Abstract: A metal gasket formed from a suitable iron-nickel chromium alloy includes at least one embossment that exhibits essentially full functional recovery at temperatures exceeding 1000° F. and including in the range of 1100° F. to 1600° F. or more and which is made from sheet material that is work hardened and strengthened by cold rolling, or a combination of cold rolling and precipitation hardening, without any post embossment heat treating that would act to further harden the material. Suitable iron-nickel-chromium alloys include those comprising, by weight, greater than 18% nickel; greater than 14% chrome and 0.1-10% of at least one element selected from the group consisting of Mo, Ti, V, Al, Co, Nb, Ta and Cu, with the balance being substantially Fe, wherein the gasket sheet alloy has a deformed microstructure.

Abstract: An electrode for an ignition device formed from a dilute nickel alloy with improved resistance to high temperature oxidation, sulfidation, corrosive wear, deformation and fracture. The electrode includes at least 90% by weight of nickel; zirconium; boron and at least one element from the group consisting of aluminum, magnesium, silicon, chromium, titanium and manganese. The weight ratio of Zr/B may range from about 0.5 to 150, and may include amounts of, by weight of the alloy, 0.05-0.5% zirconium and 0.001-0.01% boron. The oxidation resistance may be improved by the addition of hafnium in an amount that is comparable to the amount of zirconium, which may include an amount of, by weight of the alloy, 0.005-0.2% hafnium. Electrodes of dilute nickel alloys which include aluminum and silicon, as well as those which include chromium, silicon, manganese and titanium, are particularly useful as spark plug electrodes.

Abstract: A dust boot with enhanced protection from contaminants and improved lubrication characteristic includes a dust boot body having a housing opening on one end and on an opposing end a stud opening in an upper boot wall. The boot also includes a wiping lip located on an inner face of the upper boot wall in the stud opening, a grease channel on an outer surface of the upper boot wall bounded circumferentially by a rim seal, an offset opening hole through the upper boot wall into the grease channel which is offset from the wiping lip, and a flexible flap portion of said rim seal which is spaced away from said offset opening hole. The dust boot may also include an insert made from a plastic such as nylon housed in the upper boot wall such that the offset opening hole extends through the insert. The insert may also form a portion of the grease channel. The offset opening is preferably spaced opposite the flexible flap to promote the flow of grease around the outer surface of the stud.

Abstract: A gasket assembly and method of manufacture thereof provides a plurality of discrete, interconnected capsule beads spaced from one another. A sealant material is disposed in the capsule beads, such that when the capsule beads are ruptured under an applied clamping force, the gasket material is released from the capsule beads.

Abstract: A flat blade windshield wiper blade (12) has a naturally elongated curve with a delicate wiper element (16) to be protected during shipping and display for retail sales purposes. A protective package (12) surrounds the wiper (12). The package (12) is made from a single piece of sheet stock and includes a flexible, outwardly bowed front panel (24), a back panel (26), and opposing left (30) and right (28) side panels adjoining respective sides of the front (24) and back (26) panels. Top (32) and bottom (34) end flaps extend between the front (24) and back (26) panels for forcing the front (24) panel to form in a generally semi-cylindrical configuration bowed outwardly relative to the back panel (26). The wiper (12) is disposed in a shipping condition in the package (12), with a connector (22) feature of the wiper (12) bearing in direct pressing contact with the bowed front panel (24).

Abstract: A wiring assembly that allows easy installation into a vehicle and includes a connector that allows functional signals to perform a function in a connector while passing through the connector.

Abstract: An ignition wire includes a conductive core, an insulation layer surrounding the core, an insulating jacket surrounding the insulation layer and a coating layer which is grafted and bonded to at least a portion of an exterior surface of the insulating jacket. The coating layer and insulating jacket are preferably formed of silicone materials. The coating layer is operative to provide enhanced resistance to heat and abrasion, as well as other benefits to the exterior surface of the insulating jacket. The coating layer may be transparent and provide an aesthetically pleasing clear coat, or may be tinted or colored to produce various other cosmetic or decorative characteristics to the outer surface of the ignition wire. The coating layer provides these enhanced protections without the diminishing electrical or mechanical performance properties of either the insulation layer or the insulating jacket.

Abstract: A spark plug having a multilayer firing tip that minimizes the amount of precious metal used and a method of assembling a spark plug with a multilayer firing tip. The firing tip includes a discharge end and a weld end, with the weld end being connected to a center electrode, and more specifically to a base electrode on the center electrode. The weld end has a coefficient of thermal expansion, which is not between the values for the coefficients of thermal expansion for the discharge end and the base electrode. More specifically, the weld end has a coefficient of thermal expansion which is greater than the coefficients of thermal expansion for the discharge end and base electrode. The weld end is formed from Nickel and Chromium with a limited amount of additional elements. The spark plug is assembled by providing a first elongated material formed from the material used for the discharge end and a second elongated material formed from a material used for the weld end.

Abstract: A method for making a gasket (32) for an internal combustion engine (20) includes forming a generally annual stopper (38) on a metallic gasket body (40) through the process of electrochemical deposition. An electrolytic cell is completed with the gasket body (40) forming a cathode. The stopper (38) is formed with a contoured compression surface (42) by selectively varying the electrical energy delivered to selected electrodes (70) over time. Electrolyte (48) rich with metallic ions is pumped at high speed through the inter-electrode gap. A PC controller (82) switches selected electrodes (70) ON at certain times, for certain durations, which cause metallic ions in the electrolyte (48) to reduce or deposit onto the gasket body (40), which are built in columns or layers into a three-dimensional formation approximating the target surface profile (106) for the compression surface (42). The subject method for building a three-dimensional formation can be applied to work parts other than cylinder head gaskets (32).

Abstract: A connecting rod for a piston assembly includes first and second guidance members for guiding a piston assembly within a cylinder during piston stroke along a first axis. The guidance members are supported by first and second support ribs extending from a shaft of the connecting rod and include first and second sliding surfaces for contacting side walls of the cylinder. The connecting rod includes an attachment boss disposed at a first end of the shaft and defines a second axis perpendicular to the first axis. The first and second support ribs extend radially outwardly from the attachment boss and are spaced radially about the second axis by approximately 180 degrees.

Abstract: A method for assembling a ball and socket assembly (10) includes loading a housing (14) with a resilient preload washer (28), an inner bearing (30), a ball stud (12) and an outer bearing (36). A loading tool (50) forcefully compresses the assembled components, as a unit, to an overload compression condition (54), and then reduces the compression until an ideal compression condition (56) is achieved. The outer bearing (36) is staked in position while the loading tool (50) holds the assembled components in the ideal compression condition (56). Following the staking operation, the loading tool (50) can be removed, and a final crimping operation permanently sets the outer bearing (36) in position and holds the articulating components in the ideal, pre-load clearance established. The subject method is particularly well-suited for high production set-ups in which precise pre-load clearances must be achieved at high through put rates.

Abstract: A multi-branch overwrap for protecting elongated items is disclosed. The overwrap is formed from a flexible, resilient substrate. Interengageable attachments are positioned on opposite sides of the substrate for releasably attaching one surface of the substrate to the other. The substrate may be biased to form a plurality of interconnected tubes or reverse folded to form channels that receive the elongated items. Biasing or folding brings the opposite sides of the substrate into overlapping relation. The overwrap may be formed from a unitary blank or assembled from component parts. Preferred materials for the substrate include polyester felt, and preferred attachments include hook and loop fasteners distributed on the surface of the substrate.