Abstract: An injection molded component includes a plurality of integrally formed push pins that provide a simplified attachment interface for attaching the component to a vehicle structure. The injection molded component includes a base housing component with an upper and lower surfaces. Each pin extends out from the lower surface of the base housing component to a distal end. A plurality of radially extending flanges is formed about the circumference of the distal end. The flanges are spaced apart from one another and form a retention feature that is inserted into an appropriate vehicle structural component to secure the base housing component to the vehicle. The formation of flanges on the pins eliminates the need for additional injection mold tooling actions to further form the attachment interface.

Abstract: A module for providing purified air to an internal combustion engine that does not use a throttle body. The module includes a housing an inlet for receiving fresh air and a filter for filtering the fresh air to provide purified air. The module is attached to the engine by at least one mounting member. The module also includes a plurality of runners extending between the housing and the at least one mounting member, wherein the runners direct the purified air to combustion chambers of the engine.

Abstract: An air induction system comprises flow body (32) and a filter housing (20). The filter housing (20) has a first housing portion (36) and a second housing portion (40) in communication with the air flow body (32). A filter (44) is disposed in the filter housing (20). A connector comprises a wing (54) mounted to a post (70) extending from the first housing portion (36) and a slot (56) on the second housing portion (40). (FIG. 4). The first housing portion (36) has at least one cutout (60) adjacent post (72). (FIG. 4).

Abstract: Laser welding is used to attach a laser-transparent component portion to an absorbing component portion at a laser weld joint area. The transparent component portion includes a first weld surface and a first taper locking surface formed opposite from the first weld surface. The absorbing component portion includes a second weld surface and a second taper locking surface formed opposite from the second weld surface. Prior to laser welding, the first and second taper locking surfaces cooperate to force and lock the first and second weld surfaces into abutting engagement at a predetermined pressure. A laser beam is then directed toward the first and second weld surfaces to permanently attach the component portions together. The first and second taper locking surfaces maintain the predetermined pressure during the laser welding process.

Abstract: A brush holder 10 is provided for holding a hammer brush 12 of an electric motor. The brush holder includes a single piece of wire bent to define a brush-engaging portion 14 define an opening 15, and a torsion spring structure 16 connected to and spaced from the brush-engaging portion. The brush-engaging portion is constructed and arranged to prevent rotation of the hammer brush when coupled therewith.

Abstract: An occupant restraint assembly and for a motor vehicle operates to sense the tension forces on a seat belt to detect the presence of a human occupant or a child restraint seat. A sensor attached to the seat belt measures tension forces. The sensor is mounted in line with the seat belt. A strain gauge senses tension on the seat belt. An additional embodiment of the sensor includes three prongs attached to a common beam that allow the sensor to be slipped onto the seat belt without modification to the seat belt. A middle prong includes the strain gauge to sense movement relative to outside prongs. The seat belt threads over the outside prongs and under the middle prong such that tension on the seat belt forces the middle prong transversely to tension exerted on the seat belt.

Abstract: An air introduction system (10) includes an active noise control system (22) having an environmentally protected microphone (24). A microphone support structure (26) defines a louvered cage (38) over a microphone reception cavity (40). The microphone (24) is mounted to a circuit board (42) which fits within the microphone reception cavity (40). A cover (42) fits into the cavity (40) to encase the microphone (24) therein. An open cell foam (60) surround the microphone (24) and a waterproof material (58) encases the foam (60). The waterproof material (58) includes an excess of material such that waterproof material provides for internal air expansion and contraction. By locating the foam (60) between the microphone (24) and the waterproof material (58) improved transmission of acoustic waves is provided which thereby maintains microphone sensitivity.

Abstract: An intake module assembly for a vehicle engine is formed from a two-piece shell structure. First and second shells are aligned and joined together to form the entire air path from an air filter to an engine cylinder head. A throttle hose portion is formed as part of at least one of the first or second shells to conduct air to the throttle body and into the intake manifold. Other induction components such as an intake manifold, resonator, air filter holder, and throttle body components are also integrated into the first and second shells.

Abstract: An exhaust gas re-circulation (EGR) tube includes a dual seal assembly that prevents exhaust gas leakages. The EGR tube has a first end in communication with an exhaust gas source and has a second end extending into an intake manifold enclosed within an intake manifold housing. A tapered sleeve surrounds the EGR tube at the second end. The sleeve has a first end that is directly attached to the EGR tube and a second end that is spaced apart from the EGR tube to define a gap. The sleeve has a tapered body such that the cross-sectional area of the gap increases from the first end to the second end of the sleeve. A first seal is positioned between the sleeve and the intake manifold housing and a second seal is positioned between the sleeve and the intake manifold. Grooves are formed within the exterior surface of the tube to receive the seals.

Abstract: An active noise control system (100) increases system stability by modifying a spectral shaping path (112) to prevent unbounded growth in the system error. In one embodiment, a model of the physical path (114) within the spectral shaping path (112) is given a positive bias, encouraging the model to overestimate the actual characteristics of the physical path (114). In another embodiment, the gain in the spectral shaping path (112) is normalized so that the gain decreases as the system output increases, placing an upper bound on the output signal. By modifying the model or the gain in the spectral shaping path (112), the invention improves system stability by limiting the destabilizing effects of modeling errors on the system.

