Abstract: An catalytic converter is integrated with a flexible endcone to form an assembly. The assembly comprises a catalytic converter with a flexible endcone integrated connected to one end of the catalytic converter, which is optionally attached to a mounting flange or exhaust pipe. The endcone comprises a flexible bellow containing a plurality of undulating ribs. The flexible bellow is secured to an end of the catalytic converter at one or more interface points along the periphery of the flexible endcone assembly.

Abstract: Disclosed herein is a method and system for initializing a rotating device such as an electronically commutated electric machine. The system comprises: an electric machine; a position sensor subsystem operatively connected to the electric machine configured to measure a position and transmit a position signal to a controller. The controller executes a method initializing position for the electric machine, the method comprising: establishing a sensor subsystem datum indicative of a measurement reference point for a sensor subsystem; obtaining a calibration value corresponding to a distance to a selected magnetic reference position for the electric machine, relative to the sensor subsystem datum; and measuring a position and calculating a position delta relative to an initial reference. The method also includes: estimating an offset from the sensor subsystem datum to an initial reference; determining an absolute position estimate of the electric machine relative to the magnetic reference position.

Abstract: A sensing assembly senses a level of a liquid in a reservoir. The sensing assembly includes a first input port for receiving a first input voltage signal. The sensing assembly also includes a second input port for receiving a second input voltage signal. An excitation circuit is electrically connected to the first and second input ports for receiving the first and second input voltage signals and for generating a first excitation signal and a second excitation signal. A receiving circuit is disposed adjacent the excitation circuit and defines a variable capacitance with the excitation circuit. The receiving circuit produces an output voltage variable with the level of the liquid in the reservoir due to capacitance changes between the excitation circuit and the receiving circuit. The receiving circuit includes a first receiving electrode extending through a sine wave form and a second receiving electrode extending through a cosine wave form.

Abstract: An electrical connector assembly has a housing and two slide assist members that are slideably supported by the housing. The slide assist members each include at least one mating slot adapted to receive a mating portion of a mating connector. A U-shaped slide assist lever having first and second spaced apart arms is pivotally interconnected with the housing and the slide assist members to move the slide assist members and facilitate mating with the mating connector. Each slide assist member includes a notch and each lever arm includes a protrusion that mates with the corresponding notch when the slide assist member is in an engaged location and the lever is in an engaged position.

Abstract: An integrated electrical generator/starter and air conditioning compressor device driven by a common drive shaft, or other direct linkage. The device includes an electrical generator/starter and a compressor. The electrical generator/starter is coupled to the drive shaft. The compressor is coupled to the electrical generator/starter and to the drive shaft and acts to pressurize a flow of refrigerant in response to rotation of the drive shaft. The electrical generator/starter is operable in first and second states. In the first state, the electrical generator/starter generates electricity in response to rotation of the drive shaft. In the second state, the electrical generator/starter utilizes electrical power from a battery to rotate the drive shaft.

Abstract: A hand wheel actuator for a steer-by-wire steering system having a steering feel that meets drivers' expectations is provided with a housing having an aperture, a steering shaft extending through the aperture and rotatably supported by the housing, an electric motor, a position sensor and torque sensor, and a mechanical steering feel enhancement device. The mechanical steering feel enhancement device is attached to the housing and provides a positive stop function, a return-to-center function, and/or a friction/weight function. The mechanical steering feel enhancement device is in mechanical communication with the steering shaft and may exist as a separate unitary subassembly prior to being installed on the housing. The electric motor has an output shaft that is in mechanical communication with the steering shaft for imparting a torque to the steering shaft.

Abstract: A method and assembly (10) for conducting heat from a semiconductor device, such as a power flip chip (12). The assembly (10) is generally constructed to dissipate heat from the flip chip (12) when mounted to a flexible or rigid substrate (20). Heat is conducted from the flip chip (12) through upper and lower pedestals (26, 28) each of which includes a pliable pre-cured silicone adhesive pad (32, 36). The pre-cured silicon adhesive pads (32, 36) promote thermal contact while also decoupling any lateral mechanical strains that may arise as a result of different thermal expansion and movement between the flip chips (12). The housing portions (16, 18) form a housing (14) when assembled, with each housing portion (16, 18) including a configured edge (37, 41) that controls the travel of the pedestals (26, 28) toward each other, to thereby limit the pressure exerted on the flip chip (12) disposed therebetween.

Abstract: Interconnects and perimeter spacers for a fuel cell stack are provided as flexible elements which can conform to non-planarities in a stack's electrolyte elements and thereby avoid inducing torsional stresses in the electrolyte elements. The interconnects are foil elements about 0.005 inches thick, formed of a superalloy such as Hastelloy, Haynes 230, or a stainless steel. The perimeter spacers comprise a plurality of laminate thin spacer elements, each thin spacer element being a laminate of superalloy and a “soft” material such as copper, nickel, or mica. The spacer elements can slide past one another; thus the perimeter spacers can be physically thick, to form the gas flow spaces within the stack, while also being torsionally flexible.

Abstract: An electrically-insulating polymer-based material with improved thermal conductvity so as to be suitable for use as an adhesive for mounting and conducting heat from electronic devices. The polymer-based material comprises metal particles dispersed in a matrix material. The metal particles are encapsulated by a dielectric coating so that they are electrically insulated from each other. The polymer-based material may also comprise dielectric particles dispersed in the matrix material and/or the dielectric coating for the purpose of further increasing the thermal conductivity of the polymer-based material. The material is also suitable for use as a potting compound or an encapsulation material for various electronic applications.

