Abstract: A planar carbon segment commutator assembly made by forming an annular conductor substrate with an annular front projection extending integrally and axially from a front surface of the substrate. An annular carbon disk is formed on the conductor substrate by overmolding a carbon compound onto the front surface of the conductor substrate and around the annular front projection. The conductor substrate is mounted on an insulating hub. Electrically isolated, circumferentially-spaced commutator segments and corresponding mechanically interlocked conductor sections are formed by making radial cuts through the annular carbon disk and the metal substrate, respectively. According to one embodiment, each of the front projections has a greater cross-sectional area at a distal end than at a base end to mechanically lock the commutator segments onto the conductor sections.

Abstract: A planar carbon segment commutator assembly made by forming an annular conductor substrate with an annular front projection extending integrally and axially from a front surface of the substrate. An annular carbon disk is formed on the conductor substrate by overmolding a carbon compound onto the front surface of the conductor substrate and around the annular front projection. The conductor substrate is mounted on an insulating hub. Electrically isolated, circumferentially-spaced commutator segments and corresponding mechanically interlocked conductor sections are formed by making radial cuts through the annular carbon disk and the metal substrate, respectively. According to one embodiment, each of the front projections has a greater cross-sectional area at a distal end than at a base end to mechanically lock the commutator segments onto the conductor sections.

Abstract: A dual motor windshield wiper system and windshield washer system integrated together into a single assembly. The system includes two motors (22, 22′), a control circuit (12), a fluid reservoir (120), a pump (112), and at least one mounting member (108, 108′) that supports said motors. The reservoir can be located between the two motors and can be supported in place by the motors. The motors can be thermally coupled to the reservoir so that fluid within the reservoir acts as a heat sink for the motors. The positions of the wipers can be controlled to follow targeted positions that are determined in accordance with acceleration, velocity, and deceleration values that are calculated using a wiper speed setting selected by the vehicle driver.

Abstract: An air cell support system for vehicle seat and mattress applications includes an air cell constructed from facing sheets of flexible material that are sealed along their marginal edges. One of the sheets is impermeable and the other of the sheets is perforated to direct air from the air cell for ventilating an occupant support surface while providing a source of pressure for inflating the air cell.

Abstract: A vehicular seat (10) including a seat bottom (12) and a seat back (14). In one embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded frame (16) including side walls (18) extending generally upwardly from a bottom panel (20). A support mat (32) comprising fabric/rubber webbing extends across a central cut-out region (28) in the bottom panel (20) and supports an inflatable cushion (48) comprising a series of air cells (50). An extensible upholstery or trim cover layer (56) covers the inflatable cushion (48) and is joined to the frame (16). In a second embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded shell (62). An intermediate layer (64) of plastics material is provided on the shell (62) beneath an upholstery layer (68). An opening in the shell (62) allows the intermediate layer (64) to be expanded outwardly from the shell (62) as the pressure within the shell (62) is increased.

Abstract: A system of inflatable air cells (3,10) is constructed and installed in a seat (2) at locations that are strategic to the comfort of the user. The air cells are selectively pressurized to a desired comfort level and in addition, in response to a vehicle impact, are controlled by valves (62, 80) to have a occupant impact protection pressure therein for protecting the occupant against impact with the vehicle seat.

Abstract: A headlamp cleaning system has a headlamp especially suited to HID or tungsten halogen applications including a source of light and a polycarbonate lens for distributing the light and a control system for automatically controlling a pump for distributing washer fluid against the lens each time that the vehicle ignition is turned on and whenever a sensor for sensing dirt build-up on the lens signals the presence of dirt build-up thereon and the control system continues the cleaning cycle until all dirt is removed from the lens.

Abstract: A system of inflatable air cells is constructed and installed in a seat at locations that are strategic to the comfort of the user. The air cells are connected to a pump through a manifold which sequentially connects each cell independently to the pump. The manifold controls the flow of fluid in the air cell distribution system by means of a system of valves and senses the pressure in each cell by means of a transducer. A microcomputer is programmed with data representing a desired comfort level for each of the air cells. By sequentially activating individual manifold valves, a pressure signal from the transducer can be generated for each cell. The pressure signals are received by the microcomputer and are correlated with the predetermined comfort data to generate a control signal which activates the pump. In this manner each of the cells can be individually inflated or deflated to the desired pressure level.

Abstract: An occupant sensing system for a vehicle with of inflatable air cells is provided for allowing automatic sensing of the presence or absence of a seat occupant so as to eliminated unnecessary adaptive adjustment of air cell pressures and to allow the adaptive system to function without operator interaction via operating switches.

Abstract: A low energy consumption valve module (16) includes low energy consumption valves (20) having either bimorphs or monomorphs defined by a circular diaphragm (21) carrying one or more piezoelectric discs (22) (23) operative to position a sealing disc (36) for sealing a valve seat (34). In one embodiment the discs are energized across conductive seals (51,52,54,56) and in another embodiment the discs are energized by a pair of flexible conductors (150). A process for making the bimorphs or monomorphs comprises a tape cast process in which ceramic with piezoelectric properties is shaped without machining. A process for making the valve module providing a valve body (200) and valve cover (202) of either laser energy transparent or laser energy absorbent polyimide material that are joined at a line to line contact (210) and sealed upon application of a laser welding beam to the line to line contact between the valve body and the valve cover at the perimeter thereof.

