Abstract: A battery pack containing a plurality of battery modules, these modules comprising a plurality of individual battery units, these battery units comprising a plurality of bicells with opposing terminals. The battery modules are connected in series by use of a flexible circuit and by opposing positive and negative terminals of each battery unit. The terminals of each battery unit contain a region of apertures which allow the adhesive of the packaging material to seal more effectively, thereby eliminating or reducing the amount of leakage from an individual battery unit.

Abstract: A constant velocity joint includes outer and inner races with mating part-spherical surfaces in which a single functional set of ball grooves are formed bearing a single torque-transmitting ball which is urged under an applied torque load toward one axial end of the joint. A retainer is carried by one of the two races or the shafts to which they are connected and acts on the ball to maintain the ball within the grooves during all angles of the joint.

Abstract: A composite powder metal disk for a rotor assembly in a circumferential type interior permanent magnet machine. The disk includes an inner ring of magnetically conducting powder metal compacted and sintered to a high density. The disk further includes an outer ring of permanent magnets separated by magnetically non-conducting powder metal compacted and sintered to a high density. The permanent magnets additionally are radially embedded by magnetically conducting powder metal compacted and sintered to a high density with optional intermediate non-conducting powder metal bridges extending radially from the permanent magnets to the outer surface of the disk. A rotor assembly is also provided having a plurality of the composite powder metal disks mounted axially along a shaft with their magnetic configurations aligned. A method for making the composite powder metal disks is further provided including filling a die with the powder metals, compacting the powders, and sintering the compacted powders.

Abstract: An intelligent input push rod assembly for applying an input force from a brake pedal to a power booster of a brake system. The input push rod assembly includes a sensor that is capable of generating an electrical output having a magnitude that varies with the amount of force applied to the input push rod by the brake pedal. Preferably, the sensor generates an output voltage signal that is generally proportional to the input force applied to the input push rod. A shunt is provided so that springs associated with the sensor operate in a generally linear force-deflection operating range of the springs. The output signal generated by the sensor is applied to a brake light control system that is supported by the input push rod assembly. The brake light control system uses the signal generated by the sensor to determine whether the vehicle brake lights should be illuminated and also to cause direct illumination of the brake lights during a braking operation.

Abstract: A vane-type cam phaser wherein a locking pin assembly is disposed between a rotor and a stator of the phaser to selectively couple the rotor and stator together under certain operating conditions, for example, during engine start-up. The central axis of the locking pin assembly is disposed in the rotor parallel to the rotational axis of the phaser. The pin is spring loaded in a default position and is guided through its axial movement by two cylindrical guide surfaces—an inner guide surface and an outer guide surface. The lengths of these guide surfaces are optimized to minimize binding and sluggish operation of the pin caused by lateral forces exerted on the pin by the stator when in operation. The outer guide surface to inner guide surface ratio (L/I) is preferably greater than 2.

Abstract: A stator core extends along a longitudinal axis and includes a yoke, and a plurality of radially-inwardly projecting teeth separated by intervening slots. A radially innermost portion of each tooth initially includes a pair of legs separated by a recess disposed therebetween. The conventional tooth tips are unformed in the first stage, thereby defining an increased-size slot opening for allowing the insertion of stator windings. In a second processing stage, after the core itself has been manufactured and wound with stator windings, the legs are cold-formed in order to form tooth tips, which define a reduced-size slot opening to provide a magnetic flux path and provide a wire retention function. A higher stator slot fill is provided, which allows and enables higher generator efficiencies and output for a given package size.

Abstract: A heated fuel strainer assembly for a fuel tank in a vehicle includes a strainer made of a metal material and adapted to be connected to an inlet of a fuel pump disposed in the fuel tank. The heated fuel strainer assembly also includes a power source connected to the strainer supply power to the strainer to heat the strainer allow fuel to flow through the strainer to the inlet.

Abstract: An optical superposition network that utilizes a time division multiplexing (TDM) protocol includes a first optical transmitter, a second optical transmitter and a receiver. The first optical transmitter transmits information in a tertiary mode during a time slot. The second optical transmitter transmits information in a tertiary mode during a different time slot. The information transmitted across the optical superposition network has an approximately constant average intensity such that the receiver can utilize a single decision threshold for the information received from the first and second optical transmitters.

Abstract: In a fuel cell assembly, nickel-based anodes are readily oxidized when exposed to oxygen as may happen through atmospheric invasion of the assembly during cool-down following shutdown of the assembly. Repeated anode oxidation and reduction can be destructive of the anodes, leading to cracking and failure. To prevent such oxygen migration, check valves and oxygen getter devices containing oxygen-scavenging material such as metallic nickel are provided in the reformate passageways leading to and from the anodes. The check valves preferably are closed by gravity. Oxidation of the oxygen-gettering material is readily reversed through reduction by reformate when the assembly is restarted.

