Abstract: A valve-operating lever comprising a valve arm including a first aperture defining a valve arm engagement portion. The lever also includes a connector member having an outside surface and a first stop. The connector member and the first stop cooperate to define a first engagement portion. A first portion of the connector member overlays a portion of the valve arm adjacent the first aperture, and the valve arm engagement portion engages the first engagement portion.

Abstract: A composite gear includes one or more metal stamped plates, and two thermoplastic layers disposed on opposite sides of the plates. Apertures are provided in the stamped metal plates so that the molten thermoplastic material may flow through the apertures and anchor the two thermoplastic layers to each other as well as to the metal plates. The composite gear has composite gear teeth which consist of one or more metal gear teeth portions sandwiched between two thermoplastic gear teeth portions. The thermoplastic gear teeth portions extend outwardly from the metal gear teeth portions so that the thermoplastic teeth portions absorb loads under normal operating conditions. Under abnormal conditions such as when an abrupt stop occurs, the thermoplastic portions of the gear teeth are compressed and the higher torque forces resulting from the abnormal condition are absorbed by the metal gear teeth portions.

Abstract: A method of manufacturing a tool used to make a composite gear, the method including forming a cavity in a plate, the cavity being partially defined by a surface in the plate. The surface has a plurality of tool teeth. The method further includes machining at least some of the tool teeth such that some tool teeth have opposed first and second side sections and a central section disposed between the first and second side sections. The central section is larger than the side sections in a circumferential direction. The method further includes creating at least one centering protrusion on the surface. Preferably, the cavity forming step includes forming an aperture in the plate and electric discharge machining the surface of the cavity using a current carrying wire. The machining step preferably includes orbiting an electrode in a first position of the cavity to create the first side section and orbiting the electrode in a second position of the cavity to create the second side section.

Abstract: A composite gear includes one or more metal stamped plates, and two thermoplastic layers disposed on opposite sides of the plates. Apertures are provided in the stamped metal plates so that the molten thermoplastic material may flow through the apertures and anchor the two thermoplastic layers to each other as well as to the metal plates. The composite gear has composite gear teeth which consist of one or more metal gear teeth portions sandwiched between two thermoplastic gear teeth portions. The thermoplastic gear teeth portions extend outwardly from the metal gear teeth portions so that the thermoplastic teeth portions absorb loads under normal operating conditions. Under abnormal conditions such as when an abrupt stop occurs, the thermoplastic portions of the gear teeth are compressed and the higher torque forces resulting from the abnormal condition are absorbed by the metal gear teeth portions.

Abstract: The centrifugally-responsive compression release apparatus of the present invention is a compact unit which can be simply snap-fit to a position on the cam shaft during assembly and will retain that position during engine operation. The compression release apparatus relieves compression in at least one chamber of an internal combustion engine by utilizing a lift member engageable with a valve operating device and centrifugally-responsive means for changing the position of the lift member in response to engine speeds. The apparatus includes a base member which can be injection molded to a shape of a segmented cylinder thereby substantially corresponding to the shape of the outer surface of the cam shaft. The base member also provides means for integrating and retaining the dynamic components of the apparatus to the base member.

Abstract: A composite gear includes one or more metal stamped plates, and two thermoplastic layers disposed on opposite sides of the plates. Apertures are provided in the stamped metal plates so that the molten thermoplastic material may flow through the apertures and anchor the two thermoplastic layers to each other as well as to the metal plates. The composite gear has composite gear teeth which consist of one or more metal gear teeth portions sandwiched between two thermoplastic gear teeth portions. The thermoplastic gear teeth portions extend outwardly from the metal gear teeth portions so that the thermoplastic teeth portions absorb loads under normal operating conditions. Under abnormal conditions such as when an abrupt stop occurs, the thermoplastic portions of the gear teeth are compressed and the higher torque forces resulting from the abnormal condition are absorbed by the metal gear teeth portions.

Abstract: The centrifugally-responsive compression release apparatus of the present invention is a compact unit which can be simply snap-fit to a position on the cam shaft during assembly and will retain that position during engine operation. The compression release apparatus relieves compression in at least one chamber of an internal combustion engine by utilizing a lift member engageable with a valve operating device and centrifugally-responsive means for changing the position of the lift member in response to engine speeds. The apparatus includes a base member which can be injection molded to a shape of a segmented cylinder thereby substantially corresponding to the shape of the outer surface of the cam shaft. The base member also provides means for integrating and retaining the dynamic components of the apparatus to the base member.

