Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: A steering column having a composite steering column support housing formed from a fiber reinforced matrix material. By layering the fibers within the matrix material of the support housing to a specific orientation, controlling fiber length, and controlling fiber and polymer type, the performance of the steering column can be manipulated to optimize NVH, structural stiffness, load path, crash energy management, mass balance, and cost. The column support housing contains at least one mounting hole for coupling to either an instrument panel or engine compartment wall. The column support housing may have a protruding region for stabilizing the steering column to the instrument panel when the support housing is mounted to the engine compartment wall. The mounting hole can also contain an elastomeric washer or a filler material for improving dampening characteristics, and further may have a circular fiber orientation immediately surrounding the mounting hole to further improve performance characteristics.

Abstract: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: A steering column having a composite steering column support housing formed from a fiber reinforced matrix material. By layering the fibers within the matrix material of the support housing to a specific orientation, controlling fiber length, and controlling fiber and polymer type, the performance of the steering column can be manipulated to optimize NVH, structural stiffness, load path, crash energy management, mass balance, and cost. The column support housing contains at least one mounting hole for coupling to either an instrument panel or engine compartment wall. The column support housing may have a protruding region for stabilizing the steering column to the instrument panel when the support housing is mounted to the engine compartment wall. The mounting hole can also contain an elastomeric washer or a filler material for improving dampening characteristics, and further may have a circular fiber orientation immediately surrounding the mounting hole to further improve performance characteristics.

Abstract: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: A composite steering shaft that replaces traditional metal steering shafts in a steering system. The composite steering shaft is made of layers of braided fiber contained within a polymer matrix resin. Stiffness and torsional strength within the non-tilting and tilting regions may be controlled as a function of the number of layers of braided fiber, the orientation of fiber within those layers, and the type and amount of curing of the polymer matrix resin. The composite shaft may be a one-piece shaft having a compliant middle region and a stiff upper and lower portion or may be a two-piece shaft coupled together using an I-protec metal joint.