Abstract: A monobloc piston assembly for an internal combustion engine is provided. The piston assembly includes a piston body which extends along an axis and is formed of at least two pieces of material which are joined together at least one friction weld joint which extends continuously through an annular shape around the axis. One of the pieces has an upper surface with a combustion bowl having a rotationally asymmetrical shape around the axis formed therein. Another of the pieces has a dome-shaped receiving surface which is rotationally symmetrical around the axis for slidingly receiving a portion of a connecting rod.

Abstract: A multilayer cylinder head gasket has a pair of functional layers and a distance layer with aligned openings. Each functional layer has a full bead located radially outwardly from and extending about its opening. Each functional layer also has a half bead spaced from the full bead. The distance layer includes a first portion extending radially from the opening and having a first thickness. A second portion of the distance layer extends radially from the first portion and has a second thickness that is less than the first thickness. A third portion of the distance layer extends radially from the second portion and has a third thickness less than the second thickness. The distance layer comprises a plurality of pieces, and at least one of the pieces limits compression of at least one of the full beads when the functional layers are compressed together.

Abstract: A cylinder head gasket has a functional layer with a plurality of openings with a compression bead surrounding at least one of the openings. The functional layer additionally includes a plurality of stoppers, or compression limiters, spaced from the compression bead for preventing full flattening of the compression bead between the engine block and the cylinder head and for limiting the expansion and contraction of the compression bead during and between firings in the cylinders of the engine block. At least one of the stoppers has a generally frustoconical shape with a top and a reverse-frustoconical opening in the top.

Abstract: A tie rod end includes a stud with a spherical ball at one end and a bearing having a concave spherical bearing running surface for sliding abutment with the ball. The contact area of the ball or the bearing running surface has a lubrication groove to facilitate channeling grease, wherein the grooved member is coated with a bonded lubrication coating. The lubrication coating reduces the initial preload torque from that which would be ordinarily be perceived as undesirable to a torque that is perceived as desirable. The lubrication coating is substantially consumed on the high contact area over about 100 to 500 thousand cycles, with the resulting torque being remaining greater than zero, which is also perceived as being desirable.

Abstract: Processes for making press-in-place (PIP) gaskets. Representative components with gasket cavities (grooves) are prepared and the cavities are filled with a curable molding material. Once the molded gaskets are hardened, they are removed from the cavities. The molded sample gaskets are then measured, preferably by a laser scanner, and drawings are prepared based on the measurement data. Appropriate tooling is then created and the gaskets are produced.

Abstract: A high strength, low friction engineered material includes a low friction material filling interstices of a metal microlattice. The metal typically comprises 5 volume % to 25 volume % and the interstices typically comprise 75 volume % to 95 volume %, based on the total volume of the metal microlattice and the interstices. The low friction material preferably fills 100 volume % of the interstices. The metal microlattice can be formed of a single layer, or multiple layers, for example layers of nickel, copper, and tin. The low friction material is typically a polymer, such as polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), or polyoxymethylene (POM). The low friction material can also include additive particles to modify the material properties. The engineered material can be used in various automotive applications, for example as a bearing, or non-automotive applications.

Abstract: A piston assembly transportation and assembly apparatus and methods of transporting and installing a piston assembly therewith are provided. The apparatus maintains a piston assembly in its assembled state during transportation without allowing damage and contamination to the piston assembly. The apparatus also facilitates storage and installation of the piston assembly into a cylinder bore. The apparatus includes a housing having a bore bounded by an inner cylindrical surface extending from a first end of the housing toward a second end of the housing. A chamfered surface diverges radially outwardly from the first end to mate with an upper surface of a stuffing cone during assembly. The second end has a wall extending radially inwardly from the inner cylindrical surface to axially confront an upper crown of the piston assembly to both prevent the piston assembly from passing though the apparatus and to prevent contamination from entering the apparatus.

