Abstract: An internal combustion engine and piston therefor is provided. The piston has a body including an upper combustion wall, a cylindrical outer wall including a ring belt region depending from the upper combustion wall, and a pair of pin bosses having axially aligned pin bores. The piston has a first cooling gallery in radial alignment with the ring belt region with a cooling medium contained therein. An insert member is fixed to the body in axially spaced relation beneath a lower wall of the first cooling gallery. The insert member bounds a second cooling gallery beneath the lower wall of the first cooling gallery. The insert member has an inlet opening configured to allow oil to flow into the second cooling gallery against the lower wall of the first cooling gallery and a separate outlet opening configured to allow the oil to flow outwardly from the second cooling gallery.

Abstract: A spark plug (20) includes an insulator seat angle (?i) of 35° to 50° and an increased insulator thickness (ti) in selected areas around the insulator seat (28). The insulator seat angle (?i) is greater than or equal to a boundary value provided by the equation: 90°?a cos [1?(R1?R2)÷(R4+R5)], and preferably not greater than 150% of the boundary value. The radii (R1, R2, R3, R4, R5) can be adjusted to maximize R4 while maintaining an acceptable R2. A gasket is compressed between the insulator (22) and shell (58), and the inner gasket thickness (tg2) is greater than or equal to 70% of the outer gasket thickness (tg1).

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: A piston and method is provided that inhibits the potential catastrophic damage to an internal combustion engine, thereby reducing the risk of costly damage to the engine. The piston includes a piston body having an upper combustion surface separated from an internal cooling chamber by a wall. The a pocket extends into the upper combustion surface to a closed bottom surface of the wall. A tubular member is disposed in the pocket. The tubular member extends upwardly from the upper surface. Should a valve head drop from its normal operating position, the valve head impacts the tubular member and forms a blow-by through passage extending from the upper combustion surface into the cooling chamber.

Abstract: A piston for an internal combustion engine and method of construction thereof are provided. The piston includes a piston body having an upper combustion surface and an annular cooling gallery surrounding an undercrown region. An outer wall depends from the upper combustion surface. An annular ring belt region is formed in the outer wall adjacent the upper combustion surface. The ring belt region has at least one ring groove formed therein. At least one oil passage extends from the at least one ring groove to the cooling gallery. The oil passage has a first portion depending radially inwardly from the ring groove and a second portion ascending radially inwardly from the first portion to the cooling gallery.

Abstract: A piston for an internal combustion engine including a piston body (20). The piston body (20) defines a first cooling chamber (46) that is sealed closed and contains a first cooling medium (48) other than air. During operation of the piston, the first cooling medium (48) extracts heat from the surrounding regions of the piston body (20) to cool the piston body (20). The piston body (20) also defines a second cooling chamber (50) adjacent to the first cooling chamber (46). A cooling oil (51) is projected into the second cooling chamber (50) and against the portion of the piston body (20) separating the first and second cooling chambers (46, 50) to extract heat from the first cooling medium (48). The cooling oil (51) is redirected within the second cooling chamber (50) to extract additional heat from the first cooling medium (48) or directly from the piston body (20).

Abstract: A multilayer static cylinder head gasket has at least one metal functional layer and a metal distance layer having registered openings. The functional layer has a full bead located radially outwardly from and extending about its opening. The opening in the distance layer is formed in a first portion having a first thickness. A second portion of the distance layer extends radially outwardly from the opening and the first portion, wherein the second portion has a second thickness that is less than the first thickness. A compression limiter is formed in at least one of the functional layer or the distance layer. The compression limiter prevents the full bead from being completely flattened, which in turn maintains the full bead in high sealing pressure against the distance layer relative to the remaining portion of the functional layer and also prevents premature fatigue cracks from forming in the full bead.

Abstract: A wrist pin and method of reducing wear between members thereof, a piston, a connecting rod, and methods of construction thereof are provided. The wrist pin has a first portion extending between opposite ends configured for receipt in piston pin bores and a second portion extending between opposite ends configured for receipt in the pin bores. The second portion is configured for relative movement with the first portion. The piston includes a piston body having axially aligned pin bores, wherein at least one of the pin bores has a feature to prevent relative rotation of a wrist pin member. The connecting rod includes a connecting rod body having small end bore. The small end bore has a contour to allow relative rotation of a first wrist pin member therein and a feature to prevent relative rotation of a second wrist pin member therein.

Abstract: A piston has a piston body extending along a central axis. The piston body has an upper crown portion and a lower crown portion. The upper crown portion has an upper combustion wall and an at least one annular upper rib depending from the upper combustion wall to a free end. The lower crown portion has at least one annular lower rib extending to a free end that is fixed to the at least one upper rib and an inner gallery floor extending radially inwardly relative to the at least one lower rib. The upper crown portion has an upper post depending from the upper combustion wall along the central axis to a free end. The lower crown portion has a lower post extending upwardly from the inner gallery floor along the central axis to a free end. Together, the upper post and the lower post form a labyrinth passage.

