Abstract: A seal assembly for a fuel tank having a tank opening and a component disposed therein includes a seal adapted to be disposed between the component and a tank surface of the fuel tank. The seal assembly also includes an encapsulated studded ring assembly for attachment to the tank surface and adapted to be disposed about the tank opening. The seal assembly further includes a locking ring cooperating with the encapsulated studded ring assembly for engagement with the component to secure the component to the fuel tank and to seal the tank opening via the seal.

Abstract: An improved weight-based occupant characterization method distinguishes between an empty seat and a seat having a small object on it using primary and secondary classification techniques. The primary classification technique is initiated prior to vehicle movement, and characterizes the seat occupant based on measured seat pressure. If deployment of the restraint is suppressed due to the characterization of the primary classification technique, the seat occupancy is characterized by a secondary classification technique based on variation of the measured pressure once the vehicle is in motion. Once the secondary classification technique has characterized the seat occupancy, the characterization of the primary classification technique is discarded in favor of the characterization of the secondary classification technique.

Abstract: An evaporator used in a vehicle air conditioner has vertical plates with a hybrid corrugated fin between the plates. The leading section of the fin as horizontally oriented corrugations, as is normal, while the trailing section has vertically oriented corrugations. Air passes through louvers in the vertical corrugations, and their vertical orientation aids in water drainage.

Abstract: A method for attaching an integrated circuit to a flexible circuit which includes the acts of providing an integrated circuit having a plurality of contact pads formed upon a surface thereof; providing a flexible circuit possessing a plurality of contact bumps formed integral to a surface area; and attaching the integrated circuit to the flexible circuit by fusing at least some of the contact bumps of the flexible circuit to at least some of the contact pads of the integrated circuit. The contact bumps have a shape which mitigates local stress buildup within the contact bumps after attachment of the contact bumps to the contact pads, so as to enhance the reliability of the electrical connection.

Abstract: A method of assembly of a fuel injector having a valve plunger reciprocable in a guide tube for movement from a closed position engaging a valve seat to an open position engaging a valve stop by energizing of a solenoid coil to move the plunger against a biasing spring, wherein the method includes setting the valve stop at a position effective to establish the desired valve stroke, and fixing the valve stop to the guide tube by first laser spot welding the valve stop in the guide tube to fix the position of the valve stop without changing the set gap, and then laser seam welding the valve stop in the guide tube at an axial location beyond the spot welds, relative to a plunger-engagable end of the valve stop, to provide a hermetic seal around the valve stop.

Abstract: A containment structure for housing an inflatable air bag cushion and inflator. Extrusion processes are used to form the portion of the containment structure which houses the inflatable air bag cushion while non-extrusion processes are used to form the portion of the containment structure which houses the inflator in fluid communication with the inflatable cushion. The portion of the containment structure which houses the inflatable air bag cushion is preferably formed from a lightweight, readily deformable material and will preferably be formed from extruded aluminum or plastic. The portion of the containment structure housing the inflator is preferably formed by a deep drawing or molding process so as to include an integral chamber sized for the acceptance and storage of the inflator therein.

Abstract: A heater pattern for a heater of a gas sensor in which a temperature profile is manipulated utilizes a thermistor element arranged in an electrically serial configuration and disposed on a substrate. The thermistor element is arranged so as to define an edge pattern extending about a perimeter of the substrate and a center pattern serially connected to the edge pattern. The center pattern extends over a portion of the substrate that is intermediate the perimeter of the substrate. In a preferred embodiment, the thermistor element is screen printed onto the substrate to a thickness of about 5 microns to about 50 microns, and preferably to a thickness of about 10 microns to about 40 microns. The edge and center patterns are furthermore preferably formed of materials having differing coefficients of thermal resistivity, e.g., platinum and platinum/palladium blends.

Abstract: An improved weight-based occupant characterization method reliably distinguishes between an empty seat and a seat occupied by an ultralight child seat. The seat occupancy is initially characterized using a primary classification technique in which the measured seat pressure is compared to an allow threshold representative of a minimum weight adult. If the primary classification technique determines that the seat is empty and a seat belt for the passenger seat is buckled, a secondary classification technique is initiated to compare the measured seat pressure to a predetermined pressure range characteristic of occupied ultralight child seats. If the measured pressure falls within the ultralight child seat range, characterization of the primary classification technique is discarded in favor of the characterization of the secondary classification technique.

Abstract: A damper includes a piston that carries a relatively compact control valve for controlling fluid flow through the piston. The control valve provides a variable amount of damping by regulating damper fluid flow between the extension chamber and the compression chamber of the damper during extension and compression strokes. Pressure regulation across the piston is controlled through a flow path as determined by the control valve. The damping force of the damper varies depending upon the loading conditions of the vehicle. The control valve is air pressure actuated to adjust the damping force and control the flow of fluid in the flow path.

Abstract: A wheel bearing assembly for supporting a wheel is provided. The assembly includes a spindle defining a rotational axis and a support member for supporting the spindle. A wheel hub has a flange for securing the wheel thereto. The wheel hub is supported on the spindle and is rotatable about the rotational axis. A bearing assembly has first and second bearing members in spaced relationship from one another with a plurality of bearings interposed between the bearing members to permit relative rotation between the bearing members about the rotational axis. The first bearing member is arranged adjacent to the spindle and the second bearing member is arranged adjacent to either the wheel hub or the support member. An inner surface of the first bearing member has an annular counterbore. The spindle is deformed into the counterbore to axially secure the first bearing member to the spindle and prevent relative rotation between the spindle and the first bearing member about the rotational axis.

