Abstract: An oil lubricated rotating hub (14) and stationary spindle (12) assembly includes an oil bath seal (16, 16?) for establishing a dynamic sealing interface between the hub (14) and spindle (12). A wheel sensor assembly includes a variable reluctance senor (54) targeted at an encoder ring (56, 56?) which is integrated into the oil bath seal (16, 16?). The encoder ring (56, 56?) is of the permanent magnet type including a plurality of magnetically polarized sectors alternating between North and South polarities. The use of an encoder style target (56, 56?) in combination with a variable reluctance sensor (54) enables improved slow speed sensing with relatively large air gap spacing between the exposed (58, 58?) of the encoder ring (56, 56?) and the head of the VR sensor (54). Furthermore, the encoder ring (56, 56?) enables use of less expensive, lighter materials for the oil bath seal carrier (20, 20?).

Abstract: The invention provides a protective sheath for receiving elongated items. The protective sheath includes first and second elongated substrates connected to one another about at least one living hinge. The first and second elongated substrates are moveable relative to one another between an open configuration wherein the first and second substrates are positioned substantially side by side adjacent to one another and a closed configuration wherein the first and second substrates at least partially overlying one another. The protective sheath also includes a first flap attached to the first substrate along an edge. The first flap is resiliently biased into a position overlying the first substrate and operable to engage the second substrate when the first and second substrates are in the closed configuration.

Abstract: A spark plug having a pair of independent spark gaps includes a shell, inner and outer insulators, a cylindrical electrode assembly, a center wire assembly, and a pair of ground electrodes. The cylindrical electrode assembly is generally located between the two insulators and delivers a first high voltage ignition pulse to a first spark gap. The center wire assembly is located in an axial bore of the inner insulator and delivers a second high voltage ignition pulse to a second spark gap. The two insulators and two electrode assemblies are all coaxially aligned within the shell so that both insulators can be rotationally symmetrical. The first spark gap is radially oriented while the second spark gap is axially oriented, and the first and second spark gaps are located at different axial positions and can fire independently of one another. A method of assembling the spark plug is also disclosed.

Abstract: A spark plug (10) for a spark ignited internal combustion engine includes a suppressor seal pack (54) interposed between an upper terminal stud (46) and a lower center electrode (60). The suppressor seal pack (54) includes a top layer of conductive glass (52) surrounding the bottom end (50) of the terminal stud (46) and a lower glass seal layer (58) surrounding a head (62) of the center electrode (60). A resistor layer (56) fills the space between the conductive glass layers (52, 58). The resistor layer (56) has a larger first cross-sectional area (76) at its upper end and a smaller second cross-sectional area (78) at its lower end. A reducing taper (80) establishes a progressive transition between the greater and lesser cross-sectional areas (76, 78). The reducing taper (80) is located in a large shoulder region (LS) which is defined as the longitudinal dimension between the theoretical reference point (70) at the filleted transition (26) and the theoretical reference point (68) at the upper seat (17).

Abstract: A fuel vapor separator used in fuel delivery systems of a marine engine for recovery of fuel vapors and to prevent fuel spills when the engine is tilted.

Abstract: A ball and socket housing incorporating a thick housing wall of deformable material adjacent a central bore opening to provide a closure system utilizing a deformable cover-plate. The deformable cover-plate is formed to a desired configuration within the central bore to achieve a consistent internal socket preload. The cover-plate is deformed into the housing opening beyond an elastic limit to control resiliency or spring-back characteristics, thereby achieving a high-degree of repeatability and precise control of the ball and socket preload during the assembly process. The deformed cover-plate is retained in the socket housing at the cover-plate seat by swaged or rolling the perimeter of the housing to capture the perimeter of the deformed cover plate within the housing central bore opening.

