Abstract: A method and assembly (10) for conducting heat from a semiconductor device, such as a power flip chip (12). The assembly (10) is generally constructed to dissipate heat from the flip chip (12) when mounted to a flexible or rigid substrate (20). Heat is conducted from the flip chip (12) through upper and lower pedestals (26, 28) each of which includes a pliable pre-cured silicone adhesive pad (32, 36). The pre-cured silicon adhesive pads (32, 36) promote thermal contact while also decoupling any lateral mechanical strains that may arise as a result of different thermal expansion and movement between the flip chips (12). The housing portions (16, 18) form a housing (14) when assembled, with each housing portion (16, 18) including a configured edge (37, 41) that controls the travel of the pedestals (26, 28) toward each other, to thereby limit the pressure exerted on the flip chip (12) disposed therebetween.

Abstract: A high voltage electrical connection includes an electrical receptacle connector and a mating electrical plug connector. The electrical receptacle connector includes a receptacle that is mounted over a hole in the casing and fastened thereto with a plurality of terminated electrical leads that are attached to an internal component of an electrical device inside the casing and threaded through a hole in the casing. The receptacle has a chamber including an inlet at one end that is aligned with the hole in casing and an outlet at the other end. The electrical receptacle connector also includes a terminal holder and a terminal housing, both of which are made of electrical insulation material. The holder retains the plurality of terminals, of the respective leads is inserted into the chamber through the outlet of the receptacle and retained in the chamber. The terminal housing is then inserted into the chamber via the outlet with its flange being disposed in the outlet.

Abstract: An electrically-insulating polymer-based material with improved thermal conductvity so as to be suitable for use as an adhesive for mounting and conducting heat from electronic devices. The polymer-based material comprises metal particles dispersed in a matrix material. The metal particles are encapsulated by a dielectric coating so that they are electrically insulated from each other. The polymer-based material may also comprise dielectric particles dispersed in the matrix material and/or the dielectric coating for the purpose of further increasing the thermal conductivity of the polymer-based material. The material is also suitable for use as a potting compound or an encapsulation material for various electronic applications.

Abstract: A metal runner that improves the current-carrying capability of solder bumps used to electrically connect a surface-mount circuit device to a substrate. The runner comprises at least one leg portion and a pad portion, with the pad portion having a continuous region and a plurality of separate electrical paths leading to and from the continuous region. The electrical paths are delineated in the pad portion by nonconductive regions defined in the pad portion, with at least some of the nonconductive regions extending into the leg portion. The multiple electrical paths split the current flow to and from the solder bump, distributing the current around the perimeter of the solder bump in a manner that reduces current density in regions of the solder bump where electromigration is most likely.

Abstract: A hand wheel actuator for a steer-by-wire steering system having a steering feel that meets drivers' expectations is provided with a housing having an aperture, a steering shaft extending through the aperture and rotatably supported by the housing, an electric motor, a position sensor and torque sensor, and a mechanical steering feel enhancement device. The mechanical steering feel enhancement device is attached to the housing and provides a positive stop function, a return-to-center function, and/or a friction/weight function. The mechanical steering feel enhancement device is in mechanical communication with the steering shaft and may exist as a separate unitary subassembly prior to being installed on the housing. The electric motor has an output shaft that is in mechanical communication with the steering shaft for imparting a torque to the steering shaft.

Abstract: An arc magnet assembly with a virtual radial magnetization is established by placing a series of small trapezoidal-shaped magnet segments having axial magnetizations side by side to form an arc. The arc magnet assembly may be affixed to a rotating component in, e.g., a vehicle to yield a substantially linear magnetic sensor output that represents the speed and/or direction of rotation and/or position of the rotating component.

Abstract: A strengthened thin-walled catalytic converter substrate includes thin perimeter walls and thin interior walls defining cells and a catalyst washcoat selectively disposed on the substrate. Washcoat thickness is increased in those cells having the most impact on final catalyst strength, typically the outer cells defined by the perimeter walls. A method for maximizing overall catalyst strength with minimal substrate thermal mass includes selectively applying washcoat based on desired substrate strength and converter assembly method.

