Abstract: A vehicle having an electric hybrid power system is provided. A battery pack stores electricity to power the electric motor. The battery pack includes a first plurality of batteries connected in parallel with a second plurality of batteries. The first plurality of batteries are Nickel Metal Hydride (NiMH), and the second plurality of batteries provide high power output at lower temperatures. In addition, the second plurality of batteries may also have a low energy density.

Abstract: A user controllable lighting system for a vehicle instrument cluster, including: selection apparatus to select a color scheme for individual gage area components of the vehicle instrument cluster; illumination apparatus to illuminate the individual gage area components in accordance with selections made by the selection apparatus; and control apparatus operatively connected to the selection apparatus and to the illumination apparatus to receive the selections made by the selection apparatus and to furnish instructions to the illumination apparatus.

Abstract: A master cylinder assembly including a boost assembly. The hydraulic master cylinder includes a cylinder defining an elongated bore, a piston slidably positioned in said bore, inlet means in the cylinder for admitting hydraulic fluid into the bore from a reservoir, and an outlet fitting in said cylinder communicating with said bore and operative to convey hydraulic fluid out of the bore for delivery to a brake device in response to linear movement of the piston in the bore. The boost assembly includes an electric motor. A hollow ball nut and screw assembly is operably connected to the motor. A screw of the ball nut and screw assembly is positioned to advance the piston in response to actuation of the motor. An input rod extending through the screw includes a first end positioned to receive a brake input force and a second end positioned to advance the piston independently from the screw.

Abstract: An interconnect assembly and method for a semiconductor device, in which the interconnect assembly can be used in lieu of wirebond connections to form an electronic assembly. The interconnect assembly includes first and second interconnect members. The first interconnect member has a first surface with a first contact and a second surface with a second contact electrically connected to the first contact, while the second interconnect member has a flexible finger contacting the second contact of the first interconnect member. The first interconnect member is adapted to be aligned and registered with a semiconductor device having a contact on a first surface thereof, so that the first contact of the first interconnect member electrically contacts the contact of the semiconductor device.

Abstract: A gear assembly comprising a linear differential disposed at the gear assembly wherein the linear differential has a predetermined ratio from an input shaft to an output shaft, the ratio being adjustable by axially rotating the linear differential. A method of adjusting steering output as compared to steering input, which comprises powering a motor in operable communication with a worm and worm gear mechanism and rotating the worm and the worm gear mechanism fixed to a differential carrier. The method also comprises rotating the differential carrier, which comprises an input sun gear meshed with input differential planet gear, an input differential planet gear meshed with an output differential planet gear, and an output sun gear meshed with the output differential planet gear. The method further comprises rotating the output sun gear fixed to a differential output shaft.

Abstract: A linear output and non-contacting angular position sensor has a rotatable arc segment magnet arranged to rotate about the stationary components of the sensor, which include a pair of stationary flux concentrators, separated by a Hall probe; or, the magnet may be arranged to rotate at the center of the sensor with the stationary components fixed outside the magnet. With either arrangement, the Hall probe produces a direct 0 to 5 V d.c. output which varies linearly with the rotational angle of the magnet as the magnet rotates through a predetermined angle. The predetermined angle of rotation is generally equal to the arc formed by the flux concentrators and the arc of the magnet is generally 20-40% greater than the arc of the flux concentrators.

Abstract: An energy absorbing device for a steering column includes first and second elongated plastically deformable straps connected to the steering column. A bushing connected to stationary vehicle support structure is engagable with the straps in a manner such that when the steering column collapses the straps advance linearly across the bushing and thereby resist collapse of the steering column. One of the straps may be disconnected from the steering column at the instant of a crash event, in circumstances where less resistance to steering column collapse is desired.

Abstract: A wheel spindle flange (and the like) has stud holes with soft surface hardness formed therein which permit non-rotational splines, studs and the like to be press-fitted therein with minimal press force at a centered press zone established between intentionally formed and dimensioned counterbores within the flange to minimize flange distortion and lateral run out of the spindle.

Abstract: An MR fluid formulation comprising water-atomized iron powder dispersed in a liquid vehicle, wherein the atomized iron powder contributes to a higher magnetic effect, a lower viscosity and suitability for high temperature applications. The magnetizable particles are prepared by controlled water atomization and comprise iron having a passivating oxide surface layer. The passivating oxide surface layer advantageously comprises iron oxide and at least one alloying metal oxide, such as manganese oxide. Advantageously, the particles have a grain size of at least 4 &mgr;m and a mean diameter in the range of about 8-25 &mgr;m. The liquid vehicle advantageously comprises a mixture of at least two liquid components of different surface functionality and an organoclay stabilization mixture in which at least one organoclay is selected for each liquid vehicle component.

Abstract: A joint assembly has outer and inner joint members supported for relative angular movement while preventing rotation between the joint members. The outer joint member is fitted with a lip seal device presenting at least one seal lip which dynamically engages and sealingly wipes at least one corresponding sealing surface of the inner joint member at all angles to seal a space for the retention of lubricant and exclusion of contaminants.