Abstract: A seal assembly and method for the manufacture thereof is provided. The seal assembly provides a dynamic fluid seal between a housing having a bore and a shaft having an outer running surface rotating within the bore. The seal assembly comprises a rigid carrier for supporting the seal assembly within the bore of the housing. A flexible member is mounted to the rigid carrier. The flexible member is formed from an elastomeric material that allows the flexible member to flex during use. A sealing element is retained by the flexible member about the outer running surface. The sealing element is formed from a non-polytetrafluoroethylene bearing grade plastic material having a hardness relatively greater than a hardness of the elastomeric material of the flexible member. The sealing element moves with the flexible member as the flexible member flexes. The sealing element extends along the outer running surface in a plurality of helically wound convolutions.

Abstract: A BLDC motor assembly and method for manufacturing same is disclosed. The motor has a housing, a shaft supported for rotation within the housing, a stator disposed within the housing for generating an electro-magnetic field, a rotor operatively coupled to the shaft and disposed for powered rotation within the stator in response to the electro-magnetic field, at least one temperature sensitive electronic device (TSED) disposed within the housing and electrically connected to the stator for controlling or measuring an aspect of the electro-magnetic field, and a fuel resistant and electrically insulated polymeric material encapsulating the TSED so that the TSED is protected from adverse temperature and chemical agents without the need for a separate internal container or a pre-potting operating. The TSED, which may be carried on a printed circuit board within the housing, is thus overmolded with polymeric material so that the polymeric material fills, or substantially fills, a space within the housing.

Abstract: A piston for diesel engine applications has a piston body cast entirely of one piece of steel and includes a piston head with a combustion bowl, a ring belt and an oil cooling gallery. A pair of pin bosses and a piston skirt are cast as one piece with the piston head out of the same steel material.

Abstract: An ignition device for an internal combustion engine and method of construction therefore includes a housing with an insulator secured therein. A center electrode is mounted within the insulator. A ground electrode extends from the housing with a portion of the ground electrode defining a spark gap across from the center electrode. At least a selected one of the center electrode or ground electrode has a platinum or platinum-based alloy firing tip. A resistance weld joint bonds the firing tip to the selected electrode and defines a lower surface of the firing tip that is embedded a first distance beneath an outer surface of the selected electrode. A continuous bead of overlapping laser weld pools is formed over an outer periphery of the firing tip. The overlapping weld pools extend a second distance beneath the outer surface of the selected electrode, with the second distance being greater than the first distance.

Abstract: A seal joint for sealing a fluid is particularly adapted for use in extreme pressure and/or temperature environments. The seal joint includes a first member having a first sealing surface and a first opening therein, and a second member having a second sealing surface and a second opening therein, such that the first opening and the second opening comprise mating openings, and together comprise a fluid passageway. The seal joint also includes a metal gasket sheet located between the first sealing surface and the second sealing surface which has an aperture through the sheet which corresponds to the mating openings. The seal joint also includes a rigid seal which surrounds the perimeter of the aperture and which is attached to the surface of the metal gasket sheet. The rigid seal has a thickness and a width which vary as a function of position along the length of the seal.

Abstract: The thickness of a workpart (10) is measured to a high degree of accuracy by passing a coherent light beam (20) through an aperture (16) in the workpart (10). The aperture (16?) can alternatively be created between an edge of the workpart (10) and an external reference plate (30). The light is diffracted on the far side of the workpart (10) and its diffraction pattern captured by a CCD camera (22). The captured image is analyzed by a computer (24) which compares the captured diffraction pattern to a stored referenced value to determine whether the thickness of the workpart (10) is within an acceptable range. The method is capable of returning measurements with micron or submicron resolution, and is a robust process readily adaptable to high volume production quality control applications.

Abstract: A bearing having improved wear resistance has a bearing material of a copper-tin-bismuth alloy which may also include phosphorus which has excellent strength, due to the solid solution of copper, tin and phosphorus (when used), attached to a steel backing shell. The material also has good lubricity as a result of the presence of the bismuth which also promotes tin mobilization and formation of a layer of tin on the bearing surface upon use of the bearing. The addition of small amounts of relatively small hard particles in the copper-tin-matrix, particularly Fe3P, MoSi2 or a mixture thereof, provides a suitable hard surface artifact to improve the wear resistance of the bearing material. The bearing includes a sintered powder compact bearing material of a copper-tin-bismuth alloy powder and a metal compound powder which is bonded to a steel backing shell, wherein the metal compound powder has an average particle size of less than 10 ?m.