Abstract: An economical LED light module configured to emit a uniform pattern of light from a single LED utilizing a minimal amount of energy and exhibiting a long and useful life is provided. The LED light module includes a main hyperbolic reflector and a plug receptacle having an electrical connector configured for electrical communication with a power source. A LED is mounted in electrical communication with the electrical connector. An elongate light pipe extends between a light receiving end configured to receive light emitted from the LED and a light emitting end. The light emitting end has a parabolic reflector positioned concentrically about a focal point of the hyperbolic reflector.

Abstract: A wiper blade assembly has a resilient wiper element with a crown having lengthwise grooves and a tip for wiping a window. An arcuate metal flexor has inner edges disposed in the grooves of the crown and outer edges. An elongate cover has an upper wall and a pair of flanges curled inwardly in spaced relation from the upper wall to provide elongate channels. The outer edges of the flexor are disposed in the channels. The connector is configured for attachment to a wiper arm, and has a lower surface with a pair of flanges curled in spaced relation from the lower surface to provide opposite facing pockets that slidingly receive the cover flanges therein. A projection on one of the connector or the cover is received in an opening of the other of the connector or the cover to lock the connector to the cover.

Abstract: A piston for an internal combustion engine comprises a sealed cooling gallery extending circumferentially around a center axis beneath a bowl rim of an upper crown. A metal-containing composition having a high thermal conductivity fills a portion of the sealed cooling gallery to dissipate heat. The metal-containing composition includes a base material having a melting temperature less than 181° C. and a plurality of metal particles having a thermal conductivity greater than the thermal conductivity of the base material. For example, the metal-containing composition can comprise copper particles dispersed in silicone oil, or copper particles dispersed in a mixture of alkali metals. During high temperature operation, as the piston reciprocates in the cylinder bore, the base material is liquid and flows throughout the cooling gallery to dissipate heat away from the upper and lower crowns.

Abstract: A textile sleeve for protecting elongate members and method of construction thereof is provided. The sleeve includes both monofilament and multifilament yarns woven in both warp and fill directions. The warp yarns are woven in a warp-faced pattern with the fill yarns. As such, the warp yarns float over 2 or more of fill yarns. The warp monofilaments provide the sleeve with increased abrasion resistance, while the warp multifilaments provide the sleeve with increased flexibility and coverage protection to protect elongate members within a cavity of the sleeve. The fill monofilaments provide the sleeve with increased abrasion resistance and the fill multifilaments provide the sleeve with increased flexibility and coverage protection. The method includes weaving the warp and fill yarns in one of an open or closed wall construction. The method can include heat-setting the monofilament fill yarns to bias the open wall into a self-closing tubular configuration.

Abstract: The lighting assembly (20) includes a light guide (22) formed of a resin material propagating light through internal reflection. A housing (28) surrounds the light guide (22) and maintains the light guide (22) in a predetermined position. A light transmissive coating (24), such as a vacuum metalized coating, is disposed on the light guide (22) and faces outwardly of the housing (28). The light transmissive coating (24) disguises the resin light guide (22) so that the light guide (22) appears to be a metallic trim. A non-light transmissive coating (26), such as a paint, appearing to be the same material as the light transmissive coating (24), may be disposed on the light guide (22) adjacent the light transmissive coating (24).

Abstract: A multilayer cylinder head gasket has a pair of functional layers and a distance layer with aligned openings. Each functional layer has a full bead located radially outwardly from and extending about its opening. Each functional layer also has a half bead spaced from the full bead. The distance layer includes a first portion extending radially from the opening and having a first thickness. A second portion of the distance layer extends radially from the first portion and has a second thickness that is less than the first thickness. A third portion of the distance layer extends radially from the second portion and has a third thickness less than the second thickness. The distance layer comprises a plurality of pieces, and at least one of the pieces limits compression of at least one of the full beads when the functional layers are compressed together.