Abstract: A joint structure and method for bonding together two components, such as when attaching an electrical circuit element to a conductor on a substrate. The joint structure comprises a mesh infiltrated by a solder material, in which the mesh is preferably formed of a material having a higher thermal conductivity than the solder material. The joint structure is able to offer improvements in thermal conductivity, electrical conductivity, reflow processing, and stress distribution between the structures it connects. Each of these attributes of the joint structure can be tailored to some degree by the choices of materials for the mesh and the solder material.

Abstract: A combination starter-generator system for use in a vehicle is provided. The vehicle has an internal combustion engine and a battery. The system includes a starter-generator electrically coupled to the battery to generate a current and to start the internal combustion engine. A drive mechanism connects the starter-generator machine and the internal combustion engine. The starter-generator machine generates the current by receiving a charging torque from one side of the drive mechanism and starts the internal combustion engine by imparting a starting torque to a different side of the drive mechanism. The charging torque or the starting torque is a greater torque. A passive tensioning system cooperates with the drive mechanism to tension the drive mechanism only at the side of the greater torque.

Abstract: A strengthened thin-walled catalytic converter substrate includes thin perimeter walls and thin interior walls defining cells and a catalyst washcoat selectively disposed on the substrate. Washcoat thickness is increased in those cells having the most impact on final catalyst strength, typically the outer cells defined by the perimeter walls. A method for maximizing overall catalyst strength with minimal substrate thermal mass includes selectively applying washcoat based on desired substrate strength and converter assembly method.

Abstract: An arc magnet assembly with a virtual radial magnetization is established by placing a series of small trapezoidal-shaped magnet segments having axial magnetizations side by side to form an arc. The arc magnet assembly may be affixed to a rotating component in, e.g., a vehicle to yield a substantially linear magnetic sensor output that represents the speed and/or direction of rotation and/or position of the rotating component.

Abstract: A metal runner that improves the current-carrying capability of solder bumps used to electrically connect a surface-mount circuit device to a substrate. The runner comprises at least one leg portion and a pad portion, with the pad portion having a continuous region and a plurality of separate electrical paths leading to and from the continuous region. The electrical paths are delineated in the pad portion by nonconductive regions defined in the pad portion, with at least some of the nonconductive regions extending into the leg portion. The multiple electrical paths split the current flow to and from the solder bump, distributing the current around the perimeter of the solder bump in a manner that reduces current density in regions of the solder bump where electromigration is most likely.

Abstract: Shaped, contoured crushable structural members and methods for making the same are described. The contoured structural members comprise composite or metal materials sandwiching a support or stabilizing structure. The structural members are made crushable by incorporating an initiator into the structural members. The structural member crushes at the location of the initiator by absorbing the energy of an exerting load. The shaped structure is provided by bending the generally straight shape of the structural member. With a shaped, contoured, crushable, and generally non-flat structure, applications and uses for the structural members of the present invention are nearly limitless.

Abstract: Device and method including a generally flat and flexible circuit for electrically inter-connecting components therein are provided. The device includes a post including a recessed section configured to receive the flexible circuit through an opening in said circuit. The structures defining the opening in the flexible circuit may be configured to provide a snap-fit between the circuit and the recessed section of the post, and thus avoid undesirable movement of the flex circuit in the presence of vibration.

Abstract: A method is for direct application of a brazing flux material to a brazing surface. The method includes the step of applying a brazing filler material to a substrate utilizing a kinetic spray process to form a brazing surface. Following application of the brazing filler material to the substrate brazing flux material can be directly applied to the brazing surface as either a dry powder or a wet slurry. The nature of the brazing surface allows the applied flux material to adhere to the surface without the utilization of additional binders or resin materials.

Abstract: A low-loss electrode-printed structural dielectric barrier for a non-thermal plasma reactor and non-thermal plasma multi-cell stacks having low-loss electrodes. The low-loss electrode-printed structural dielectric barriers include a structural dielectric barrier having a first side and a second opposite side; a low-loss electrode pattern disposed on the second side of the structural dielectric barrier; the low-loss electrode pattern comprising first and second major electrode sections that are offset from any ribs, supports, ligaments, spacers, tines, or other structure that serves as a structural dielectric connection between dielectric barriers in a multi-cell stack, a connector disposed between and electrically connecting the first and second major electrode sections and offset relative to a centerline perpendicular to the rib orientation, and a bus path connector electrically connected to one of the major electrode sections and offset relative to the centerline.

Abstract: A high voltage electrical connection includes an electrical receptacle connector and a mating electrical plug connector. The electrical receptacle connector includes a receptacle that is mounted over a hole in the casing and fastened thereto with a plurality of terminated electrical leads that are attached to an internal component of an electrical device inside the casing and threaded through a hole in the casing. The receptacle has a chamber including an inlet at one end that is aligned with the hole in casing and an outlet at the other end. The electrical receptacle connector also includes a terminal holder and a terminal housing, both of which are made of electrical insulation material. The holder retains the plurality of terminals, of the respective leads is inserted into the chamber through the outlet of the receptacle and retained in the chamber. The terminal housing is then inserted into the chamber via the outlet with its flange being disposed in the outlet.

Abstract: A heat sink with integrated electronics having a cavity with one or more facing sides. Hybrid circuits are housed in the cavities. A bottom portion seals the housing and has a row of pins is provided for interconnecting the circuits housed in the separate cavities to an external device, thereby allowing the integration of different types of circuits in a single, fully enclosed, yet partitioned, housing.