Low cost components for use in motorcycle, marine, and racing applications manufactured from conductive loaded resin-based materials

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention relates to vehicle components and, more particularly, to components for motorcycle, marine, and racing applications where these components are molded of conductive loaded resin-based materials comprising micron conductive powders, micron conductive fibers, or a combination thereof, substantially homogenized within a base resin when molded. This manufacturing process yields a conductive part or material usable within the EMF, thermal, acoustic, or electronic spectrum(s).

(2) Description of the Prior Art

Motorcycle, marine, and racing vehicles are typically constructed from a large number of components. Major systems, such as engines, are typically made up of sub-systems, such as intake and exhaust systems, ignition systems, and the like. Systems and sub-systems are constructed from a variety of materials. For example, transmission cases and other housings exposed to relatively high temperatures are typically formed of metal. Low temperature cases may be formed of plastic. Electrical components may be formed with copper wiring or windings. Marine hulls may be formed of fiberglass. In each case, manufacturers select material types to meet the performance and cost requirements of the components. Material choices present motorcycle, marine, and racing vehicle designers with serious limitations and difficult tradeoffs. For example, high strength-to-weight ratio metals are ideal for many uses on motorcycle and racing applications. However, high strength-to-weight ratio metals typically cost a great deal more than low strength-to-weight ratio metals. Therefore, in cost sensitive applications, such as consumer motorcycles, the designer may not be able to choose the optimum material. Composite materials are desirable as metal substitutes but these materials typically lack features typical to metals such as electrical and thermal conductivity. A principle object of the present invention is to provide an alternative material for motorcycle, marine, and racing components that combines material properties found in metals with those found in plastics.

Several prior art inventions relate to motorcycle components as they relate to conductive resin-based materials. U.S. Pat. No. 6,581,579 B1 to Knight et al teaches a vapor separator for a fuel pump assembly that utilizes a baffle that is formed of a heat conductive injection molded plastic. U.S. Patent Publication US 2002/0101342 A1 to Yamagiwa et al teaches an air pressure detection device for a wheel that utilizes an antenna that is formed of an electrically conductive resin. U.S. Patent Publication US 2003/0029668 A1 to Suzuki teaches a brake mechanism for a small vehicle comprising a brake disc and a brake caliper. U.S. Patent Publication US 2001/0047896 A1 to Matsuura et al teaches an electrical outlet arrangement for an ATV.

Several prior art inventions relate to marine vehicle components as they relate to conductive resin-based materials. U.S. Pat. No. 5,394,379 to Weichart et al teaches a hydrophone for a marine seismic streamer that utilizes a non-conductive synthetic resin coating covering the hydrophone and the connecting wires. U.S. Pat. No. 6,466,719 B2 to Stottlemyer et al teaches an optical temperature sensing arrangement for a towed cable that is able to adapt to existing cables. This invention utilizes an outer layer of thermally conductive polymers that is smooth to facilitate winding and unwinding. U.S. Pat. No. 4,932,795 to Guinn teaches the use of electrically conductive plastic bushings for a marine propulsion system which allows for the conductive path of a cathodic protection system in order to eliminate unsightly and expensive ground wires.

U.S. Pat. No. 5,066,424 to Dixon et al teaches a composite material for EMI/EMP hardening protection in marine environments utilizing indium tin oxide and nickel flakes as a filler in a polyether etherketone matrix for forming or machining into electrical enclosures. This invention also teaches that this composite material exhibits a current-controlled and voltage-controlled negative resistance (VCNR/CCNR) meaning that the conductivity of the material increases as the field and/or voltage increases. U.S. Pat. No. 4,097,111 to Martin teaches an electrical connector for low current devices such as found in vehicle and marine lighting systems that utilizes a resilient conductive plastic as the contact points in the electrical connections. U.S. Pat. No. 5,517,939 to Harman et al teaches a thermoplastic bottom inflatable boat constructed entirely of thermoplastic material making it invisible to radar and having the potential to be made bullet proof by increasing the material thickness.

