Abstract: A battery pack is provided that includes a case and at least one battery module disposed within the case. The battery pack further includes a flexible circuit to which the battery module may be electrically coupled. The flexible circuit includes a plurality of airflow openings configured to distribute air throughout the battery pack. In a preferred embodiment, the airflow openings vary in size relative to their proximity to an air source.

Abstract: An automotive ball screw rack assembly for positioning a road wheel is presented. The assembly comprises an actuator housing; a ball screw disposed within the actuator housing; at least one tie rod assembly connected to the ball screw and the road wheel; and a motor coupled to the ball screw and connected to the actuator housing for controlling the disposition of the ball screw within the actuator housing.

Abstract: An apparatus and method for simultaneously setting the stroke and biasing force of a valve assembly, the apparatus utilizes a securement member which individually sets the biasing force of a valve assembly. The stop assembly allows a stop member, for setting the stroke of the valve assembly, and a securement member, for setting the biasing force of the valve assembly, to be secured simultaneously.

Abstract: An automotive latch assembly (46) includes an integrally molded seal (54) surrounding three sides of a striker entry hole (52), formed from the same relatively inflexible material as the latch assembly housing (48). The seal (54) comprises a general C shape, including a first wall (56) and two second walls (58), each of which slopes outwardly from said housing (48) and each of which is joined to an adjacent wall (56,58) at an obtuse angle. Each juncture of adjacent walls (56,58) comprises a flex joint (60) that includes a concave fold that flattens out as said adjacent walls (56,58) tend to diverge from one another as they are bent downwardly. This allows the seal (54) as a whole to effectively flex.

Abstract: A suppressor diode for use in an ignition coil, the suppressor diode provides a diode that prevents “make voltages” from breaking down a spark gap of a spark plug. In addition, the resistive inductor prevents electromagnetic interference from the spark plug. The suppressor diode is configured for securement in a confined area of an ignition coil. In particular, the suppressor diode is located between a high-voltage terminal and a high-voltage end of a secondary coil. The suppressor diode includes a spool with a winding surface, a diode is molded into the spool and the diode has a first end connection and a second end connection. The diode is oriented to prevent current flow from the first end connection to the second end connection. A suppressive winding is disposed on to the winding surface, an end cap electrically connects the first end connection of the diode to the suppressor winding.

Abstract: An optical connection unit for the optically conducting connection of optical elements which conduct, receive or emit light is described. The optical connection unit comprises an optical transmission element which has at least one coupling surface for the optical coupling on at a coupling surface of one of the optical elements. Furthermore, the optical transmission element is designed as a spring element so that the coupling surface of the transmission element can be subjected to a bias force in the direction of the coupling surface of the optical element.

Abstract: An engine management system for an internal combustion engine for an automobile includes an architecture for a super ultra low evaporative emission capability. In the present architecture, the fuel rail and injectors are located within the intake manifold such that permeating and evaporative emissions are contained within the intake manifold and a sealing throttle body and/or shut-off check valve is located between the air cleaner/induction components and the throttle body prevent hydrocarbon emissions from reaching the atmosphere. Additionally, a shut-off valve and/or programmable valve train are included to prevent hydrocarbons from the PCV valve and fresh air supply line from being vented to atmosphere. A one way check valve is located between the air induction and cleaner and the PCV fresh air supply such that hydrocarbons that are produced within the intake manifold may pass into the PCV fresh air supply line.

Abstract: A fuel cell system is disclosed. The fuel cell system comprises a thermophotovoltaic insulation disposed around at least a portion of a fuel cell. Methods for operating the fuel cell system are also disclosed.

Abstract: A variable valve mechanism includes an elongate input shaft having a central axis. An input cam lobe is disposed on the input shaft and is eccentric relative to the central axis. A guide member is pivotally mounted on the input shaft. A frame is disposed in engagement with the input cam lobe, and is pivotally and slidably coupled to the guide member. A link has a first end pivotally coupled to the frame. An output cam is pivotally mounted on the input shaft. The output cam is pivotally coupled to a second end of the link arm. The output cam is configured for oscillating engagement of a roller of a roller finger follower.

Abstract: A control-by-wire control system comprising a plurality of control device(s), each control device is responsive to, and configured to receive a control signal. Also included in the control-by-wire control system is a plurality of sensors wherein certain sensors are coupled to particular control devices. The sensors, each sense a parameter of the system and generate various sensor signals in response. A plurality of control modules is also included in control-by-wire control system. Each control module is interfaced to at least one of the control devices and is adapted to receive at least one or more sensor signals. The control modules also generate control signals for communication to the control devices. A communication interface of at least two communication networks provides communications among various control modules.

Abstract: Heat sinks are provided that achieve very high convective heat transfer surface per unit volume. These heat sinks comprise a spreader plate, at least three fins and at least one porous reticulated foam block that fills the space between the fins.