Abstract: A valve seat retainer is formed having a flange that extends over the valve seat and that applies both a radial and a longitudinal force to the valve seat. The flange extends an order of magnitude further than typical prior art valve seat retaining flanges. The flange is created by a rolling method with a roller having a unique surface profile. The roller surface has a pair of spaced ridges with a groove in between, and a curved convex surface adjacent to one of the ridges. When a downward force is applied to the roller, the curved surface on the roller causes the roller to move radially inward while at the same time material from the upper surface of the engine block is disposed in the groove and is moved to create the flange.

Abstract: A valve seat retainer is formed having a flange that extends over the valve seat and that applies both a radial and a longitudinal force to the valve seat. The flange extends an order of magnitude further than typical prior art valve seat retaining flanges. The flange is created by a rolling method with a roller having a unique surface profile. The roller surface has a pair of spaced ridges with a groove in between, and a curved convex surface adjacent to one of the ridges. When a downward force is applied to the roller, the curved surface on the roller causes the roller to move radially inward while at the same time material from the upper surface of the engine block is disposed in the groove and is moved to create the flange.

Abstract: A piston--piston ring assembly for an internal combustion engine reduces hydrocarbon emissions without significantly increasing the cost of the engine. The assembly includes an upper piston ring groove and a piston ring which acts as check valve to prevent combustion gases trapped below the upper piston ring from re-entering the combustion chamber when the exhaust valve is opened. The invention also includes a venting means for providing fluid flow communication between the crankcase side of the upper piston ring and the crankcase, around one or more lower piston rings, so that any trapped combustion gases are vented only in the downward direction toward the crankcase. The venting means includes a vent passageway slot in the lower piston groove, as well as an aperture adjacent to the lower piston ring groove.

Abstract: A valve seat retainer is formed having a flange that extends over the valve seat and that applies both a radial and a longitudinal force to the valve seat. The flange extends an order of magnitude further than typical prior art valve seat retaining flanges. The flange is created by a rolling method with a roller having a unique surface profile. The roller surface has a pair of spaced ridges with a groove in between, and a curved convex surface adjacent to one of the ridges. When a downward force is applied to the roller, the curved surface on the roller causes the roller to move radially inward while at the same time material from the upper surface of the engine block is disposed in the groove and is moved to create the flange.

Abstract: A fuel ignition products adhesive coating is disposed on the surface of an internal combustion engine piston. The coating protects the surface from corrosion and wear caused by the combustion of fuel in the cylinder.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear. A method of forming the wheel assembly is also disclosed.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear. A method of forming the wheel assembly is also disclosed.

Abstract: An ignition magneto having an improved primary wiring assembly that consists of a plastic bobbin having a generally rectangular configuration and composed of a pair of end flanges connected together by a pair of side walls and a pair of end walls. The side edges of each wall are spaced from the side edges of adjacent walls, to provide a gap or slot at each corner of the bobbin. A wire is wound in a plurality of turns around the walls and extends across the slots. One end flange is provided with grooves within which the free ends of the wire are gripped. The primary winding assembly is positioned in a cup-shaped casing around a central upstanding chimney which extends upwardly from the bottom of the casing. After installing a transistor and trigger coil, as well as a secondary winding around the primary winding assembly, the components are potted in the casing with a thermosetting resin.

Abstract: In a flywheel magneto ignition system, opposite terminals of the primary winding are respectively connected with the collector and emitter terminals of a transistor device. A biasing coil, inductively coupled with the magneto armature core, has its terminals respectively connected to the transistor base and emitter terminals to bias the transistor on during an interval terminating at the time of ignition. An SCR, non-conductive during said interval, is connected for short circuiting the biasing coil. A trigger coil, connected with the SCR gate through a zener diode, provides gating current for the SCR at the time of ignition. A diode in series with the biasing coil and the base-emitter junction of the transistor ensures fast transistor turn-off.

Abstract: An automatic coil winding machine having mechanism for automatically emplacing a sheet of insulating material upon completion of the winding of each layer of turns, as disclosed in U.S. Pat. No. 2,688,450, is improved to effect tight winding of the sheets. A row of resilient spring fingers is mounted on the sheet delivering element of the machine. When that element is in its forward, sheet-delivering position, a localized surface portion of each finger engages under bias against the coil form, to impose a slight drag on the sheet being wound, said surfaces being located to first engage the sheet after about half a turn of its wrap around the coil form. When the sheet delivering element is in its rearward position, the fingers are spaced from the coil form.

Abstract: To form winding slot plugs in a dynamoelectric machine armature, viscous uncured plastic is fed onto the cylindrical surface of the armature core, intermediate its ends, while the armature is rotated in contact with a paddle that wipingly forces the plastic into the winding slots. Preferably this is done simultaneously with coating the windings. The viscous plug material comprises the same plastic used for coating the windings, but admixed with enough inert powered material to be nonflowing.