Abstract: An improved motor vehicle electrical system includes a flexible topology DC-to-DC converter for coupling an engine-driven alternator to vehicle electrical loads at a mode-dependent transfer ratio. The output voltage of the alternator is regulated based the load voltage, and the converter is operable in one of a number of different modes based on engine speed, including a forward boost mode, a forward unity mode, and a forward buck mode. In the forward boost mode, the converter output voltage is boosted above that of the alternator to enable battery charging at low engine speeds; in the forward unity mode, the alternator output voltage is transferred to the battery and electrical loads at a unity transfer ratio; and in the forward buck mode, the converter output voltage is reduced below that of the alternator to enhance the alternator power output at medium-to-high engine speeds.

Abstract: A roller finger follower. includes an elongate body having first and second opposing sides each having respective inside surfaces. First and second grooves are defined by the respective inside surfaces. A slider bracket includes a top plate having a top surface that is substantially perpendicular to the first and second sides. First and second projections are affixed to or integral with the top plate, and protrude therefrom in a generally parallel manner relative to the top surface. The first projection is slidably disposed within the first groove and the second projection is slidably disposed within the second groove. A locking pin assembly is carried by the slider bracket, and selectively couples and decouples the slider bracket to and from the body.

Abstract: An EGR valve having a self-compensating bearing assembly for use with a valve member having a shaft reciprocable within a valve body, includes a rigid bearing member for providing radial support and axial guidance to the valve shaft as the shaft reciprocates in the valve body; and a pliant annulus supporting the bearing member, where the pliant annulus has a density and thickness sufficient to accommodate distortion of the rigid bearing member in response to changes in temperature without interfering with shaft actuation.

Abstract: An apparatus and method for detecting radar system blockage includes a radar system having an antenna unit configured to transmit radar signals and receive reflected radar signals. In one embodiment, fixed frequency continuous wave radar signals are transmitted, and corresponding reflected signals are sampled and processed to determine a mainbeam clutter signal peak in frequency bins near those corresponding to vehicle speed. If this peak is less than a power threshold, the antenna unit is at least partially blocked. In another embodiment, a number of most recent reflected tracking signal amplitudes are sampled, normalized to a predefined range value and filtered to produce a smoothed tracking amplitude. If the smoothed tracking amplitude drops below an amplitude threshold, the antenna unit is at least partially blocked. The two embodiments may be combined to determine a radar antenna blockage status as a function of both techniques.

Abstract: A zero emissions fuel system includes a fuel tank fluidly interconnected with a fuel vapor containment and absorption canister. The canister is further interconnected with an engine intake manifold via a purge solenoid valve that controls the extent to which a vacuum in the intake manifold affects the canister. The canister is also interconnected with the ambient environment via at least one selectively operable valve. During normal operation of the engine, the purge solenoid valve allows the intake manifold to draw fuel vapor from the canister for consumption by the engine. At a predetermined vacuum pressure, the at least one valve opens, thereby allowing outside air to flow into the system through the vacuum relief valve to facilitate purging of the canister.

Abstract: A vehicle heater of the type that uses diverted engine coolant is provided with an accelerated warm up process that takes the coolant to a temperature suitable for passenger space heating more quickly. The fan that normally pulls outside air through the front end grill is, after vehicle start up, run in reverse, so as to actually retard the flow of air through the grill. The net effect of a separate structure that physically blocks air flow is achieved merely by using existing components in a new way.

Abstract: A fuel injector comprising a nozzle body provided with first and second outlet openings for fuel, a valve needle slidable within a valve needle bore defined in the nozzle body, the valve needle bore being shaped to define a seating with which the valve needle is engageable to control fuel flow to a chamber, the valve needle being provided with a flow passage communicating with the chamber, movement of the valve needle away from the seating into a first fuel injecting position permitting fuel delivery through the first outlet opening and whereby movement of the valve needle away from the seating into a second fuel injecting position causes fuel in the chamber to flow through the flow passage for delivery through the second outlet opening. The nozzle body may include an upper nozzle body part provided with a through bore and a lower nozzle body part provided with a blind bore, the lower nozzle body part being received in the through bore to close an open end thereof.

Abstract: A sensor is disclosed that comprises an electrolyte disposed between and in intimate contact with a sensing electrode and a reference electrode. A protective coating is disposed on the protective layer adjacent to the sensing electrode. The protective coating comprises a mixture of a metal oxide, a zeolite, and an alumina. A method for making the sensor is also disclosed.

Abstract: A limit switch includes a housing, a plunger, an actuator, a prime contactor, a redundant prime contactor, an adjustment contactor, and a redundant adjustment contactor disposed within the housing. The prime contactor and adjustment contactor are electrically coupled in series. The prime and redundant prime contactors are openable by the plunger, and the adjustment and redundant adjustment contactors are closable by the plunger. The redundant adjustment contact is electrically coupled in series with the redundant prime contactor. The limit switch controls a circuit by aligning the limit switch in a mid-position alignment. Opening the prime contactor or redundant prime contactor de-energizes the electrical circuit. Closing the prime contactor and the redundant prime contactor while the adjustment contactor and the redundant adjustment contactor are maintained closed energizes the electrical circuit.

Abstract: An air bag assembly including an inflator for discharging inflation gas and a gas receiving expansible air bag cushion of winged geometry disposed in fluid communication with the inflator such that upon release of inflation gas from the inflator the air bag cushion is deployed substantially over the windshield of an automobile as well as the pillars adjacent the windshield. View ports are present within the interior of the air bag cushion so as to maintain a degree of visibility for the vehicle operator after deployment has taken place. Mesh netting or a like material which does not unduly restrict visibility may extend across the internally formed view ports.

