Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.

Abstract: The invention is directed to a rotor having a vented hat section. A plurality of spaced apart vents are defined in the rotor hat wall. The vents are defined by a first aperture in the radially outer hat wall surface, a second aperture in the radially inner hat wall surface and a vent wall extending therebetween. The vent wall includes an upper surface and a lower surface which extend from the from the first aperture to the second aperture. The upper surface and lower surfaces form an angle A with respect to the outer surface of the hat wall which partially determines the quantity of air moved through the vents when the rotor turns. The vent wall also preferably includes a pair of approximately parallel side surfaces between the upper and lower surfaces which extend through the hat wall. The angle B of the vent wall side surfaces with respect to the radius of the rotor partially determines the quantity of air pushed or pumped through the vents when the rotor turns.

Abstract: The present invention discloses a vented brake rotor having tubular ducts. The rotor includes universal rotor blank having a hat section and a peripheral section radially extending therefrom. The hat section includes a mounting face and hat wall extending from the periphery of the mounting face. The peripheral section includes a first and a second braking plate joined together in a parallel, spaced apart relationship by a plurality of spacers. A plurality of duct tubes are fastened to the inner surfaces of the braking plates. Each one of the duct tubes has an inlet and an outlet allowing air to flow through the duct tube to provide an airflow path between the braking plates for cooling the rotor. In an alternate embodiment, the present invention may include a plurality of fins fastened to the inner surfaces of the braking plates. The fins extend between the braking plates forming a passages between them. A plurality of duct tubes are fastened in the passages between the fins.

Abstract: A bracket for a machine frame, such as a core molding machine frame, having horizontal and vertical members includes first and second legs adapted for attachment to the machine frame members. The first and second legs are formed from a plate material and extend perpendicular to each other. The bracket is welded around its periphery to the machine frame. A free end of at least one of the first and second legs has a tapered portion, and one or more openings may be provided in the bracket. An outer periphery of the tapered portion and an inner periphery of the openings are welded to the machine frame for further extending the total weld length and reducing stress concentration in the weld joints.

Abstract: A composite brake drum for a motor vehicle or the like. The brake drum has a drum body that is comprised of a first material, preferably a cast metal, such as gray iron. The drum body has a cylindrical section, a shoulder, a mounting face, and a balancing skirt. The brake drum also includes an annular band formed from a second material, preferably a stamped metal such as steel. The annular band encircles the cylindrical section of the drum body. The balancing skirt extends from the cylindrical section and along a portion of a radially outer surface of the annular band. The steel annular band is positioned in a mold apparatus and molten iron is introduced into a mold cavity defined thereby. The mold and annular band are maintained in a static condition during the casting process. In a second embodiment, the cylindrical section and the skirt may be formed from the first material. The mounting face, the shoulder, and the annular band may be formed from the second material.

Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer and a lower half shell formed from a polymer and joined to the upper half shell. The upper half shell formed includes an upper perimeter flange having a pair of side flanges and a pair of end flanges, the side flanges having an inner surface and the end flanges having an inner surface. The lower half shell includes a lower perimeter flange having a pair of side flanges and a pair of end flanges, the side flanges having an inner surface and the end flanges having an inner surface. The lower half shell is joined to the upper half shell to define a housing having an internal cavity.

Abstract: The invention is directed to a vehicle braking system having a plurality of two-state actuators disposed at each vehicle wheel and method braking same. The vehicle braking system further includes a brake rotor or brake drum secured to each vehicle wheel for rotation therewith. The brake rotors or drums each include a plurality of friction surfaces. A plurality of brake pads are disposed adjacent the friction surfaces such that a different brake pad corresponds to each friction surface. A different two-state actuator corresponding to each brake pad is disposed adjacent the corresponding brake pad. Each two-state actuator is either unactuated or actuated to provide a maximum translational force against the corresponding brake pad to achieve the desired braking force requirements at each vehicle wheel.

Abstract: The invention is directed to a brake rotor including a central hat section, a peripheral annular friction section having a pair of annular spaced apart friction plates, and plurality of posts extending between said friction plates. The posts include a plurality of first posts having an elongated cross sectional shape, and a plurality of second posts having a circular cross sectional shape. The posts are arranged in a plurality of circumferentially extending rows and radially extending columns to form vents for cooling the rotor.

Abstract: An apparatus for spin forming two partial wheel rims including a mandrel having a first portion for spin forming a first partial wheel rim and second portion for spin forming a second partial wheel rim. The first and second portions of the mandrel have different shapes such that the first and second wheel rims have different shapes. The mandrel is mounted upon a spin forming machine and is utilized to spin form a hoop of metal into a double wheel rim which is split to form the two partial wheel rims.

Abstract: The noise created by a vehicle rotor is reduced by adjusting the natural or resonant frequency at which the rotor tends to vibrate. The resonant frequency is moved away from the frequencies of excitation of such sources as the brake pads and vehicle drive train components. The resonant frequency of the rotor is adjusted by manipulating the geometry and mass of the rotor by adjusting the number, size, shape, spacing and location of cooling vents formed in the hat section of the rotor. The resulting rotor exhibits improved vibrational control.