Abstract: An emulator affixed to a brake arm connected to a brake pedal of an electric brake system is capable of emulating a hydraulic brake. The emulator includes a housing defining a fluid chamber containing a magneto-rheological (MR) fluid. A piston is slideably disposed within the piston chamber and a spring biases the piston to resist depression of the brake pedal. A magnetic source generates a magnetic field upon the MR fluid thereby increasing the sheer resistance of the MR fluid further resisting depression of the brake pedal emulating a hydraulic brake system. The amount of resistance can be varied according to the strength of the magnetic field exerted on the MR fluid.

Abstract: The present invention provides a rotary holding device for an electrically actuated brake system in a vehicle including a rotor assembly including a plurality of teeth and a stator assembly including a plurality of teeth. The stator assembly teeth are positioned adjacent the rotor assembly teeth and a coil is positioned to allow a magnetic flux to align the rotor assembly teeth and the stator assembly teeth when the coil is energized to hold a motor shaft coupled to the device.

Abstract: A vibration damper for a vehicle suspension system includes a pumping cylinder concentrically aligned inside a housing defining a pumping chamber having a piston stroking therein for reducing the level of vehicle vibration. An intermediate cylinder defines an intermediate chamber with the pumping cylinder and an outer chamber with the housing. Suspension fluid flows throughout each of the chambers. A valve is operably connected to an air supply of a suspension system having an air pressure relative to a mass loaded on the vehicle. The controls the distribution of fluid between the chambers relative to the pressure of the air supply and controls the amount of vibration damping inside the pumping chamber relative to the mass loaded on the vehicle.

Abstract: A damper includes a piston that carries a relatively compact control valve for controlling fluid flow through the piston. The control valve provides a variable amount of damping by regulating damper fluid flow between the extension chamber and the compression chamber of the damper during extension and compression strokes. Pressure regulation across the piston is controlled through a flow path as determined by the control valve. The damping force of the damper varies depending upon the loading conditions of the vehicle. The control valve is air pressure actuated to adjust the damping force and control the flow of fluid in the flow path. The piston and rod assembly include unique features such as a seal plate design, and spring retainer that aid in the efficient and reliable assembly in a commercial production setting.

Abstract: In one aspect of the invention, a temperature sensing system, including: control components; and an infrared sensor to provide a temperature input signal to the control components, the infrared sensor being located remotely from the control components. In an additional aspect of the invention, a circuit board for an infrared temperature sensing system, including: a first portion; a second portion coplanar with the first portion; and at least one necked down portion joining the first portion and the second portion. In a further aspect of the invention, a housing for an infrared temperature sensing system, including: a base member; and first support members attached to the base member to permit an infrared temperature sensor to be mounted in a selected one of two positions.

Abstract: An object sensing system is capable of masking certain detected objects such that the system does not provide an alarm. Initially, a projected path of the vehicle is determined by using a current steering angle of the vehicle. Next, a desired warning distance is determined based upon the current steering angle. Then, a current distance to a sensed object, as derived from an object sensor, is determined. Finally, an alarm is provided only if the sensed object is within the desired warning distance.

Abstract: A power distribution module utilizes a planar substrate having an array of repeating slots configured to accept two types of relays, one having four terminals and the other having five terminals. Both relays can mate with the slots of the substrate in a variety of orientations, including reverse orientations wherein the relay terminal footprint can be rotated 180 degrees and still mate with a corresponding, yet shifted, slot footprint.

Abstract: A full function antilock brake valve including a master cylinder port, a wheel port, and an accumulator port. The valve includes a first fluid path coupling the wheel port and the master cylinder port, and a second fluid path coupling the wheel port and the accumulator port. The valve has a normally open valve portion for controlling the flow of fluid through the first fluid path, and the normally open valve portion includes an armature having a plunger that engages a seat. The first fluid path includes an inflow portion that delivers flow from the wheel port to the normally open valve portion. The valve further includes a normally closed valve portion for controlling the flow of fluid from the wheel port to the accumulator port, the normally closed valve portion including an armature having a plunger that engages a seat.

Abstract: An air bag module includes an air bag and an inflator being activatable to discharge inflator gas for inflating the air bag. The inflator has at least one discharge port through which inflator gas is discharged. A housing includes at least one inflator vent opening aligned with the discharge port. A variable inflation device is mounted on the inflator and includes a movable member alignable with the vent opening. The movable member is movable relative to the vent opening for opening and closing the vent opening at a predetermined time during inflator activation to control the amount of inflator gas discharged into the air bag and the amount of inflator gas expelled out through the vent opening of the housing. Preferably, the variable inflation device includes an initiator device being activatable during activation of the inflator to move the movable member relative to the vent opening at the predetermined time during inflator activation.

Abstract: A fuel injector comprises a first needle, and a second needle slidably within a passage formed in the first needle. The needles are engageable with respective seatings to control fuel delivery through respective groups of outlet openings. Load transmitting means are provided whereby movement of the first needle can be transmitted to the second needle. Also described is an injector in which a second needle is provided with formations defining an integral resilient biasing arrangement.