Abstract: A fuel injector comprising a valve needle which is slidable within a bore and engageable with a seating to control fuel delivery through first and second outlet openings. The valve needle is moveable between a closed position and first and second fuel injecting positions. The fuel injector further comprises a fuel supply passage for supplying fuel under pressure to the bore and a control chamber which is arranged to receive fuel from the fuel passage, in use. The valve needle is acted upon in use by a force due to fuel pressure within the control chamber. An actuator arrangement controls fuel pressure within the control chamber, and a damping means are provided for damping movement of the valve needle away from the seating into the first or second fuel injecting position. The supply passage for fuel may be provided with a restricted flow passage which serves to limit the amplitude of pressure waves within the supply passage.

Abstract: A multi-blade electrical connector featuring a guidingly movable blade stabilizer which prevents blade misalignment and foreign article entry into the blade environment. A shroud provides a shroud cavity which communicates with terminal cavities. A bladed terminal is received in a respective terminal cavity, wherein the blade thereof projects into the shroud cavity. The shroud has a top wall and a bottom wall and have formed therein at least one pair of mutually opposed slot sets, each being composed of a prestage slot and a staging slot mutually aligned and separated by a prestage detent. The blade stabilizer has a plurality of blade apertures for snugly receiving a blade, respectively. Opposing edges of the blade stabilizer each have at least one staging nib for being respectively received into the at least one prestage and staging slots, wherein the blade stabilizer is at a prestage position when the staging nibs are at the prestaging slots, and at a sliding staging position when at the staging slots.

Abstract: A steering column differential angle position sensor includes an upper flux shutter and a lower flux shutter, both of which form a plurality of similarly shaped openings. Receiver and transmitter coils are coaxially aligned with the shutters. The transmitter coil provides a magnetic field around the shutters, with changes in the field being sensed by the receiver coil upon differential motion of the flux shutters. Using the output of the receiver coil, the torque on a steering column that is mechanically coupled to the shutters can be obtained.

Abstract: A pressure atomizer includes a silicon plate having a top surface and a bottom surface. A portion of the top surface defines a turbulent chamber. The turbulent chamber is peripherally bounded by the top surface of the plate. The turbulent chamber is recessed a predetermined depth relative to the top surface. The silicon plate further defines at least one flow orifice. Each flow orifice extends from the bottom surface of the silicon plate to intersect with and open into the turbulent chamber. Each flow orifice is in fluid communication with the turbulent chamber.

Abstract: The present invention is directed to liquid-cooled or air-cooled metallic heat sinks formed as unibody structures that include a planar base and upright fins. The fins are located on one side of the heat sink and the ratio of fin spacing to fin height is low. In order to achieve low value of the ratio of fin spacing to fin height, a fin density of greater than about twelve fins per centimeter is employed. The length of the fins in the flow direction is restricted in order to yield high rate of heat dissipation from the finned surface. Furthermore, flow of the cooling fluid over the fins is maintained laminar in order to reduce the noise level and pumping power for the fluid.

Abstract: A method of a manufacturing rotating electromagnetic component to have both soft and hard (permanent) magnet regions, in which powder technologies are used to net-shape mold the component. A soft magnet powder material and an insert or powder of a permanent magnet material are compacted to form a rotating electromagnetic body containing soft and hard magnet regions. A partial sintering operation is then performed on the body at a temperature of 1600° F. (about 870° C.) or less, preferably about 1400° F. to 1500° F. (about 760° C. and 830° C.), and most preferably at 1500° F. to at least partially fuse the soft magnet powder materials with the permanent magnet material. The soft powder component of the resulting electromagnetic body is sufficiently fused to exhibit mechanical properties comparable to a fully sintered body (i.e., sintered at 2050° F. (about 1120° C.) or more), but without degrading the magnetic properties of the hard magnet region.

Abstract: A heating, ventilating, and air conditioning (HVAC) assembly for a motor vehicle includes an evaporator core for cooling air and a heater core for heating air. A heater casing of the HVAC assembly surrounds the heater core. A drain portion of the HVAC assembly extends from the heater casing and includes a partition. The partition defines two basins in the drain portion for separate drainage of evaporator condensate generated at the evaporator core and liquids from the heater core.

Abstract: A hydraulically actuated exhaust gas recirculation valve assembly for metering exhaust gas to the intake of an internal combustion engine. The exhaust gas recirculation valve assembly includes a base having an internal cavity with a control portion and a flow-through portion permitting flow-through of exhaust gas. The base has a hydraulic control port in fluid communication with the control portion of the cavity, the control port having an inlet. A valve body is rotationally mounted within the base, the valve body including a hydraulic control spool disposed within the control portion of the internal cavity. The hydraulic control spool generates a rotational force in response to a hydraulic pressure applied to the control port.

Abstract: A door trim panel assembly and method of making same for attachment to structure of a vehicle includes a door trim panel and a carrier formed from a plastic material attached to the door trim panel and for attachment to the structure of the vehicle. The door trim panel assembly also includes a seal integral with the carrier for contacting the structure to seal the carrier to the structure.