Abstract: A system of inflatable air cells is constructed and installed in a seat at locations that are strategic to the comfort of the user. The air cells are connected to a pump through a manifold which sequentially connects each cell independently to the pump. The manifold controls the flow of fluid in the air cell distribution system by means of a system of valves and senses the pressure in each cell by means of a transducer. A microcomputer is programmed with data representing a desired comfort level for each of the air cells. By sequentially activating individual manifold valves, a pressure signal from the transducer can be generated for each cell. The pressure signals are received by the microcomputer and are correlated with the predetermined comfort data to generate a control signal which activates the pump. In this manner each of the cells can be individually inflated or deflated to the desired pressure level.

Abstract: A vehicular seat (10) including a seat bottom (12) and a seat back (14). In one embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded frame (16) including side walls (18) extending generally upwardly from a bottom panel (20). A support mat (32) comprising fabric/rubber webbing extends across a central cut-out region (28) in the bottom panel (20) and supports an inflatable cushion (48) comprising a series of air cells (50). An extensible upholstery or trim cover layer (56) covers the inflatable cushion (48) and is joined to the frame (16). In a second embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded shell (62). An intermediate layer (64) of plastics material is provided on the shell (62) beneath an upholstery layer (68). An opening in the shell (62) allows the intermediate layer (64) to be expanded outwardly from the shell (62) as the pressure within the shell (62) is increased.

Abstract: An adjustable lumbar support mechanism includes a flexible support member, a cushioning yoke, and a cable assembly. The flexible support member has oppositely disposed first and second longitudinal ends. The cushioning yoke has a first end attached to the flexible support member proximate to the first longitudinal end of the flexible support member. The cushioning yoke extends to its second end which is disposed between the first end of the cushioning yoke and the second end of the flexible support member. The yoke has a plurality of undulations disposed between the yokes first end and second end. The cable assembly has a sleeve and a cable slidably disposed therein. The sleeve has a first end attached to one of the second end of the cushioning yoke and the second end of the flexible support member. A first end of the cable is attached to the other of the second end of the cushioning yoke and the second end of the flexible support member.

Abstract: A carbon-segment face commutator assembly for an electric motor includes an annular array of copper conductor sections stamped from a single copper blank. The annular array is overmolded with an electrical-conducting resin-bonded carbon composition that mechanically interlocks the conductor sections and defines a circular commutating surface. During overmolding, radial grooves are formed in a bottom surface of the carbon overmold opposite the commutating surface. An annular hub is then formed by overmolding an insulator material around and under the carbon overmold and the conductor section array. The hub insulator material flows into the radial grooves of the carbon overmold and leaves only the circular-commutating surface exposed. The carbon overmold is formed into an annular array of eight electrically-isolated carbon segments by machining radial slots inward from the commutating surface of the carbon overmold to the underlying radial grooves.

Abstract: A carbon-segment face commutator assembly for an electric motor includes an annular array of copper conductor sections stamped from a single copper blank. The annular array is overmolded with an electrical-conducting resin-bonded carbon composition which mechanically interlocks the conductor sections and defines a circular commutating surface. During overmolding, radial grooves are formed in a bottom surface of the carbon overmold opposite the commutating surface. An annular hub is then formed by overmolding an insulator material around and under the carbon overmold and the conductor section array. The hub insulator material flows into the radial grooves of the carbon overmold and leaves only the circular commutating surface exposed. The carbon overmold is formed into an annular array of eight electrically-isolated carbon segments by machining radial slots inward from the commutating surface of the carbon overmold to the underlying radial grooves.

Abstract: An inflatable lumbar support system for a vehicle seat includes an inflatable air cell, or cells, coupled by an air line to a motorized diaphragm pump. The outlet valve of the pump is in the form of an umbrella valve which serves not only to seal the pump on the intake strokes, but is of such character to provide the sole seal between the air cell and pump, thereby eliminating the need to have a separate external check valve between the pump and air cell to assure that the air cell does not leak once pressurized.

Abstract: A pneumatically controlled seat for a vehicle has a multiple air cell inflation system which can adjust the pressure in each of the cells simultaneously or sequentially to individually inflate or deflate the cells to a desired pressure level to control the tilt angle of a lumbar support.

Abstract: A vehicle seat having an adjustable side bolster includes a seat frame, a first plate, a second plate, a living hinge and a displacement mechanism. The first plate is fixed to the seat frame. The second plate is pivotably mounted to the first plate. The living hinge resiliently connects the first plate and the second plate. A displacement mechanism is disposed between the first plate and the second plate, selectively moving the second plate relative to the first plate between the first position and the second position. The living hinge provides a spring force tending to return the second plate to one of the first position and the second position.

Abstract: Lever actuator assembly includes the use of at least one clutch member for providing selective adjustment of the length or tension of a cable. The clutch member provides for a stationary position of a item such as a cable relative to the assembly housing absent any rotational force. Applying a rotational force in a selected manner results in an adjustment through movement of the clutch member relative to the housing. A disclosed embodiment is particularly useful for applications that require adjusting a relative length of a cable.

Abstract: An air cell system for vehicle seat and mattress applications includes an air cell constructed from facing sheets of flexible air-impermeable material that are sealed along their marginal edges. A gap is provided at a prescribed location along the seam to accommodate and air tube. The portion of the air tube received in the gap has a generally diamond shaped cross section including a central tubular region and opposed lateral side sections that taper radially outwardly in order to occupy correspondingly shaped regions of the gap. The shaped end of the air tube is sealed to the facing cell layer material to provide an airtight, unstressed seal therebetween.