Abstract: An assembled mold base member for a wheel component includes a universal base support member which is combined with one of a plurality of interchangeable center members to form an assembled mold base. The assembled mold base cooperates with an assembled top core having an interchangeable end member combined with one of a plurality of universal top core members and side members to form the wheel component mold.

Abstract: A full face wheel assembly comprises a full face disc and a rim. The disc is preferably cast from aluminum whereas the rim is rolled from aluminum strip stock. The full face disc comprises an outboard bead seat flange, an outboard bead seat and an outboard well side wall. The disc may also include lightener pockets or a continuous re-entrant channel adjacent the outboard bead seat. The rim comprises an inboard bead seat flange, an inboard bead seat, an inboard leg, and a deep well. The disc and rim are welded together in the deep well or bead seat regions by gas metal arc welding, electron beam welding or other suitable welding technique.

Abstract: A vented rotor for caliper disc brakes and the like includes an outer friction portion having two ring sections with a plurality of radially extending ribs extending therebetween. The ribs include support ribs extending from the hat wall, and secondary ribs space radially from the hat wall. The support ribs and secondary ribs fixedly interconnect the ring sections in a mutually parallel, spaced apart relationship in such a manner that the inner diameter of each the ring section is spaced apart from the hat wall. Vents are formed between the support ribs and secondary ribs. The vents have a constant cross sectional area along their length to enhance the airflow therethrough. As a result, cooling air is permitted to flow into the vents between the inboard and the outboard ring sections from both the inboard and outboard sides of the outer friction portion of the rotor, providing enhanced overall air flow past the ring sections.

Abstract: A layer of sealant is applied to a portion of the surface of a vehicle wheel to prevent air leakage therethrough.

Abstract: The invention is a method of manufacturing a composite drum ring and a composite brake drum having a drum ring. The invention is a method of manufacturing a brake drum ring. An annular band is provided, which is formed by any suitable known method. A cast metal insert is cast in the radially inner surface of the band. Upon casting the molten metal is cooled to an initial solidification temperature to at least partially solidify the molten metal, followed by hot rolling the drum band to reduce the roundness run out of the composite drum ring. The hot rolling operation includes rotating the drum band, providing a roll forming roll and applying the roll forming roll against the radially outer surface of the rotating drum band. A feedback sensor may by provided for determining the roundness run out of the composite drum ring. The hot rolling step may include adjusting the force applied to the roll forming roll in proportion to the roundness run out.

Abstract: The invention relates to an air flow test apparatus for determining the amount of air moving through vents in a turning ventilated rotor. The air flow test apparatus includes an elongated cylindrical shaft journalled for rotation in spaced apart bearing blocks mounted in a frame. A conventional belt drive couples the shaft to a variable speed motor for rotation. An adapter is mounted to the shaft and a work piece is mounted to the adapter end for rotation with the shaft. The work piece includes a hub secured to the adapter for receiving a plurality of different sized rotors, and a ventilated rotor mounted to the hub. The work piece may also include other vehicle components such as the caliper, a wheel, even an entire corner portion of a vehicle for simulation purposes. A pressure gauge is disposed adjacent the rotor, near the vents, to measure the air pressure near the turning rotor.

Abstract: An apparatus and method for reclaiming metal chips formed while machining metal castings to their finished shape. The apparatus includes a stationary charging tube extending in a generally perpendicular direction from the charge well of a reverbratory furnace. The lower end of the charging tube is attached to a box-shaped structure which has an open bottom. The sides of the structure extend into a pool of molten metal contained in the charge well. A variable rate feeder provides a continuous supply of metal chips to the charging tube at a rate which is essentially the same as the rate at which the chips are being produced. The chips form a column within the charging tube which extends through the box-shaped structure and into the pool of molten metal. As the chips at the bottom of the column are melted, additional chips are added to the top, forcing the bottom of the column of chips into the pool of molten metal.

Abstract: A wheel component has an annular extension formed upon an end. The extension is clamped to a wheel lathe and allows turning a tire bead seat upon the wheel component adjacent to the extension.

Abstract: A basket assembly for holding a vehicle wheel rim. The basket assembly includes a basket adapted to hold the wheel rim, and a pair of pads connected to the basket. At least one of the pads is adjustable between a first position, in which the pads do not capture the wheel rim within the basket, and a second position, in which the pads are effective to capture the wheel rim within the basket. The basket assembly is useful in an apparatus for transferring wheel rims between metal forming stations during manufacture of the wheel rims.

Abstract: A vehicle wheel assembly having a stylized outer wheel disc permanently attached to a universal base wheel. The universal base wheel can be utilized on a plurality of vehicle platforms. The structure of the base wheel is designed for optimal strength and minimum weight to structurally support the weight of a vehicle. The outer wheel disc provides a pleasing aesthetic appearance and provides no structural support to the vehicle.