U.S. Pat. No. 4,479,994 to Berg teaches a wide band energy absorbing camouflage blanket used for protecting tactical military equipment, especially vehicles, from detection by hostile forces. This invention teaches the use of a bottom layer of conductive foil or sheet metal to suppress radar detection and two or more outer layers having thermal or acoustic properties to suppress any thermal or acoustic energy which may be emitted from the protected equipment. U.S. Patent Publication US 2004/0082245 A1 to Hexels teaches a polyester formed camouflage net comprising metal sheathed polyamide fibers and additional polyamide fibers containing conductive pigments or fibers of silver. U.S. Pat. No. 5,661,484 to Shumaker et al teaches multi-fiber species artificial dielectric radar absorbing material and a method of manufacture utilizing graphite filaments and metal coated graphite filaments randomly dispersed in a dielectric binder.

U.S. Pat. No. 5,225,454 to Löfgren teaches a radar camouflage material comprising PVC cellular plastic and carbon fibers having a length of about 1 cm and 0.050 percent by weight useful for dampening electromagnetic radiation within the radar range to at least 1-3 dB per cm. U.S. Patent Publication US 2002 0171578 A1 to Strait et al teaches a non-skid radar absorbing system and a method of manufacture utilizing tungsten plated glass micro-balloons in the first layer with a urethane binder then coating with a non-skid layer of carbon fibers in an epoxy resin. U.S. Pat. No. 6,072,928 to Ruffa teaches a tow cable with a conductive polymer jacket for measuring the temperature of a water column utilizing polyaniline and a conductive filler.

U.S. Pat. No. 6,379,589 B1 to Aldissi teaches a super-wide band shielding material that is formed by disposing a conductive polymer over a metal-coated ferromagnetic particle and blended in a polymer matrix and processed to form single layered coatings and freestanding films and sheets useful for sophisticated electronics and military hardware. U.S. Pat. No. 6,111,534 to Escarmant teaches a structural composite material for absorbing radar waves comprising an inner layer of a non-magnetic dielectric material loaded with carbon particles having a substantial amount of electrical conductivity, an intermediate layer of a non-magnetic dielectric material, and an outer layer of a non-magnetic dielectric material having a low radar wave reflection index.

Several prior art inventions relate to racing vehicle components as they relate to conductive resin-based materials. U.S. Patent Publication US 2004/0103684 A1 to Kreutzmann et al teaches an in-car hydration system that utilizes a bladder comprising a layer of Kevlar fiber and aluminized Mylar with insulation between the interior lining and outside layers to aid in keeping the liquid cool. U.S. Patent Publication US 2003/0098143 A1 to Winkle teaches a fluid heat exchanger assembly and personal cooling device for use by race car drivers. This invention utilizes aluminum as the conduit for the fluid. U.S. Pat. No. 5,041,471 to Brinzey teaches of friction materials with universal core of non-asbestos fibers for use in high performance brake pads for automotive racing. This invention teaches a mixture of aramid (Kevlar) fiber pulp, carbon fiber, ceramic fiber, and polybenzimidazole fiber to form 41% by weight of the total mixture added to the resin base and friction particles and friction modifiers.

U.S. Pat. No. 5,491,022 to Smith teaches a fire and chemical resistant fabric and garments made thereof that possess anti-static characteristics, provide a barrier against chemicals and are self-extinguishing in a fire. The invention teaches the steps of forming by co-extrusion at least two layers of polymeric sheets with an intermediate layer of a polar resin or a hydrophilic polymer, then adhering the combined layer to a fabric scrim comprising a blend of polyester and cellulosic fibers which has been treated with a fire resistant and anti-static agent. U.S. Pat. No. 5,199,526 to Derviller teaches a lightweight high performance road racing vehicle that utilizes body panels comprising molded FRP using carbon fiber, Kevlar or fiberglass and resin bonding which are riveted or otherwise fastened to the chassis. U.S. Pat. No. 5,863,090 to Englar teaches a pneumatic aerodynamic force-augmentation, control and drag reduction device for racing cars and high-performance sports cars. This invention teaches using compressed air being discharged through slots formed on the body of the race car to help with controlling drag and lift during high speeds and braking.

SUMMARY OF THE INVENTION

A principal object of the present invention is to provide an effective motorcycle vehicle component.

Another principal object of the present invention is to provide an effective marine vehicle component.