Abstract: Disclosed is a system and a method for applying both a kinetic spray applied coating layer and a thermal spray applied layer onto a substrate using a single application nozzle. The system includes a higher heat capacity gas heater to permit oscillation between a kinetic spray mode wherein the particles being applied are not thermally softened and a thermal spray mode wherein the particles being applied are thermally softened prior to application. The system increases the versatility of the spray nozzle and addresses several problems inherent in kinetic spray applied coatings.

Abstract: A wheel bearing assembly for a vehicle has a wheel hub with a spindle that extends axially from the hub. A rolling element bearing is coupled to the hub, over the spindle, and is secured to the spindle by a deformed end of the spindle. The deformed end engages a radially outward facing portion of a lip that extends from an inner ring of the rolling element bearing, such that no radially outward force is exerted on the inner ring by the deformed end.

Abstract: A brake corner module includes a wheel bearing assembly which is configured to be coupled to the steering knuckle of the module without requiring bolts or press fit. An outer ring of the bearing assembly has a flange on one end which engages the knuckle at one end of a bore through the knuckle and a second end which is configured to be deformed to engage the second end of the knuckle bore. The wheel bearing assembly is thus captured within the bore, eliminating the need for press fit or a snap ring to retain the wheel bearing assembly.

Abstract: Method and system for controlling a permanent magnet machine driven by an inverter is provided. The method allows for monitoring a signal indicative of a fault condition. The method further allows for generating during the fault condition a respective signal configured to maintain a field weakening current even though electrical power from an energy source is absent during said fault condition. The level of the maintained field-weakening current enables the machine to operate in a safe mode so that the inverter is protected from excess voltage.

Abstract: In one embodiment of the present disclosure a preformed heating member is disclosed, the preformed heating element comprising: a first layer having a conductive layer for receiving an electrical current and providing a source of heat, the conductive layer being disposed on a sheet of formable film; and an outer layer disposed over the conductive layer; and a second structural layer adhered to the first layer, wherein the preformed heating element is capable of being configure to be positioned over a corresponding location.

Abstract: A method for continuously predicting remaining engine oil life includes counting down a remaining oil life (ROL) from 100% ROL to a predetermined warning threshold at a first rate. If an oil life event occurs prior to the threshold, the countdown rate is increased until the threshold is reached. On the other hand, if the threshold is reached and the oil life event has not yet occurred, the countdown rate is decreased until the oil life event occurs. During the countdown, if fresh oil or an additive is added to the oil, the countdown rate is adjusted in a positive direction. On the other hand, if the oil becomes contaminated, the countdown rate is adjusted in a negative direction.

Abstract: The present invention provides an electrical distribution center assembly and a method of constructing the same. The electrical distribution center assembly includes an electrical distribution center member, an electrical connector, a support member which retains the electrical connector and includes at least one cam follower projection, at least one cam lever rotatably mounted to the electrical distribution center member, and a driver member for abutting the cam lever arm. An engagement movement of the driver member causes the cam lever to rotate and engage the cam follower projection thereby multiplying an engagement force to draw together the electrical distribution center member and the electrical connector against a resistance. The cam lever also leverages a disengagement force applied to the driver member to separate the electrical distribution center from the electrical connector.

Abstract: An apparatus and method sensing the absolute position of a gauge. A pointer having a predefined rotation with a circular travel pattern. At least one light emitting diode that generates an optical signal. An optical sensor placed in a fixed position along the circular travel pattern of the pointer. A pointer driver for driving the pointer.

Abstract: Provided for herein is a process of forming a negative battery paste comprising combining a barium containing material at least partially dissolved in a portion of water with an organic expander, carbon black, and a lead oxide containing material to form a first mixture, followed by combining the first mixture with an amount of sulfuric acid to form the negative battery paste.

Abstract: In an ignition coil assembly of an ion sensing ignition system having an ignition coil output, a buffered ion-sense current source circuit is provided and includes a current sensing circuit, the current sensing circuit being disposed so as to be communicated with the ignition coil output and an active current source circuit, the active current source circuit being disposed so as to be communicated with the current sensing circuit and a current measuring device.

Abstract: A multi-chip circuit component comprising first and second substrate members, each of which are formed of an electrically-nonconductive material. Each substrate member has oppositely-disposed first and second surfaces, with an outer layer of thermally-conductive material on the first surface thereof and electrically-conductive areas on the second surface thereof. At least two circuit devices are present between the first and second substrate members, with each circuit device having a first surface electrically contacting at least one of the electrically-conductive areas of the first substrate member, and each circuit device having a second surface electrically contacting a corresponding one of the electrically-conductive areas of the second substrate member. First lead members are electrically coupled to the electrically-conductive areas of the first substrate member, and second lead members are electrically coupled to the electrically-conductive areas of the second substrate member.