Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method for controlling an engine that operates with negative valve overlap between an intake valve and an exhaust valve during at least some conditions, the method comprising of providing an engine stop position with at least one cylinder near top dead center of piston position and adjusting at least one of the intake valve and the exhaust valve to position the at least one of the intake and exhaust valves of said at least one cylinder so that the at least one of said intake and exhaust valves is substantially closed at said engine stop position.

Abstract: A process for spot-welding hydroformed members allows at least one hydroformed member to be positioned with an end butted against a lateral side of the second hydroformed member. A structural shell member sandwiches the joint around the two hydroformed members to provide a surface to which each of the hydroformed members can be spot-welded. The U-shaped structural support receives the lateral side of one hydroformed member in the bight portion thereof and has arms that are positioned against the perpendicularly positioned second hydroformed member. Each of the hydroformed members are formed with access openings therein to allow spot-welding electrodes to be positioned against an appropriate wall of the hydroformed member and the adjacent portion of the U-shaped structural shell member. The joint is rigidly formed by spot-welding each of the hydroformed members to the structural support. The process is particularly adapted for utilization in the manufacture of automotive frames.

Abstract: An internal combustion engine is disclosed in which at least one cylinder is adapted to run in homogeneous-charge compression-ignition (HCCI) combustion mode and at least one cylinder is adapted to run in spark-ignition (SI) combustion mode with the HCCI cylinder having a compression ratio at least 2 ratios higher than the SI cylinder. The intakes and exhausts of the HCCI and SI cylinders are separated with a throttle valve disposed in each intake and exhaust aftertreatment devices tailored to each combustion mode disposed in the exhausts.

Abstract: An exhaust aftertreatment system for an internal combustion engine is disclosed which mitigates deleterious poisoning of a catalytic converter or exhaust gas oxygen sensor by phosphorus containing species.

Abstract: A hybrid electric vehicle powertrain has an engine and a motor at the torque input side of a power transmission. The motor has a single stator and dual rotors. A selectively engageable rotor clutch connects the rotors together for torque delivery during a driving mode. During a key start and a rolling start of the engine, the rotor clutches are selectively engaged and released.

Abstract: A seating system for an automotive vehicle includes a side airbag mounted to an outboard portion of a seatback, with the side airbag having an occupant reaction surface which is combined with deployable upper and lower reaction members attached to the airbag to define an augmented occupant reaction surface available upon inflation of the airbag.

Abstract: A method of reducing heat generated in a fuel injector driver controlled by an engine control unit (ECU) of a vehicle engine, the injector coupled to the engine, the method comprising of varying a number of fuel injector injections in an engine cycle as a temperature of the ECU varies, where during a first ECU temperature condition said injector performs a first number of injections in an engine cycle, said first number being at least two injections, and during a second temperature condition higher than said first temperature condition said injector performs a second number of injections less than said first number of injection in an engine cycle, said second number being at least one injection.

Abstract: A hybrid electric vehicle 10 having a propulsion system 12 which integrates a motor-generator 14 and a variable displacement internal combustion engine 16. Motor-generator 14 and engine 16 are each operatively coupled to drive train 17 of vehicle 10, and cooperatively power vehicle 10.

Abstract: A method of operating an internal combustion engine having a combustion chamber with a piston and a spark plug, when transitioning between spark ignition combustion and autoignition combustion, creating a first mixture of air and fuel, adjusting an operating condition of the engine so that said first mixture of air and fuel in the combustion chamber approaches, but does not achieve, the autoignition temperature, and performing a spark from the spark plug so that at least a portion of said first mixture combusts to raise a remaining portion of said first mixture to said autoignition temperature.

Abstract: An internal combustion engine cylinder head unit includes a number of gas flow ports extending upwardly from a fire deck. A common coolant passage extends between adjacent ones of the gas flow ports. A first coolant flow director includes a flow splitter extending downwardly into the common coolant passage so as to cause a coolant flow within the common coolant passage to remain attached upon an upper surface of the fire deck between adjacent ports. A second coolant passage runs about a radially outboard portion of the cylinder head unit, and flow in this passage is directed by a truncated bulk flow displacer extending from a rear wall of the second coolant flow passage. The second flow director causes the impingement of coolant upon both an upper surface of the fire deck and upon an outboard portion of at least one of the cylinder ports.

Abstract: A variable cam-timing phaser, including a stator having a plurality of inwardly-extending stator lobes and a rotor having a plurality of outwardly-extending rotor lobes. The rotor is rotatably disposed within the stator so that the rotor lobes interleave with the stator lobes to form a first timing chamber and a second timing chamber between each of the stator lobes. The phaser further includes a hydraulic valve, where the phaser is configured so that, upon operation of the valve to selectively couple the second timing chambers to a hydraulic fluid supply and the first timing chambers to a hydraulic fluid sink, the rotor is caused to rotate toward a terminal position, in which at least one of the first timing chambers is at least partially sealed off from the hydraulic fluid sink, thereby producing a tendency toward pressure equalization between the first timing chambers and the second timing chambers.

Abstract: A reduced radius hem assembly and method for joining an inner panel and an outer panel together. The inner panel has an outwardly extending perimeter flange comprising an end surface, an inboard surface, and a beveled surface located between the end surface and the inboard surface. The outer panel has a peripheral edge comprising a bend portion, an intermediate portion, and an end portion. In the finished hem assembly, the intermediate portion is adjacent to the beveled surface of the perimeter flange and the end portion overlies a portion of the inboard surface of the perimeter flange. The method provides a reduced radius hem while allowing the peripheral edge of the outer panel to cover the marriage gap and minimizing the potential for interference between the inner panel and the outer panel in the hem assembly.

Abstract: A method for operating an engine in a vehicle, the engine having at least a cylinder, is described. The method comprises decreasing rotational speed of the engine; and when said engine speed falls in a specified region, adjusting a valve timing of the cylinder to generate one of expansion or compression braking torque to stop rotation of said engine in a desired range.

Abstract: A tailgate assembly having an inner panel and an outer panel which is selectively coupled to the inner panel. The tailgate assembly further includes at least one stiffening member which is selectively and operatively contained between the panels and which increases the strength and durability of the tailgate assembly.