Abstract: A method of linking commutator bars of a commutator for a motor wherein N is the number of magnetic poles of the motor and N is an even integer greater than 2. The method include a) arranging a plurality of commutator bars to be generally equally spaced in a circular arrangement to define the commutator, each commutator bar having a tang extending therefrom, b) contacting an end of a continuous, insulated conductive member to a tang, c) moving the member to contact a second tang which is disposed at an angle of 720°/N from the previously contacted tang to form a link, and when N is greater than four, repeating this step until N/2−1 links are created, d) moving the member to contact a tang which is immediately adjacent to the second tang contacted in step (c) such that the member defines a bridging portion between the adjacent tangs, e) repeating steps (c) and (d) and until all tangs have been contacted by the member, and f) cutting the bridging portion between adjacent tangs.

Abstract: An air cleaner, intake manifold, and valve cover are integrated together for attachment to a vehicle engine. The air cleaner is positioned directly between the intake manifold and valve cover to provide a compact induction module. The induction module is mounted to the engine as a single unit. A throttle body is also incorporated into the intake manifold. A tube interconnects the air cleaner and the throttle body. An air filter is installed within the air cleaner to remove contaminants from air prior to entry into the tube.

Abstract: A heat sink 28 is provided for removing heat from a component 30 on a circuit board 22. The heat sink 28 includes a base 12 having a top 14, a bottom 16, and opposing sides 18 and 20. The top is generally planar for being adhered to a circuit board. Each of the opposing sides has a cutout defining a stepped shoulder 26. The heat sink also includes a plurality of fins 24 extending from the bottom of the base. Locating structure 50 is provided on the top of the heat sink for locating the heat sink with respect to the circuit board 22. Since the heat sink can be glued to the circuit board, a common heat sink can be used for any power electronics component.

Abstract: A vehicle fuel intake system (10) includes an intake manifold (14), an injector pack assembly (18) and an air cleaner assembly (16). The injector pack assembly (18) includes an encapsulated lead frame (36) that provides electrical communication to fuel injectors (26). The intake manifold defines a fuel rail (22) and a cavity (24). Fuel vapors permeating from the fuel rail (22) are trapped in the cavity (24) and channeled back into the air intake passages (20). The air cleaner assembly (16) includes a filter (28) for absorbing fuel vapor emissions from unburned fuel escaping a non-operating engine (12). An actuator (30) moves the filter (28) between an open and closed position. Once the engine begins operation, the actuator (30) opens the filter (28) to allow unrestricted airflow through the intake manifold (14).

Abstract: A flow tube for an induction system with a turbo charger defines a longitudinal flow path and includes a noise attenuation plate positioned within the flow tube. A plurality of ribs formed on an internal surface of the tube. The ribs are spaced apart from one another and are tuned to a desired frequency. The noise attenuation plate includes a plurality of holes having varying diameter and depths. When acoustic energy created by the turbo charger encounters the noise attenuation plate and the ribs, the change in impedance results in acoustic reflections back toward the turbo charger. Thus the noise attenuation plate cooperates with the ribs to serve as a low pass filter that attenuates high frequencies while allowing lower frequencies through.

Abstract: An air introduction system (10) provides an active noise control system which includes a speaker assembly (28) in which the speaker support ring (36) is mounted to a speaker housing (32) without fasteners. In one speaker assembly, the speaker housing includes a plurality of extensions (40) which extend radially from an outer periphery of the speaker housing (32). The speaker support ring includes an edge (42) which at least partially surrounds the extensions (40). In another speaker assembly, the speaker support ring (50) includes a plurality of apertures (52) through a flange (54) which closely fits a speaker housing (32). The housing edge (54) and the speaker protection cone edge (56) are heated to a melting point of the material and the speaker support ring (50) is sandwiched therebetween. Heated material from the housing edge and the speaker protection cone edge pass through the apertures (52) to provide an effective bond therebetween.

Abstract: A valve including a wall, a closure member, a motive force device, and a coupling member. The wall defines a flow passage that is disposed along a longitudinal axis. The closure member is disposed in the flow passage and is rotatable on a first axis that is oblique to the longitudinal axis. The closure member is rotatable between a first position that substantially prevents flow through the flow passage and a second position that generally permits flow through the flow passage. The motive force device rotates the closure member between the first position and the second position. The device includes a rotor that is rotatably supported by a bearing, a stator that is proximate to the rotor, and an overmolded housing that positions the stator with respect to the bearing. The coupling member conveys motive force from the device to rotation of the closure member.

Abstract: An active noise control system (20) includes a controller (26) that drives a speaker (28) to cancel out or reduce noise. A microphone (30) provides information to the controller (26) regarding the system response to the noise source sound and the cancellation signal. The controller (26) uses a selected noise source sound as a calibration reference. By subsequently comparing the system response to the same sound, the controller (26) is able to calibrate the system and make any adjustments necessary to account for microphone drift, for example.

Abstract: A motor control system 10 includes an engine cooling module 14 including a DC motor 12. The system includes a switch 18 constructed and arranged to be controlled by a pulse width modulated (PWM) signal 26. The switch 18 is operatively associated with the DC motor to control current to the DC motor and thus control the speed of the DC motor. A controller 20 is operatively associated with the switch. The controller is constructed and arranged to select periods, of a limited-pool of frequencies each being less than 500 Hz, from a pseudo-random sequence of periods and to send the selected periods to the switch, thereby controlling noise and vibration of the module.

Abstract: A vibration weld fixture assembly provides a three-piece component joined together with two separate welding operations. The vibration weld fixture assembly includes fixed upper and lower tools that support first and second component pieces, respectively. A center tool, movable relative to the upper and lower tools, moves a third component piece into engagement with one of the first or second component pieces for a first vibration weld operation. The center tool then moves the third component piece into engagement with the other of the first or second component pieces for a second vibration weld operation. A linear actuator assembly moves the center tool back and forth between the upper and lower tools.