Abstract: A roof railing assembly (20) includes a rail (22), a bracket attachment (28) disposed on the rail (22), and a fastener (44, 46, 48) on the bracket attachment (28), wherein the bracket attachment (28) is a defined by a structural layer of material (40) which defines a plurality of small voids (42). A flange (54) is disposed about the fastener (44, 46, 48) for restricting axial movement. An insulating layer (56) is disposed about the supported end (50) of the fastener (44, 46, 48) for absorbing force. The outer diameter of the flange (54) is greater than the outer diameter of the insulating layer (56) to further restrict axial movement. A torque limiter (58) is disposed about the fastener (44, 46, 48) for disconnecting the fastener (44, 46, 48) from the vehicle roof to avoid excessive loading on the fastener (44, 46, 48).

Abstract: A thermostat housing assembly (10, 100) includes a housing (12, 102) having a flange (16, 106) for mounting the housing (12, 102) on a support structure and a tubular spout (18, 108) extending from the flange (16, 106) and defining a passageway (20, 110). The flange (16, 106) presents a mounting face (26, 112) defining a seal groove (28, 114) extending annularly about the flange (16, 106) opening and having opposing side walls (32, 34, 116, 118). A seal (36, 124) is disposed in the seal groove (28, 114) for sealing the flange (16, 106) to the support structure. The seal (36, 124) has annular rings (42, 44, 126, 128). The opposing side walls (32, 34, 116, 118) include opposing channels (38, 40, 120, 122) defined therein to mechanically engage the annular rings (42, 44, 126, 128) extending radially into the opposing channels (38, 40, 120, 122) for retaining the seal (36, 124) in the seal groove (28, 114).

Abstract: A method (10) includes the steps of placing an insert (12) into a mold cavity (20), molding an insulating layer (30) of a homogeneous and continuous composition (28) over the insert (12). The next step includes placing the insert (12) with the insulating layer (30) into a second mold cavity (36) followed by the step of molding the part (46) of a homogeneous part composition (44) over the insert (12). The insulating layer (30) is disposed between the insert (12) and the part (46) and bonded thereto. The method (10) includes painting the part (46) wherein a paint (48) is injected into the second mold cavity (32) over the part composition (44). Flexible properties of the insulating layer (30) adapt to the differences between coefficient of thermal expansion of the part (46) and the insert (12) thereby eliminating problems of potential cracks, sink-marks, and the like.

Abstract: A cantilevered fin (34) or spoiler includes an upper shell (36) and a lower shell (38) Each shell (36, 38) extends from the cover (32) of the roof to engaging distal edges (40). The cover (32) includes a frame (42) and a sheet (44) supported by the frame (42).

Abstract: A fuel filter assembly (10) comprising an electrically non-conductive housing (12) with a layer (28) of electrically conductive material extending from the distal end (22) of an inlet connector (20) to the distal end (26) of an outlet connector (24) for conducting electrical charges completely through the housing (12) from distal end (22) to distal end (26). The housing (12) is fabricated by first forming an inlet half of the housing (12) with an opening and forming an outlet half of the housing (12) with an opening. The conductive layer (28) is disposed separately over the interior of the respective housing halves. Thereafter, the respective openings of the housing halves are fused together with the housing material fused together and the conductive layers (28) of the respective halves in electrical contact.

Abstract: An exhaust manifold (10) of the present invention comprises a liner (12) that includes inner surface (14) defining manifold passages and an outer surface (16). The exhaust manifold (10) includes a shell (18) of a homogeneous and continuous material disposed over the outer surface (16) of the liner (12). The shell (18) and liner (12) of the exhaust manifold (10) include first (60) and second (72) composition formed from ferrous and non-ferrous metal powders (62), ceramic powder (64), and a binder (74) added thereto to form the manifold (10). The invention discloses a method of making the exhaust manifold (80). Accordingly, the exhaust manifold (10) of the subject invention has a reduced weight and dissipates heat energy contained in the exhaust thereby increasing the efficiency of the catalytic converter (42).

