Abstract:
Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.
Abstract:
An illumination device (74) that includes an elongated light pipe (90) and attachment wings (92, 94) integrally formed on the sides of the light pipe so that the illumination device can be easily, yet securely, installed within a containment channel (16), such as those found on the underside of a vehicle step rail (14). The elongated light pipe is made of an optically transmissive material, the attachment wings are made of a different resilient material, and the overall device is a single extruded component that has a co-extrusion boundary (132, 132') separating the two materials. The illumination device illuminates the ground, for example, when passengers are entering or exiting the vehicle.
Abstract:
A clip unit (42) and an edge mount light emitting diode (LED) assembly (40) comprising the clip unit. The clip unit provides a mounting structure for mounting a light source (12), such as an LED, to an edge (30) of a printed circuit board (PCB) (22). A surface mount LED, for example, can thus be easily mounted to the edge of the PCB so as to project light in a direction normal to the edge surface of the PCB, instead of the typical mounting orientation that allows for the projection of light normal to the primary surface of the PCB. The clip unit includes an anode retention clip (58) and a cathode retention clip (60) which are electrically isolated from one another within an insulative housing portion (56).
Abstract:
An illumination device (14), such as the type used for vehicle exterior applications, includes a housing (30) with light collimating and spreading portions (40, 42), a circuit card assembly (32) with one or more light sources (34) (e.g., LEDs), and a lens (36). The illumination device may be arranged so that light emitted by the LEDs reflects off of a metalized interior surface of the light collimating portion in a collimated fashion and travels towards the light spreading portion, the collimated light then reflects off of a metalized interior surface of the light spreading portion in a spread fashion and travels towards the lens, and the spread light passes through the lens and travels towards an intended target region. The illumination device may be installed, for example, in a rear hatch (16) of a vehicle (10) and used in conjunction with a backup camera.
Abstract:
A pre-fuse assembly (10) designed to protect certain components within a vehicle electrical system against short circuits and to provide a user with easy access to a jump post (30) for jump starting a dead battery. The pre-fuse assembly is a current-limiting electrical device that is mounted on top of the vehicle battery (12) and includes fuses (56) for limiting the current from the vehicle battery to a power distribution device and includes a horizontal jump post (30) for providing easy access when jump starting a dead battery without increasing the overall height of the device. In one embodiment, the pre-fuse assembly (10) includes a lower housing (20), an upper housing (22), a battery post connector (24), a master fuse (26), a fastener (28), a horizontal jump post (30) and any number of other components.
Abstract:
A welded blank assembly (200) includes a capping material (210) in a weld region (220) of the assembly. The capping material can help protect a weld joint (208) joining first and second sheet metal pieces (12, 112) together. At least one of the sheet metal pieces has a coating material layer (18) that is removed prior to forming the weld joint so that the coating material does not contaminate the weld joint. The removed coating material can be collected before the weld joint is formed and reapplied as part of the capping material after the weld joint is formed, effectively changing the coating material from a potential weld contaminant to a weld joint protectant. The capping material may also include additional material from a source other than the coating material layer.
Abstract:
Sheet metal pieces intended to be welded can be made with weld notches located along one or more edges. A. weld notch (30) is characterized by the absence of certain material constituents (16, 18) so that they do not unacceptably contaminate nearby welds. The weld notch can be created by first forming an ablation trench (130) along the sheet metal piece (12), then separating the sheet metal piece along the formed ablation trench into two separate pieces, at least one of which includes a newly formed and weldable edge (28).
Abstract:
A spark plug (10) includes a metallic shell (16), an insulator (14), a center electrode body (12), a ground electrode body (18), and a ground electrode tip (56). In one embodiment, the ground electrode tip (56) includes a non-precious metal piece (58) and a precious metal piece (60) attached to each other. The non-precious metal piece (58) has a side surface (62) attached to a free end surface (36) of the ground electrode body (18).
Abstract:
A method of producing a composite component (10) that includes both a structural insert (12) and a plastic casing (14). According to an exemplary embodiment, the method uses a closed- loop control system and includes the following steps: evaluating the structural insert (12) for various attributes, placing the structural insert (12) in a mold cavity (62), adjusting the position and/or orientation of the structural insert (12) with respect to the mold cavity (62) based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity (62) so that it at least partially surrounds the structural insert (12).
Abstract:
A metal framing member (12) for use in a wide variety of applications including interior and exterior walls, structural insulated panels (SIPs), as well as floors, ceilings and roofs of residential and commercial buildings, to name but a few. The metal framing member generally includes first and second metal components (20, 22), where each of the metal components is a separate piece and includes an elongated support (30) with a series of fingers (34) extending therefrom. The two metal components are attached together near tips (52) of the fingers so that an alternating sequence of fingers and spaces (34, 36) is formed in an intermediate area between the two supports. This sequence can result in weight, material and cost savings, reduced thermal and acoustic conductivity across the metal framing member, and trade-ready holes for passing through items such as wires, pipes, etc.