A principal object of the present invention is to provide an effective racing vehicle component.

A further object of the present invention is to provide a method to form a motorcycle, marine, or racing vehicle component comprising conductive loaded resin-based material.

A further object of the present invention is to provide motorcycle, marine, or racing vehicle components formed by molding processes.

A further object is to provide a replacement material for metal in motorcycle, marine, or racing vehicle components.

A yet further object of the present invention is to provide a motorcycle, marine, and racing vehicle components molded of conductive loaded resin-based material where the electric or thermal characteristics can be altered or the visual characteristics can be altered by forming a metal layer over the conductive loaded resin-based material.

A yet further object of the present invention is to provide methods to fabricate motorcycle, marine, or racing vehicle components from a conductive loaded resin-based material incorporating various forms of the material.

In accordance with the objects of this invention, a marine vehicle device is achieved. The device comprises a hull. An engine is attached to the hull. A component is attached to the hull or the engine. The component comprises a conductive loaded, resin-based material comprising micron conductive fiber in a base resin host.

Also in accordance with the objects of this invention, a motorcycle vehicle device is achieved. The device comprises a frame. An engine is attached to the frame. Two wheels are attached to the frame. A component is attached to the frame or the engine. The component comprises a conductive loaded, resin-based material comprising micron conductive fiber in a base resin host.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings forming a material part of this description, there is shown:

FIG. 1 illustrates a first preferred embodiment of the present invention showing a motorcycle vehicle with components comprising a conductive loaded resin-based material.

FIG. 2 illustrates a first preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise a powder.

FIG. 3 illustrates a second preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise micron conductive fibers.

FIG. 4 illustrates a third preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise both conductive powder and micron conductive fibers.

FIGS. 5
a and 5b illustrate a fourth preferred embodiment wherein conductive fabric-like materials are formed from the conductive loaded resin-based material.

FIGS. 6
a and 6b illustrate, in simplified schematic form, an injection molding apparatus and an extrusion molding apparatus that may be used to mold vehicle components of a conductive loaded resin-based material.

FIG. 7 illustrates a second preferred embodiment of the present invention showing a recreational marine vehicle with components comprising a conductive loaded resin-based material.

FIG. 8 illustrates a third preferred embodiment of the present invention showing a military marine vehicle with components comprising a conductive loaded resin-based material.

FIG. 9 illustrates a fourth preferred embodiment of the present invention showing a racing vehicle with components comprising a conductive loaded resin-based material.

FIG. 10 illustrates a fifth preferred embodiment of the present invention showing an electronic ignition switch formed in part of conductive loaded resin-based material.

FIG. 11 illustrates a sixth preferred embodiment of the present invention showing an electrical connector formed in part of conductive loaded resin-based material.

FIG. 12 illustrates a seventh preferred embodiment of the present invention showing a fuse box formed in part of conductive loaded resin-based material.

FIG. 13 illustrates an eighth preferred embodiment of the present invention showing wiring conduit comprising conductive loaded resin-based material.

FIG. 14 illustrates a ninth preferred embodiment of the present invention showing an ignition control module formed in part of conductive loaded resin-based material.

FIG. 15 illustrates a tenth preferred embodiment of the present invention showing a rocker switch formed in part of conductive loaded resin-based material.

FIG. 16 illustrates an eleventh preferred embodiment of the present invention showing a toggle switch formed in part of conductive loaded resin-based material.

FIG. 17 illustrates a twelfth preferred embodiment of the present invention showing an electronic device case comprising conductive loaded resin-based material.

FIG. 18 illustrates a thirteenth preferred embodiment of the present invention showing plug wires formed in part of conductive loaded resin-based material.

FIG. 19 illustrates a fourteenth preferred embodiment of the present invention showing an air hose comprising a conductive loaded resin-based material.

FIG. 20 illustrates a fifteenth preferred embodiment of the present invention showing fuel lines comprising a conductive loaded resin-based material.

FIG. 21 illustrates a sixteenth preferred embodiment of the present invention showing a fuel filter formed in part of conductive loaded resin-based material.

