaining rails complementarily engage retaining grooves formed on the portions of the housings which are received within the opening of the flexible slide mounting member.

Abstract: Retention of a roller follower shaft in a follower body is provided by keyed ends formed by flats on the shaft with which a follower roller forms an assembly, together with additional bearings if needed. Slots are provided extending from shaft bore openings through spaced arms of the body to distal ends of the arms. The roller follower assembly is inserted in a pocket between the arms by sliding the keyed ends of the shaft through the slots of the arms to axially align the shaft with the shaft openings. The shaft is then turned about 90 degrees in the openings in which a slight interference fit retains the shaft against lateral motion.

Abstract: A method of, and device (10) for, connecting a plurality of flexible printed circuits (12) each comprising a layer (14) of electrically insulating material and a layer (16) of electrically conducting material. The method including the steps of forming a hole (18) through each flexible printed circuit; positioning first and second substantially rigid plates (20,22) of electrically insulating material on either side of the flexible printed circuits with the holes in the flexible printed circuits aligned with a corresponding hole (26,28) in each plate; extending a rivet (24) of electrically conducting material through the aligned holes to electrically connect with the layers of electrically conducting material on the flexible printed circuits; and enlarging the ends (30,32) of the rivet to secure the flexible printed circuits between the plates. Provides an improved electrical and mechanical connection between FPCs.

Abstract: Disclosed herein is a battery design for bi-cell polymer matrix batteries. Each bi-cell comprises, sequentially, a first counter electrode, a first separator membrane, a centrally located electrode, a second separator membrane, and a second counter electrode. The current collector of each of the counter electrodes is positioned other than medially within the counter electrode. Generally, the current collector of the counter electrode is located within the outer half of the counter electrode. When the current collector is located at the extreme outer edge of the counter electrode, a capping film of polymer matrix material is preferably laminated to the perforated current collector, and, through the perforated current collector, to the counter electrode material itself.

Abstract: A novel and improved magnetorheological (MR) damper charging system is provided which simply and effectively substantially minimizes MR fluid leakage during a MR damper assembly process thereby minimizing cleanup and reducing costs. The damper charging system includes a charging body having a bore for receiving damper components and damper fluid, at least one inlet formed in the charging body for delivering fluid to the bore, and a magnetic field generating assembly mounted at the inlet and operable in an energized state to generate a magnetic field across the inlet to cause MR fluid in the inlet to experience a MR effect sufficient to prevent leakage flow through and from the inlet. An inlet valve is mounted on the charging body for controlling flow of fluid through the inlet into the bore.

Abstract: An actuator assembly for actuating a valve assembly having a shaft is provided. The actuator assembly includes a mounting member having a hole therethrough and a first attachment member. A first gear has a portion that extends through the hole for actuating the valve assembly. The actuator assembly also includes an actuator for driving the first gear. A second gear is interposed between the actuator and the first gear with the second gear coupled to the first gear. A carrier has a second attachment member for slidably engaging the first attachment member and securing the carrier to the mounting member. The carrier includes a cradle portion that supports the actuator and a bearing portion that supports the first gear when the carrier and mounting member are in an assembled position. In the assembled position, the cradle aligns the first and second gears with one another.

Abstract: An energy absorbing air bag module includes a housing and a mounting member integral with the housing for attaching the housing to a structural portion of the vehicle. The energy absorbing air bag module also includes an energy absorbing mechanism integral with the mounting member, wherein the energy absorbing mechanism deforms when a contact force strikes the energy absorbing air bag module to absorb energy and move away from the contact force.

Abstract: An electronic compass system for eliminating magnetic noise which is integrated with an instrument cluster. A vehicle accessory, such as a stepper motor, also located in the instrument cluster, generates a known, consistent, magnetic field of intensity sufficient to cause a static magnetic offset in the electronic compass for each of its' electrical states. A magnetic field sensor detects a combination of The Earth's magnetic field and this stray magnetic field. A controller uses a predetermined correction factor, corresponding to the electrical state, to eliminate the effect of the static magnetic offset. The controller then displays a heading unaffected by the static magnetic offset.

Abstract: Disclosed is a method of shaping powdered metal parts comprising: (a) providing powdered metal from a source; (b) applying a heated fugitive coating to the powdered metal; (c) passing the powdered metal through a heated tube from a supply thereof to the die for the molding of the part; (d) monitoring the temperature of the heated tube during the passage of the powdered metal there through; (e) heating the die and monitoring the temperature thereof; (f) heating a punch die and monitoring the temperature thereof; (g) after filling the die with coated powdered metal, compacting the powdered metal by applying pressure from the punch die to the filled die thereby compacting the metal to a desired shape.

Abstract: An electronic compass system using magnetic signatures to detect a vehicle event which is integrated with an instrument cluster. A vehicle accessory, such as a rear defrost grid, generates a known, consistent, magnetic field of intensity sufficient to cause a static magnetic offset in the electronic compass for each of its' electrical states. This known consistent, magnetic field has a magnetic signature. A magnetic field sensor detects a combination of Earth's magnetic field and the stray magnetic field produced by the vehicle accessory. A controller is coupled to the magnetic field sensor and searches the magnetic field signal for the magnetic signature. The controller then looks up a predetermined correction factor, or uses an algorithm to determine a correction factor, corresponding to the magnetic signature, to eliminate the effect of the static magnetic offset. The controller then displays a heading unaffected by the static magnetic offset.