Abstract: A method of vehicle assembly (10) comprises the step (A) of fabricating a vehicle body (12) having a floor (14) and door (16) openings and roof pillars (18) defining window openings (20), and a roof (17) supported on the pillars (18) and defining a roof opening (22). The following step (B) includes placing the body (12) on a vehicle chassis (24) followed by the step (E) through (I) of inserting interior components (26) through the opening (22) in the roof (17) and securing the components (26) to the interior of the vehicle body (12). The final step (G) of the assembly includes placing a roof panel (38) on the roof (17) to close the opening (22) therein after the interior components (26) are inserted through the opening (22). The method (10) of vehicle assembly of the present invention will provide new, efficient, and economical method for assembling automotive vehicles that will reduce assembly time and will not be labor intensive.

Abstract: A roof and rack assembly (10) for an automotive vehicle includes a roof panel (12) received from polymeric organic material that has a top surface (14) and edges (16), (18) extending between a first or front (20) and a second or rear (22) ends of the roof panel (12). The roof panel (12) includes retaining elements (30) that are integrally formed and extend upwardly from the top surface (14) of the roof panel (12). The roof and rack assembly (10) further includes a track (24) for receiving a roof rack (26) and slidably adjusting the position of the roof rack (26) along the track (24), and a mounting member (28) for securing the track (24) to the retaining elements (30). The roof and rack assembly (10) provides an effective and a quick way of fastening the roof rack (26) to the roof panel (12) and is efficient, not time consuming and easy way to install the roof rack (26).

Abstract: A plastic thermostat housing having a vent passage including a valve portion (46), a cap portion (48), and an outlet portion (54), with the cap portion (48) being larger in cross sectional area than the cap, portion (48). A check valve (52) is inserted into the valve portion (46) and a cap (50) with a vent hole (56) is inserted into the cap portion (48) for retaining the check valve (52) in the vent passage. The assembly is characterized by the plastic material of the housing (12) being deformed into engagement with the cap (50) for retaining the cap (50) in the valve portion (48) of the vent passage. The cap (50) may comprise a plastic material to be fused to the housing (12).

Abstract: A vehicle body assembly (10) includes a roof (12) defining an opening having a periphery. The roof (12) has a roof panel (18) having a peripheral edge (20). The vehicle body assembly (10) comprises a clamping mechanism (22) for clamping the edges (20) of the roof panel (18) to the periphery of the opening in sandwiched relationship to one another. The present invention provides several advantages over the prior art patents including an effective and a quick way of fastening a roof panel onto a body of a vehicle. Therefore, the present invention provides another vehicle body assembly that is efficient and easy to use.

Abstract: A fuel filter assembly (10) comprising an electrically non-conductive housing (12) with a layer (28) of electrically conductive material extending from the distal end (22) of an inlet connector (20) to the distal end (26) of an outlet connector (24) for conducting electrical charges completely through the housing (12) from distal end (22) to distal end (26). The housing (12) is fabricated by first forming an inlet half of the housing (12) with an opening and forming an outlet half of the housing (12) with an opening. The conductive layer (28) is disposed separately over the interior of the respective housing halves. Thereafter, the respective openings of the housing halves are fused together with the housing material fused together and the conductive layers (28) of the respective halves in electrical contact.

Abstract: An exhaust manifold (10) of the present invention comprises a liner (12) that includes inner surface (14) defining manifold passages and an outlet surface (16). The exhaust manifold (10) includes a shell (18) of a homogeneous and continuous material disposed over the outer surface (16) of the liner (12). The shell (18) and liner (12) of the exhaust manifold (10) include first (60) and second (72) composition formed from ferrous and non-ferrous metal powders (62), ceramic powder (64), and a binder (74) added thereto to form the manifold (10). The invention discloses a method of making the exhaust manifold (80) that comprises the steps of forming the liner (12) and molding the shell (18) of a homogeneous and continuous material completely encapsulating the outer surface (16) of the liner (12). Accordingly, the exhaust manifold (10) of the subject invention has a reduced weight and dissipates heat energy contained in the exhaust thereby increasing the efficiency of the catalytic converter (42).