Abstract: A joint structure and method for bonding together two components, such as when attaching an electrical circuit element to a conductor on a substrate. The joint structure comprises a mesh infiltrated by a solder material, in which the mesh is preferably formed of a material having a higher thermal conductivity than the solder material. The joint structure is able to offer improvements in thermal conductivity, electrical conductivity, reflow processing, and stress distribution between the structures it connects. Each of these attributes of the joint structure can be tailored to some degree by the choices of materials for the mesh and the solder material.

Abstract: A heat sink with integrated electronics having a cavity with one or more facing sides. Hybrid circuits are housed in the cavities. A bottom portion seals the housing and has a row of pins is provided for interconnecting the circuits housed in the separate cavities to an external device, thereby allowing the integration of different types of circuits in a single, fully enclosed, yet partitioned, housing.

Abstract: Shaped, contoured crushable structural members and methods for making the same are described. The contoured structural members comprise composite or metal materials sandwiching a support or stabilizing structure. The structural members are made crushable by incorporating an initiator into the structural members. The structural member crushes at the location of the initiator by absorbing the energy of an exerting load. The shaped structure is provided by bending the generally straight shape of the structural member. With a shaped, contoured, crushable, and generally non-flat structure, applications and uses for the structural members of the present invention are nearly limitless.

Abstract: Device and method including a generally flat and flexible circuit for electrically inter-connecting components therein are provided. The device includes a post including a recessed section configured to receive the flexible circuit through an opening in said circuit. The structures defining the opening in the flexible circuit may be configured to provide a snap-fit between the circuit and the recessed section of the post, and thus avoid undesirable movement of the flex circuit in the presence of vibration.

Abstract: A combination starter-generator system for use in a vehicle is provided. The vehicle has an internal combustion engine and a battery. The system includes a starter-generator electrically coupled to the battery to generate a current and to start the internal combustion engine. A drive mechanism connects the starter-generator machine and the internal combustion engine. The starter-generator machine generates the current by receiving a charging torque from one side of the drive mechanism and starts the internal combustion engine by imparting a starting torque to a different side of the drive mechanism. The charging torque or the starting torque is a greater torque. A passive tensioning system cooperates with the drive mechanism to tension the drive mechanism only at the side of the greater torque.

Abstract: A low-loss electrode-printed structural dielectric barrier for a non-thermal plasma reactor and non-thermal plasma multi-cell stacks having low-loss electrodes. The low-loss electrode-printed structural dielectric barriers include a structural dielectric barrier having a first side and a second opposite side; a low-loss electrode pattern disposed on the second side of the structural dielectric barrier; the low-loss electrode pattern comprising first and second major electrode sections that are offset from any ribs, supports, ligaments, spacers, tines, or other structure that serves as a structural dielectric connection between dielectric barriers in a multi-cell stack, a connector disposed between and electrically connecting the first and second major electrode sections and offset relative to a centerline perpendicular to the rib orientation, and a bus path connector electrically connected to one of the major electrode sections and offset relative to the centerline.

Abstract: Interconnects and perimeter spacers for a fuel cell stack are provided as flexible elements which can conform to non-planarities in a stack's electrolyte elements and thereby avoid inducing torsional stresses in the electrolyte elements. The interconnects are foil elements about 0.005 inches thick, formed of a superalloy such as Hastelloy, Haynes 230, or a stainless steel. The perimeter spacers comprise a plurality of laminate thin spacer elements, each thin spacer element being a laminate of superalloy and a “soft” material such as copper, nickel, or mica. The spacer elements can slide past one another; thus the perimeter spacers can be physically thick, to form the gas flow spaces within the stack, while also being torsionally flexible.

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: 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: 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 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 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.