Abstract: This present invention provides a method for creating a gas restrictive interface between a battery case partition formed in a battery case and a battery plate strap, which extends through the partition in a series connection and is part of a battery cell block, which is received within the battery case. The battery case partition includes a notch having a sealing material disposed thereon so that when a heated battery plate strap is positioned within and across the notch, a first gas restrictive interface results between the battery plate strap and the case partition. A battery case lid having a partition tab extending therefrom forms a second gas restrictive interface with top surface if the battery plate strap by being received and secured within the notch of the battery case partition. The bottom edge of the partition tab includes the sealing material to complete the gas restrictive interface.

Abstract: A shield for a gas management pintle valve, such as an exhaust gas recirculation valve for an internal combustion engine, for mitigating leakage of gas and moisture along the valve pintle into the actuator, to prevent corrosion and failure of the actuator. The shield is a tubular member having an equatorial radial flange and is slidably mounted on the pintle in an annular chamber between the valve body and the actuator. The inner diameter of the tube is selected to be as close-fitting to the pintle as possible while still being slidable thereupon to be adapted to either of two operating positions. During engine shutdowns, the shield is drawn by gravity toward the valve body to form a first seal with the flange against the pintle bearing or a bearing splash shield, preventing or minimizing the escape of moist, hot gases under low pressure from the valve along the pintle.

Abstract: An evaporative control valve for a vehicle. The valve has a valve body for containing a solenoid that manipulates a plunger between an open position and a closed position, the plunger has a valve end and an adjustment end. The valve body also has a receiving area, a first port, as well as a conduit for connecting the first port to the receiving area. A port member is received and engaged within the receiving area and the port member provides a passageway from the receiving area to outside the valve body and the valve end seals the passageway when the plunger is in its closed position. The first port is aligned with and provides access to set the stroke of the solenoid.

Abstract: A brake pedal feel emulator for a motor vehicle brake system includes a housing having a bore for supporting a first piston operably connected to a brake pedal. An elastomer spring encapsulating a magnet or magnetized by the dispersion of ferrous particles throughout the spring body is engageable by the first piston and is disposed in the emulator housing. A second piston is disposed in the housing and engaged with the elastomer spring and with a mechanical spring. Hall effect sensors mounted on the emulator housing sense changes in a magnetic field generated by the magnet to provide signals to a controller proportional to travel and force exerted on the brake pedal for use in controlling the vehicle brake system.

Abstract: A catalytic converter for an exhaust system of a motor vehicle comprising a housing having an inlet and an outlet; a first brick positioned inside the housing adjacent the inlet for initiating catalytic light-off functions of exhaust gases flowing through the first brick; a second brick positioned adjacent the first brick downstream of the inlet for three way conversion of exhaust gases flowing through the second brick; a third brick positioned adjacent the second brick downstream of the inlet for hydrocarbon adsorption and oxidation of exhaust gases flowing through the third brick; and a fourth brick positioned adjacent and spaced from the third brick downstream of the inlet for light-off of exhaust gases flowing through the fourth brick; wherein the third brick is substantially annular with a through bore extending axially therethrough; and wherein the second brick has a closed bore extending axially and opening into the through bore of the third brick.

Abstract: An improved magnetorheological fluid damper is provided which effectively provides a smooth transition, without a sharp break in the damper force/velocity curve, between very low damping forces near zero damper velocity to higher damping forces at higher piston velocities while maintaining desirable maximum force levels. The damper includes a piston assembly, including a magnet assembly and a flow gap extending through the piston assembly to permit fluid flow between the chambers. The force/velocity optimization feature includes at least one groove open to the flow gap, formed in a non-magnetic portion of the piston and positioned in series with a part of the flow gap in a magnetic circuit generated by the magnet assembly and dimensioned/sized to permit fluid flowing the passage to experience a magnetorheological effect less than a magnetorheological effect experienced by fluid flowing through the flow gap but not through the groove.

Abstract: A method for producing thin film alloy by a sputtering deposition process comprising using a target having compartments of individual components arranged in concentric circles.

Abstract: An NOx reducing exhaust treatment system includes a non-thermal plasma reactor assembly which initiates NOx reduction reactions that are completed by a catalytic converter downstream of the reactor in the system. The reactor assembly includes a monolithic reactor element formed of insulating plates and spacers made of high dielectric material, such as alumina. Some of the plates carry electrodes and connecting conductors which may be painted on with conductive ink and baked on as a surface coating. The electrodes are patterned to provide a distance between the electrodes and the connectors of alternate electrodes that is sufficient to prevent arc over. The plates and spacers form a plurality of thin gas passages each lying between a pair of electrodes, one to be charged with an AC voltage and the other grounded to impress the alternating voltage across each passage.

Abstract: A coil assembly includes a spool (102) having an upper flange (104), a medial flange (106) and a lower flange (108). A terminal groove (118) is established between the upper flange (104) and the medial flange (106), and a winding bay (110) is established between the medial flange (106) and the lower flange (108). Ramps (130) are formed in the groove (118) and at least two terminal posts (126), each having a foot (128), are inserted through the upper flange such that each foot (128) is disposed within the groove (118). Each terminal post (126) is movable between a winding position, wherein the foot (128) protrudes outwardly to facilitate engaging a coil wire end (132), and a retracted position, wherein the foot (128) is retracted behind the respective ramp (130).

Abstract: An improved table look-up method for dynamic control applications, wherein a previous index value is used as a starting point for quickly and efficiently identifying the independent variable values that bracket the input value. At each table look-up request, the input is compared to the independent variable value associated with the last index value from the previous look-up request, and the index is then incremented or decremented from that point to identify the pair of independent variable data points that bracket the input value. In most dynamic control applications, the table is used to update the dependent variable at a fast rate relative to the rate of change of the input value, and the subject look-up method provides a significant speed improvement.