Abstract: A ball joint assembly (28) for a vehicular steering or suspension application includes a cap-like housing (42) in which is captured the articulating ball portion (32) of a stud (30). A shank (34) extends from the ball portion (32), outwardly from the housing cap (42), to provide a connection and anchoring interface for the suspension member (16) or other anchoring component. The connection interface with the anchoring suspension member (16) is characterized by a specially designed surface which is convenient to machine, provides increased surface-to-surface contact area, and provides additional advantages such as improved stress distribution and NVH benefits. A washer-like cone adaptor (54) mates with a specially formed adaptor interface region (48) on the stud (30). On its outer surface, the adaptor (54) has a broad tapering feature (56) designed to seat in a complementary-shaped receiving flare (58) in the anchoring suspension member (16).

Abstract: A system and method for testing the operation of fuel pump is disclosed. The apparatus includes a pressure measurement portion, a flow measurement portion, an electrical diagnostic portion, and a fault simulation portion, where a user can simulate a number of potential fuel system failures to determine the diagnostics of the fuel system. The method includes the steps of measuring an electrical value related to said fuel pump, measuring a pressure related to said fuel pump, measuring a fuel flow related to said fuel pump, simulating a fuel system failure condition, and determining an operating status of said fuel pump.

Abstract: A spark plug which includes a center electrode metal shell and an insulator disposed therebetween utilizes for the insulator or ceramic with improved high temperature electrical properties which includes alumina in an amount between about 90 and about 99% by weight, a zirconium containing compound in an amount between about 0 and about 1% by weight, and an oxide mixture in an amount between about 1 and about 10% by weight. The oxide mixture includes a glass former, a network modifier and alumina in an amount between about 16% and about 40% by weight after firing, wherein the molar ratio of the glass former to the network modifier ranges between about 0.8:1 and 1.2:1. The ceramic insulator is particularly adapted for use as an insulator in a spark plug to provide improved dielectric strength and shunt resistance of greater than one 1000 megaohms at 1000 degrees Fahrenheit, so as to reduce the shunting of the spark plug and thereby improve the quality of the spark generated by the spark plug.

Abstract: A piston head has a top extending radially about a first axis and first and second pin bosses depending downwardly and defining first and second pin bores. A connecting rod includes a fork having first and second connecting bosses spaced apart from each other and defining first and second connecting bores. A piston skirt extends cylindrically and includes a bridge extending diametrically through the first axis defining a skirt bore for axial alignment with said pin bores and said connecting bores. The bridge is disposed between the first and second connecting bosses, which are disposed between the pin bosses. The pin bores are axially aligned with the connecting bores and with the skirt bore. A wrist pin extends within the pin bores and the connecting bores and the skirt bore along the second axis to interconnect the piston head and the connecting rod and the piston skirt.

Abstract: A diesel engine piston assembly comprises a piston body having a top wall with a combustion bowl formed in the top wall and having a combustion bowl edge, an outer ring belt formed with a plurality of ring grooves including a top ring groove with an upper wall of the top ring groove and a top land portion of the ring belt disposed between the top ring groove and the top wall, a pair of pin bosses with aligned pin bores and a skirt; and a diamond dispersed chromium composite coating applied to at least the top wall, the combustion bowl edge, the top land portion and the upper wall of the top ring groove.

Abstract: A sparkplug having ground and center electrodes that include a firing tip formed from a noble metal or noble metal alloy by reflowing of a noble metal preform. The present invention also includes a method of manufacturing a metal electrode having an ignition tip for an ignition device, including forming a metal electrode having a firing tip portion; applying a noble metal preform to the firing tip portion; and reflowing the noble metal preform to form a noble metal firing tip.

Abstract: A multilayer metal gasket, such as a multilayer steel head gasket, for an internal combustion engine has upper and lower functional layers and at least one intermediate layer. At least one of these layers has a circumferential compression control feature in the form of a protrusion or groove which varies in thickness or depth, respectively, around its circumference. The variable thickness of the compression control feature enables uniform sealing pressure on the sealing surfaces of the gasket.