FIG. 22 illustrates a seventeenth preferred embodiment of the present invention showing an oil pan comprising a conductive loaded resin-based material.

FIG. 23 illustrates an eighteenth preferred embodiment of the present invention showing brake pads comprising a conductive loaded resin-based material.

FIG. 24 illustrates a nineteenth preferred embodiment of the present invention showing an exhaust pipe comprising a conductive loaded resin-based material.

FIG. 25 illustrates a twentieth preferred embodiment of the present invention showing a horn conductive ring comprising a conductive loaded resin-based material.

FIG. 26 illustrates a twenty first preferred embodiment of the present invention showing a kill switch comprising a conductive loaded resin-based material.

FIG. 27 illustrates a twenty second preferred embodiment of the present invention showing a horn switch comprising a conductive loaded resin-based material.

FIG. 28 illustrates a twenty third preferred embodiment of the present invention showing marine light comprising a conductive loaded resin-based material.

FIG. 29 illustrates a twenty fourth preferred embodiment of the present invention showing a distributor comprising a conductive loaded resin-based material.

FIG. 30 illustrates a twenty fifth preferred embodiment of the present invention showing an alternator comprising a conductive loaded resin-based material.

FIG. 31 illustrates a twenty sixth preferred embodiment of the present invention showing a starter comprising a conductive loaded resin-based material.

FIG. 32 illustrates a twenty seventh preferred embodiment of the present invention showing a fuel rail comprising a conductive loaded resin-based material.

FIG. 33 illustrates a twenty eighth preferred embodiment of the present invention showing a torque converter comprising a conductive loaded resin-based material.

FIG. 34 illustrates a twenty ninth preferred embodiment of the present invention showing a water pump comprising a conductive loaded resin-based material.

FIG. 35 illustrates a thirtieth preferred embodiment of the present invention showing an engine head cover comprising a conductive loaded resin-based material.

FIG. 36 illustrates a thirty first preferred embodiment of the present invention showing a radiator hose comprising a conductive loaded resin-based material.

FIG. 37 illustrates a thirty second preferred embodiment of the present invention showing a radiator comprising a conductive loaded resin-based material.

FIG. 38 illustrates a thirty third preferred embodiment of the present invention showing a radiator shroud and fan comprising a conductive loaded resin-based material.

FIG. 39 illustrates a thirty fourth preferred embodiment of the present invention showing a brake pedal assembly comprising a conductive loaded resin-based material.

FIG. 40 illustrates a thirty fifth preferred embodiment of the present invention showing a clutch assembly comprising a conductive loaded resin-based material.

FIG. 41 illustrates a thirty sixth preferred embodiment of the present invention showing a transmission cooler comprising a conductive loaded resin-based material.

FIG. 42 illustrates a thirty seventh preferred embodiment of the present invention showing engine headers comprising a conductive loaded resin-based material.

FIG. 43 illustrates a thirty eighth preferred embodiment of the present invention showing an engine manifold comprising a conductive loaded resin-based material.

FIG. 44 illustrates a thirty ninth preferred embodiment of the present invention showing an oil cooler comprising a conductive loaded resin-based material.

FIG. 45 illustrates a fortieth preferred embodiment of the present invention showing a power steering cooler comprising a conductive loaded resin-based material.

FIG. 46 illustrates a forty first preferred embodiment of the present invention showing an oil tube cooler comprising a conductive loaded resin-based material.

FIG. 47 illustrates a forty second preferred embodiment of the present invention showing a transmission case comprising a conductive loaded resin-based material.

FIG. 48 illustrates a forty third preferred embodiment of the present invention showing a fuel tank comprising a conductive loaded resin-based material.

FIG. 49 illustrates a forty fourth preferred embodiment of the present invention showing a power steering pump comprising a conductive loaded resin-based material.

FIG. 50 illustrates a forty fifth preferred embodiment of the present invention showing a fuel pump comprising a conductive loaded resin-based material.

FIG. 51 illustrates a forty sixth preferred embodiment of the present invention showing hydraulic lines comprising a conductive loaded resin-based material.

FIG. 52 illustrates a forty seventh preferred embodiment of the present invention showing a fuel dump can comprise a conductive loaded resin-based material.

