Abstract: An intake air heating system for an internal combustion engine is disclosed and includes an electric heater that heats the intake air and a control module that switches a voltage to the electric heater based on a control signal. The control module includes a gate drive module that includes a bootstrap charge pump module and generates a gate drive signal based on the control signal and that is referenced to the voltage. The control module also includes a power module that switches the power to the electric heater based on the gate drive signal.

Abstract: An electric vehicle battery heater includes a housing having a coolant inlet and a coolant outlet. A heating element is positioned within the housing in a heat transfer relationship with coolant for transferring heat to an electric vehicle battery. A thermistor is positioned in the housing to output a signal indicative of a temperature of the battery coolant. A controller energizes the heating element when the signal represents that the coolant temperature is less than a predetermined lower limit.

Abstract: A control system comprises a solid-state switch, a mechanical current interrupting device, and a control module. The solid-state switch is connected in series with a power source and an intake air heater. The mechanical current interrupting device is connected in series with the power source and the solid-state switch. The control module selectively closes the solid-state switch to provide power to the intake air heater. The control module also causes the mechanical current interrupting device to mechanically interrupt current flow to the intake air heater when a voltage of the intake air heater is outside of a desired range.

Abstract: An intake air heating system for an internal combustion engine includes an electric heater that heats the intake air, a control circuit that switches a voltage to the electric heater based on a control signal and an over-temperature signal, a temperature sensor that generates a temperature signal based on a temperature of the control circuit, and a temperature sensing circuit that generates the over-temperature signal based on the temperature signal and a predetermined temperature.

Abstract: A method of manufacturing a heater having a heating element, an insulator and a spring is disclosed. The method includes forming a spring from an annealed superalloy material, heat treating the spring after forming, positioning the heating element in contact with the insulator, and biasedly engaging the spring with the insulator to maintain contact between the insulator and the heating element.

Abstract: An air heater for heating air entering a combustion chamber of an internal combustion engine is disclosed. The air heater includes a heating element having a substantially planar portion and a flange portion. The flange portion is positioned at an angle to the planar portion. The planar portion is positioned within an air flow at an upstream location relative to the flange portion. A structure is operable to position the heating element in communication with the air entering the combustion chamber of the engine. In addition, a thermal expansion joint for interconnecting a heating element and a frame is disclosed.

Abstract: A control system comprises a solid-state switch, a mechanical current interrupting device, and a control module. The solid-state switch is connected in series with a power source and an intake air heater. The mechanical current interrupting device is connected in series with the power source and the solid-state switch. The control module selectively closes the solid-state switch to provide power to the intake air heater. The control module also causes the mechanical current interrupting device to mechanically interrupt current flow to the intake air heater when a voltage of the intake air heater is outside of a desired range.

Abstract: A wiring arrangement for interconnecting an alternating current power source to a receptacle within a motor vehicle includes a first wire harness having a current rating and a second wire harness having a similar current rating. A coupling mechanism electrically interconnects the first and second wire harnesses of similar current ratings. The coupling mechanism restricts interconnection of wire harnesses having dissimilar current ratings.

Abstract: An air heater for heating air entering a combustion chamber of an internal combustion engine is disclosed. The air heater includes a heating element having a substantially planar portion and a flange portion. The flange portion is positioned at an angle to the planar portion. The planar portion is positioned within an air flow at an upstream location relative to the flange portion. A structure is operable to position the heating element in communication with the air entering the combustion chamber of the engine. In addition, a thermal expansion joint for interconnecting a heating element and a frame is disclosed.

Abstract: An air intake heater system includes an air heater adapted to be positioned in communication with an intake passageway of an engine and a controller. The controller is operable to repeatedly supply current and discontinue the supply of current to provide a desired energy output of the air heater.

Abstract: An electrical indicator system and a method for operating the system includes a plug adapted to be electrically coupled to a power source remote from the vehicle and an indicator adapted to be mounted to the vehicle at a visible location. The indicator is operable to provide a first visual indication when electrical power is present at the plug. The indicator provides a second visual indication, different from the first visual indication, when current is flowing through the plug.