Abstract: A multilayer metal gasket (40) having first (28) and second (30) functional layers. Each layer (28, 30) includes an opening (34, 38). Sealing beads (42, 44) are formed in each layer (28, 30) and, preferably, arranged to contact each other in crest-to-crest orientation to perfect a seal therebetween. A stopper feature (54) is provided to restrict compression of the sealing beads (42, 44) in use. The stopper feature (54) is arranged in a generally circular pattern and is composed of a plurality of discrete nesting embossments (56) which are closely spaced to one another but do not touch. Each discrete nesting embossment (56) is substantially identical in shape to the next adjacent discrete nesting embossment (56) but oriented approximately 180 degrees therefrom. The embossments (56) may be formed entirely on one of the functional layers (28, 30) or on both functional layers.

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 main bearing (20) for supporting a rotating crankshaft (56) includes an upper shell (22) and a lower shell (24). An upper inner surface (32) of the upper shell (22) has an oil supply groove (26) extending circumferentially therealong, an oil stem groove (28) extending obliquely from the oil supply groove (26), and a pair of oil distribution grooves (30) extending from the oil stem groove (28) along and parallel to the oil supply groove (26) to present an F-shape along the upper inner surface (32) of the main bearing (20). The oil grooves (26, 28, 30) provide for improved lubrication of the main bearing (20) at startup and when the engine is idle or stopped, especially in electric and hybrid vehicles. The main bearing (20) also has exceptional strength and load bearing capacity.

Abstract: A piston pin hole boring system and method of forming pin holes therewith includes fixing a piston to a fixture supported by a slide member. Then, rotating a cutting member about a first axis and moving the slide member with the fixture thereon toward the cutting member along the first axis and bringing the piston into cutting contact with the cutting member. Further, moving the fixture along second and third axes, each extending transversely to the first axis and machining the desired pin hole contours in the piston with the cutting member.

Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.

Abstract: A power amplifier circuit that has an inductor and capacitor connected to one end of the output winding of an RF transformer. The other end of the output winding is connected to a resistor that in turn is connected to ground. The transformer has two primary windings. Both primary windings have one end connected to a variable DC voltage supply. The other end of each primary winding is attached to a switch, such as a MOSFET. All three windings are wound around a core. Current flowing from the DC voltage supply to the switches causes a magnetic flux in the core. A voltage is generated on the secondary winding resistor. This voltage is fed back to the switches, controlling on and off timing. In this way the need to measure and record natural frequency is eliminated.

Abstract: A radial shaft seal configured for receipt in a housing and about a shaft to sealingly isolate an air-side of the shaft seal from an oil-side of the shaft seal is provided. The seal includes an annular mounting portion and a seal lip operably attached to the mounting portion. The seal lip has an annular inner sealing surface extending axially between an oil-side end and a free air-side end. The inner sealing surface has a first groove region extending along the shaft in sealed engagement therewith and a second groove region extending along the shaft in sealed engagement therewith. The first groove region and the second groove region are spaced axially from one another by an intermediate non-grooved region. The first groove region is configured to direct contamination toward the air-side of the seal and the second groove region is configured to direct lubrication toward the oil-side of the seal.

Abstract: A radial shaft seal configured for receipt in a housing and about a shaft to sealingly isolate an air side of the seal from an oil side of the shaft seal is provided. The seal includes a mounting portion and a seal lip having an annular sealing surface extending between an oil side end and a free air side end. An annular bridge is connected to the oil side end of the seal lip by a first hinge and to the mounting portion by a second hinge. The bridge extends from the first hinge to the second hinge in radially overlying relation to the seal lip. An annular projection extends from the mounting portion axially away from the bridge. The projection has an oil side facing the seal lip and confronts the air side end of the seal lip upon the seal lip pivoting about the first hinge.

Abstract: A multilayer metal static cylinder head gasket for establishing a gas/fluid-tight seal between a cylinder head and an engine block includes a pair of functional layers having openings configured to register with a combustion chamber and annular seal beads configured to form a seal about the openings. The gasket further includes a primary compression limiter formed of a separate piece of material from the functional layers. The primary compression limiter extends at least partially about the openings to facilitate inhibiting the seal beads from being fully flattened between the cylinder head and the engine block. The pair of functional layers have nested protrusions forming a secondary compression limiter spaced radially outwardly from the primary compression limiter to further inhibit the seal beads from being fully flattened between the cylinder head and the engine block.

Abstract: A sensor assembly for sensing the level and type of fuel in a reservoir is provided. The sensor assembly includes a pair of electrically conductive plates extending longitudinally between opposite ends and positioned in laterally spaced relationship with respect to one another. The pair of plates are encapsulated within a substrate of a less electrically conductive material to isolate the plates from one another and from their external environment. The substrate is of a spring-like material which is expandable and contractible in order to vary the height of the sensor assembly.

Abstract: A multi-layered composite gasket (10) includes three, preferably metallic cores (12, 14). A solid center core (12) is flanked on both sides by bonded paper layers (30). Perforated cores (14) mechanically interlock with each paper layer (30) through inwardly directed tangs (22). Graphite layers (26) are disposed outside of each perforated core (14) and are mechanically interlocked thereto by outwardly directed tangs (20) extending from the perforated cores (14). When using the gasket (10) material for sealing cylinder heads in internal combustion engines, a fire ring (46) may be affixed with a fire ring holder (48). The gasket (10) can be manufactured by making first and second preform sheets (32) comprised of one perforated core (14) sided with one paper layer (30) and one graphite layer (26). The preform sheets (32) are then bonded to a center core (12) using a heat activated adhesive.