Abstract: A method of coating all surfaces of a plurality of piston rings in a single run by a chemical vapor deposition (CVD) process is provided. The method can include providing a coil formed of an iron-based material; heating the coil; and depositing a coating on all surfaces of the coil during a single continuous period of time, without having to move the coil during the CVD process. The coil is maintained in a fixed position during the depositing step. The method next includes splitting the coil into a plurality of separate coated piston rings. Alternatively, the method can include providing a plurality of stacked keystone piston ring bodies; and disposing a cylinder around the stack to maintain the keystone piston ring bodies in position while depositing the CVD coating on all surfaces of the keystone piston ring bodies during the single coating run.

Abstract: A static cylinder head gasket assembly includes an inner distance layer having an opening extending between opposite planar sides with the opening being configured to register with a cylinder bore of an internal combustion engine. A plurality of inner functional layers overlie each of the opposite sides of the inner distance layer. The inner functional layers have axially aligned, nested annular sealing beads extending about the opening in the distance layer. The gasket assembly further includes a plurality of outer functional layers separate from the inner functional layers. The outer functional layers have annular inner peripheries spaced axially from one another to provide a gap configured to receive at least a portion of the inner distance layer therein. The outer periphery of the inner distance layer is captured axially between the outer functional layers and thus, the inner distance layer is prevented from being disassembled from the outer functional layers.

Abstract: A continuous hot bonding method for producing a bi-material strip with a strong bond therebetween is provided. The method comprises sanding a first strip formed of steel; and applying a layer of first particles, typically formed of copper, to the sanded first strip. The method next includes heating the first strip and the layer of the first particles, followed by pressing a second strip formed of an aluminum alloy onto the heated layer of the first particles. The aluminum alloy of the second strip includes tin particles, and the heat causes the second particles to liquefy and dissolve into the melted first particles. The first particles and the second particles bond together to form bond enhancing metal particles, which typically comprise bronze.

Abstract: A shaft seal assembly includes a metal case having a wall extending cylindrically about a central axis with an annular leg extending radially inwardly from the wall toward the central axis. An elastomeric material is bonded to the leg and a primary seal lip is operably attached to the elastomeric material. The primary seal lip separates an oil side of the assembly from an air side of the seal assembly. The elastomer material has an annular groove formed on the air side of the primary seal lip. The assembly further includes an auxiliary lip subassembly including an annular metal washer with at least one auxiliary lip fixed thereto as a one-piece subassembly. The annular metal washer has an annular outer periphery snappingly received within the annular groove.

Abstract: An improved piston for an opposed piston internal combustion engine is provided. The piston includes a piston body that extends along an axis from a crown portion to a skirt portion with a full piston skirt and to a pin boss portion. The piston body includes a plurality of ring grooves in the crown portion and at least one ring groove in the skirt portion. A wrist pin which has a length that is longer than a maximum diameter of the piston body is joined with the piston body at the pin boss portion and extends past the pin boss portion for receiving a pair of connecting rods on opposite sides of the piston body. The piston body is a monobloc piston body which is made of one integral piece or of multiple pieces that are welded or adhered together.

Abstract: A piston assembly and method of construction thereof for an internal combustion engine are provided. The assembly includes a piston head having an upper combustion wall with an undercrown surface and a ring belt region. The piston head has a floor with an upper surface and a bottom surface. The floor is spaced beneath the upper combustion wall in radial alignment with the ring belt region. A substantially enclosed, annular cooling gallery is bounded by the undercrown surface and the floor. A pair of pin bores depends directly from the floor of the cooling gallery. The assembly further includes a pin having ends configured for oscillating receipt in the pin bores. A pin bearing surface extends within the pin bores and between the pin bores in the lower surface of the floor. The assembly includes a connecting rod with an end fixed to the pin for conjoint oscillation therewith.

Abstract: A piston for an internal combustion engine is provided. The piston includes a piston body which is made of steel. The piston body has a crown portion with an upper combustion surface, a pair of skirts which depend from the crown surface, a pair of pin bosses for receiving a wrist pin and a plurality of pin boss bridges which extend from the pin bosses to the skirts. Each of the pin boss bridges extends axially to a lower end which is opposite of the crown portion and has a rib with an increased thickness at its lower end. At least one of the pin boss bridges has a generally flat counter-bore surface for providing a reference location for machining of the piston body.