A manufacturing method includes: forming a tubular portion of a rack housing by press forming from prepregs formed by stacking fiber-reinforced composite materials obtained by impregnating fiber sheets with a thermoplastic resin; and thereafter injecting a thermoplastic resin containing fillers for injection molding to form coupling portions integrated with metal rings. A rack housing is manufactured by the manufacturing method described above.

An automatic transmission device comprises a flat steel plate for placing in between an automatic transmission pump body and an automatic transmission bellhousing that supports both rotating pump gears and completely encloses said gears within pump housing, and eleven holes, the device configured so that seven holes are for pump mounting bolts, three holes are for fluid passage that directly mimic the size, shape, dimension and position of the holes in the pump body, and one center hole for pump gear operation.

A gearbox housing of an aircraft includes a surface configured to contact with and support a load of a component of the aircraft such that the surface is susceptible to corrosion. The surface has an area from which a portion of material was removed. A structural deposit is formed by cold spraying one or more layers of powdered material within the area. The structural deposit is configured to share the load applied to the surface by the component.

A differential gear mechanism constructed in accordance to one example of the present disclosure can include a differential casing having a first case housing portion and a second case housing portion. The first and second case housing portions can be coupled together with fasteners. A first and a second side gear can be rotatably mounted within the differential casing. A plurality of pinion gears can be mounted between the first and second side gears. Each of the plurality of pinion gears can be rotatably mounted on a respective pinion gear shaft. Each pinion gear shaft can have first and second ends. The first end of each pinion gear shaft can be aligned with a fastener of the plurality of fasteners such that axial movement of the respective pinion gear shafts is inhibited by contact with a corresponding fastener of the plurality of fasteners.

A method in accordance with the invention includes a headrail bracket configured to be inserted into a headrail at an angle from a top thereof. The headrail bracket includes clips snap into a top edge of the headrail, and an attachment mechanism to attach to a gearbox assembly configured to rotate a tilt rod of a window blind tilting mechanism. In certain embodiments, the headrail bracket is a single component with a substantially low profile. This headrail bracket may span a top of the headrail. In other embodiments, the headrail bracket includes a first component to secure a first end of the gearbox assembly to the headrail and a second component to secure a second end of the gearbox assembly to the headrail. In certain embodiments, the first component slides over the first end of the gearbox assembly and the second component slides over the second end of the gearbox assembly.

A Knuckle Jointed Lance (KJL), comprising a segmented lance including a plurality of connected KJL segments in a concatenated string thereof. The first end of one KJL segment is rotatably connected to the second end of a neighboring KJL segment via a pinned connection. Responsive to user assignment of a predetermined length to each KJL segment in the concatenated string according to the KJL segment's corresponding pre-ordained position in the concatenated string, the lance is disposed to spool onto a reel in nested fashion, such that as the lance makes spooling revolutions onto the reel, (a) KJL segments stack in circumferential registered layers around the reel and (b) pinned connections trace substantially radial vectors from a center of the reel. Other embodiments provide additional features to facilitate nesting and to generally strengthen the KJL.

The invention is a motorized gearbox assembly. The motorized gearbox assembly includes a motor that drives an output shaft. The output shaft actuates a window covering by applying torque to a tilt rod of the window covering. The output shaft extends substantially an entire length of the motorized gearbox assembly. It also has a through-channel that extends substantially an entire length of the output shaft, so that the tilt rod can pass entirely through the motorized gearbox assembly. Because of this, the motorized gearbox assembly can be used for retrofitting blinds. In some embodiments, the motorized gearbox assembly has a diametrically polarized magnet driven by the output shaft, and a position encoder that measures the output shaft's position and number of rotations.

A method for calibrating an automated window covering includes electromechanically actuating a window covering and measuring electrical current required to actuate the window covering. The method further measures movement of the window covering, where such movement includes one or more of a change in position and velocity of the window covering. The method estimates a size (e.g., height, width, area, etc.) of the window covering and/or an amount of force required to actuate the window covering based on the measured electrical current and movement. A corresponding apparatus is also disclosed herein.

A transfer case for a normally rear wheel drive vehicle having selectively engageable front wheel drive is provided. The transfer case includes a rear housing with a main drive shaft aperture and an aluminum cast front housing threadably connected with the rear housing. The front housing has a main drive shaft aperture axially aligned with the rear housing main drive shaft aperture. The front housing has an integrally formed cylindrical yoke forming an isolation mount for receiving a polymeric isolator allowing for connection of the transfer case with a chassis structure of the vehicle. The cylindrical yoke has a cylindrical preform therein.

A differential gear mechanism constructed in accordance to one example of the present disclosure can include a differential casing having a first case housing portion and a second case housing portion. The first and second case housing portions can be coupled together with fasteners. A first and a second side gear can be rotatably mounted within the differential casing. A plurality of pinion gears can be mounted between the first and second side gears. Each of the plurality of pinion gears can be rotatably mounted on a respective pinion gear shaft. Each pinion gear shaft can have first and second ends. The first end of each pinion gear shaft can be aligned with a fastener of the plurality of fasteners such that axial movement of the respective pinion gear shafts is inhibited by contact with a corresponding fastener of the plurality of fasteners.