Abstract: An ion sensor glow plug assembly includes a shell for attachment to a cylinder head of a compression ignition engine and having a passageway extending axially therethrough. The ion sensor glow plug assembly also includes a center terminal disposed at least partially in the passageway of the shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a glow sheath disposed at least partially is the passageway of the shell and about the center terminal to create an ion sensing circuit. The ion sensor glow plug assembly further includes an insulator disposed at least partially in the passageway of the shell and about a portion of the glow sheath and extending axially therefrom to clean off soot on the glow sheath. The ion sensor glow plug assembly includes a coating disposed about a portion of the glow sheath between the glow sheath and the shell to isolate the shell from the glow sheath.

Abstract: An overmolded electronic assembly (10) and method for forming the assembly (1) that entails enclosing a circuit board (12) having one or more circuit devices (16) mounted to its surface. The assembly (10) includes a heat-conductive member (18) in thermal contact with one or more of the circuit devices (16) mounted to the circuit board (12). An overmolded body (22) encloses the circuit board (12) and the circuit devices (16) with the heat-conductive member (18), such that the overmolded body (22) and heat-conductive member (18) form a moisture-impermeable seal around the circuit board (12) and circuit devices (16). The overmolded body (22) also includes a connector housing (28) integrally-formed in its outer surface. The method for manufacturing the overmolded electronic assembly (10) generally entails supporting the circuit board (12) with the heat-conductive member (18) such that the heat-conductive member (18) thermally contacts the circuit devices (16).

Abstract: An airbag module for motor vehicles includes a housing for a folded together inflatable airbag and a holder element that can be locked at the housing. The holder element has at least one locking section, which in the locked state extends along the housing wall and latches with a holder section of the housing at its side which faces away from the housing wall.

Abstract: A magnetorheological fluid damper is provided which permits effective control of damping while minimizing assembly size and costs by including a thin-walled insert in a flow gap formed between a flux ring and a piston body. The insert may include a thin-walled tubular insert having a generally smooth cylindrical shape for increasing the shear surface area. Alternatively, a corrugated insert may be provided having corrugations formed by edges extending axially along the insert. The corrugations may be formed in a variety of locations, sizes, shapes and spacings along the axial extent of the insert and the circumference of the insert. The corrugations advantageously effectively align the insert within the flow gap and also function to securely connect the flux ring to the piston body without the use of other devices such as plates thereby reducing the size and cost of the assembly.

Abstract: A method for solder bumping a surface-mount circuit component, as well as electrically and mechanically connecting the component to a conductor on a substrate, and the components and assemblies formed thereby. The method generally entails forming a multilayer metal bump containing discrete layers, including at least one layer of a solder alloy, a first metallic layer having a sufficiently high melting point so as not to melt or deform at the reflow temperature of the solder alloy, and a second metallic layer containing at least one metal that is soluble in the solder alloy. During reflow, the first metallic layer does not collapse, while the solder layer and the second metallic layer readily flow and subsequently bond the first metallic layer to suitable structures on the component and substrate.

Abstract: An improved magnetorheological fluid damper is provided which closely approximates ideal performance requirements by providing an increased turn-up ratio and improving the linearity of damping force response. The MR damper includes a plurality of concentric annular flow gaps formed between concentrically mounted flux rings positioned on a piston core. By utilizing multiple flow gaps, the present damper increases the overall magnetorheological damping affect thereby creating a higher damping force and an increased tun-up ratio for a given piston size. Alternatively, the present multiple flow gap design permits a given damping force requirement to be achieved with a piston having a significantly reduced length thereby permitting a longer piston stroke. Also, multiple flow gaps permit greater design optimization for controlling damping force linearity.

Abstract: A method for controlling a power supply for a vehicle engine utilizes two sensors monitoring a power supply control member. In the event of a disturbance of the one of the sensor signals, the other sensor signal is used for determining the actuator control signals. If such other sensor signal exceeds a limit value, the actuator control signals are determined by a proportional-plus integral control, with the integral portion of the control being based on an operating state of the vehicle when the limit value is exceeded.

Abstract: A relief valve for an anti-lock braking system includes a plunger-operated ball and a valve body that defines a seat for receiving the ball thereon. The valve body also defines a relief passageway for relieving hydraulic fluid through the passageway at a rate that is appropriate for prevent brake locking, i.e., skidding. To establish the rate, an orifice is integrally formed on the valve body in the passageway, thereby obviating the need for a separate orifice cup.

Abstract: A flat cable connection system includes a flat cable module having a power input segment and drop connectors that provides a low profile configuration; the drop connectors include a spring component, a non-spliced flat cable end portion and a connector body that serves to capture the flat cable end portion and to provide an electrical connection to an electrical accessory of the type associated with a headliner of a vehicle.

Abstract: A mass flow sensor for measuring flow of a medium comprises a body, a membrane fixed on the body, a pair of thin film heating elements arranged on the membrane, and a sensing element arranged on the membrane adjacent the pair of heating elements and connected between the pair of heating elements. The heating elements are further arranged in a spaced relationship, transverse to the direction of medium flow such that one heating element is upstream of the other heating element in the medium flow. The sensing element provides an electrical signal for determining the voltage across the total series resistance of the heating elements which is indicative of the medium flow magnitude, and for determining the relative resistance of the upstream heating element compared to the downstream heating element which is indicative of medium flow direction. In another aspect of the invention a system for measuring flow of a medium is disclosed.