Abstract: An electrical connector system for use with an electrically powered accessory mounted to a vehicle is disclosed. The electrical connector system includes a connector adapted to be mounted to the vehicle as well as a cord having a first end adapted to be electrically coupled to the accessory and a second end having a plug. The plug is adapted to be electrically coupled to a power source remote from the vehicle, is removably coupled to the connector and includes a flexible finger having a tab engaging the connector. The electrical connector system also includes an indicator mounted to the connector and in electrical communication with the plug. The indicator is operable to provide a visual indication when electrical power is present at the plug.

Abstract: A heating device for use in an internal combustion engine having an intake defining a passage is disclosed. The intake includes an opening in communication with the passage. The heating device includes a one-piece housing having a mounting flange portion and a first leg portion positioned substantially parallel to and spaced apart from a second leg portion. The mounting flange is adapted to mount to the intake and cover the opening. The heating element is coupled to the one-piece housing and positioned between the first and second leg portions. The heating element is positioned in a heat transfer relation with the passage to thereby heat air flowing through the passage.

Abstract: A breakable connector for connecting a vehicle to a power source includes a first fitting and a second fitting coupled to one another. The first fitting includes a radially extending flange, a plurality of radially extending ribs and an electrical connector. The second fitting includes an electrical connector and a receptacle for receiving a portion of the first fitting. The flange biasedly engages a first portion of the receptacle and the ribs engage a second portion of the receptacle. The first and second fittings are separable from one another when placed under a predetermined tensile force.

Abstract: A cord set for connecting a vehicle to a power source includes a first cord having a first connector adapted to be selectively connected to the power source and a second cord having a second connector adapted to be selectively connected to the vehicle. In addition, the cord set includes a coupling mechanism that selectively couples the first cord to the second cord. The coupling mechanism includes a first fitting fixedly attached to the first cord having a plurality of projections and a second fitting fixedly attached to the second cord having a plurality of apertures for matingly receiving the projections of the first fitting. The projections engage the apertures to connect the first fitting to the second fitting under normal operation and disengage the apertures to disconnect the first fitting from the second fitting when the cord set is place under a predetermined tensile force.

Abstract: The present invention relates to an electrical thermostatic cord assembly and a method of manufacturing the same. The cord assembly includes an electrical subassembly, a protective cap, and a one-piece body. The electrical subassembly includes a thermally sensitive switch mechanism. The protective cap is disposed on at least a portion of the switch mechanism. The one-piece body is molded over the electrical subassembly such that a portion of the protective cap is exposed to allow the switch mechanism to respond to ambient temperature changes.

Abstract: An air intake assembly for an internal combustion engine includes an intake member having a passage for communicating air and a heater. The heater includes a first holder, a second holder, a heating element positioned between the first holder and the second holder, biasing means for urging one of the first holder and the second holder away from the other of the first holder and the second holder, and a retention mechanism coupling the first holder and the second holder to the intake member within the passage. The retention mechanism includes first and second tabs coupled to the first holder and second holders which biasedly engage the intake member.

Abstract: A dual media connector having a first media wire and a second media wire disposed within each of a housing insert, a rear seal, a conduit and a grommet, the first and second media wires adapted to electrically interconnect first and second communications devices with external communication signals.

Abstract: An air intake heater for use in a motor vehicle has an engine with an engine block and an intake manifold defining an air passageway. The air intake heater includes a gasket having a conductor plate disposed between two non-conducting sealant layers, the conductor plate has at least one inner terminal adapted for positioning inside the air passageway and at least one outer terminal adapted for positioning outside the air passageway. A heating element is coupled to the gasket and adapted to be disposed within the air passageway, wherein the inner terminal is electrically coupled to the heating element and the outer terminal is electrically coupled to a power source.

Abstract: A heater for heating air in an intake passage of an internal combustion engine. The heater includes a heating element coupled to a first holder and a second holder. The heating element has a preselected resistance corresponding to plurality apertures formed therethrough. A second embodiment includes a heating element positioned within a housing. The heating element includes a plurality of selectively removable slugs. After removal of one or more of the slugs, the electrical resistance of the heating element increases.