Abstract: An integrated intake manifold assembly including a first poppet valve assembly disposed at the air inlet to the manifold to regulate air flow into the manifold; a second poppet valve assembly disposed on the manifold to regulate exhaust gas flow into the air intake system; and a bi-directional camshaft with cams for operating simultaneously the manifold vacuum regulating (MVR) valve and the exhaust gas recirculation (EGR) valve. The valve bodies are integrally formed in the wall of the intake manifold. The camshaft is driven by a DC motor and gear train. The cams are arranged on the shaft to provide optimum synchronized opening and closing of the related valves. When used on a diesel engine, the manifold assembly may further include a swirl valve plate disposed between the manifold and the engine head and having a plurality of ganged swirl valves actuated by levers connected to the camshaft for coordinated motion with the MVR and EGR valves.

Abstract: The method of making a wide range oxygen sensor of the present invention enables ease of handling and processing, particularly in a mass production environment. This process comprises forming planar composite elements of the sensor where the elements are individually laminated. These laminated composites are easily handled and readily stacked. Furthermore, electrodes and electrode leads can be readily deposited on the laminated composites, across the intersection of the various materials forming the composite. After deposition of the electrodes, leads, and a heater, the elements are stacked accordingly and laminated to produce the oxygen sensor.

Abstract: A head-up display (HUD) uses reduced reflectivity projection optics to reduce the harmful effects of intense solar radiation on HUD components. In a HUD generally having a display, a mirror, and a combiner, an image is projected from the display to the combiner via the mirror. The reflectance of the mirror is reduced to prevent high thermal stress on HUD components. The light source is brighter than a conventional backlight, and thus compensates for the reduction in the reflectance of the mirror. Reduced mirror reflectance translates into a reduced thermal load on the display, lens, case, electronics, or wherever the solar radiation is directed.

Abstract: An adjustable pedal assembly includes a support structure adapted to connect to a vehicle, with the support structure defining first and second slots arranged in a spaced-apart manner. A pedal assembly is disposed adjacent the support structure, where the pedal assembly includes a pedal. First and second pins extend from the pedal assembly through the first and second slots whereby the pedal assembly is supported for sliding movement on the support structure along the slots. A linear actuator is interconnected with the pedal assembly for sliding the pedal assembly to a desired position along the support structure. The invention may be adapted for use in connection with brake pedals, clutch pedals, and accelerator pedals. In the case of accelerator pedals, the invention can be adapted for use with conventional pedals as well as electronic throttle control pedals.

Abstract: A seat restraint tensioner for a seat restraint system in a vehicle includes a housing for operative connection to vehicle structure and a movable piston disposed in the housing. The seat restraint tensioner also includes a gas generator operatively connected to the housing for expelling a gas to move the piston. The piston includes a passageway extending therethrough to control a rate of stroke of the piston when the gas is generated to apply a force for pulling-down belt webbing of the seat restraint system.

Abstract: A powertrain mount comprises an orifice plate and a slug. The orifice plate defines an orifice track having a first cross-sectional area. The slug is disposed in the orifice track, and has a bore with a second cross-sectional area less than the first cross-sectional area.

Abstract: The invention provides a drilling apparatus and method for drilling a hole in a workpiece. The drilling apparatus includes means for rotating a drill bit and means for advancing the rotating drill bit into a workpiece to a first depth. The drilling apparatus further includes means for dwelling the drill bit within the workpiece at the first depth for a dwell time and means for further advancing the rotating bit to a second depth after the dwell time has expired. The drilling method includes rotating a drill bit and advancing the rotating drill bit into the workpiece to a first depth. The method farther includes dwelling the drill bit within the workpiece at the first depth for a dwell time and further advancing the rotating bit to a second depth after the dwell time has expired.

Abstract: A powertrain mount comprises an orifice plate and a track member. The orifice plate has an exit, a first surface sloping toward the exit, and an inner surface. The track member has an outer surface proximate the first surface of the orifice plate, and the outer surface of the track member has an entrance. A containment plate forms an orifice track with the first and inner surfaces of the orifice plate and with the outer surface of the track member.

Abstract: A valve spool for a suspension damper comprises a body portion and a bridge connected to the body portion. The body portion has an upper edge, and the bridge extends at least partially beyond the upper edge of the body portion.

Abstract: A method for engaging a plurality of control systems in a vehicle, enabling a main menu of a main control program; providing a means for scrolling through a plurality of selections of the main menu; providing an audible text messages for each of the plurality of selections, the audible text messages are activated as an individual scrolls through the plurality of selections; and providing a selector switch for selecting one of the plurality of selections. The means for scrolling through the plurality of selections is located on an upper surface of a spoke of a steering wheel and the selector switch is located on a lower surface of the spoke. The method also includes providing a visual representation of the main menu.