FIG. 53 illustrates a forty eighth preferred embodiment of the present invention showing a hydraulic brake cylinder comprising a conductive loaded resin-based material.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention relates to vehicle components for motorcycle, marine, and racing applications wherein these components are molded of conductive loaded resin-based materials comprising micron conductive powders, micron conductive fibers, or a combination thereof, substantially homogenized within a base resin when molded.

The conductive loaded resin-based materials of the invention are base resins loaded with conductive materials, which then makes any base resin a conductor rather than an insulator. The resins provide the structural integrity to the molded part. The micron conductive fibers, micron conductive powders, or a combination thereof, are substantially homogenized within the resin during the molding process, providing the electrical, thermal, and/or acoustical continuity.

The conductive loaded resin-based materials can be molded, extruded or the like to provide almost any desired shape or size. The molded conductive loaded resin-based materials can also be cut, stamped, or vacuumed formed from an injection molded or extruded sheet or bar stock, over-molded, laminated, milled or the like to provide the desired shape and size. The thermal or electrical conductivity characteristics of the motorcycle, marine, and racing components fabricated using conductive loaded resin-based materials depend on the composition of the conductive loaded resin-based materials, of which the loading or doping parameters can be adjusted, to aid in achieving the desired structural, electrical or other physical characteristics of the material. The selected materials used to fabricate the devices are substantially homogenized together using molding techniques and or methods such as injection molding, over-molding, insert molding, thermo-set, protrusion, extrusion, calendaring, or the like. Characteristics related to 2D, 3D, 4D, and 5D designs, molding and electrical characteristics, include the physical and electrical advantages that can be achieved during the molding process of the actual parts and the polymer physics associated within the conductive networks within the molded part(s) or formed material(s).

In the conductive loaded resin-based material, electrons travel from point to point when under stress, following the path of least resistance. Most resin-based materials are insulators and represent a high resistance to electron passage. The doping of the conductive loading into the resin-based material alters the inherent resistance of the polymers. At a threshold concentration of conductive loading, the resistance through the combined mass is lowered enough to allow electron movement. Speed of electron movement depends on conductive loading concentration, that is, the separation between the conductive loading particles. Increasing conductive loading content reduces interparticle separation distance, and, at a critical distance known as the percolation point, resistance decreases dramatically and electrons move rapidly.

Resistivity is a material property that depends on the atomic bonding and on the microstructure of the material. The atomic microstructure material properties within the conductive loaded resin-based material are altered when molded into a structure. A substantially homogenized conductive microstructure of delocalized valance electrons is created. This microstructure provides sufficient charge carriers within the molded matrix structure. As a result, a low density, low resistivity, lightweight, durable, resin based polymer microstructure material is achieved. This material exhibits conductivity comparable to that of highly conductive metals such as silver, copper or aluminum, while maintaining the superior structural characteristics found in many plastics and rubbers or other structural resin based materials.

The use of conductive loaded resin-based materials in the fabrication of motorcycle, marine, and racing components significantly lowers the cost of materials and the design and manufacturing processes used to hold ease of close tolerances, by forming these materials into desired shapes and sizes. The components can be manufactured into infinite shapes and sizes using conventional forming methods such as injection molding, over-molding, or extrusion, calendaring, or the like. The conductive loaded resin-based materials, when molded, typically but not exclusively produce a desirable usable range of resistivity from between about 5 and 25 ohms per square, but other resistivities can be achieved by varying the doping parameters and/or resin selection(s).

The conductive loaded resin-based materials comprise micron conductive powders, micron conductive fibers, or any combination thereof, which are substantially homogenized together within the base resin, during the molding process, yielding an easy to produce low cost, electrically conductive, close tolerance manufactured part or circuit. The resulting molded article comprises a three dimensional, continuous network of conductive loading and polymer matrix. Exemplary micron conductive powders include carbons, graphites, amines or the like, and/or of metal powders such as nickel, copper, silver, aluminum, nichrome, or plated or the like. The use of carbons or other forms of powders such as graphite(s) etc. can create additional low level electron exchange and, when used in combination with micron conductive fibers, creates a micron filler element within the micron conductive network of fiber(s) producing further electrical conductivity as well as acting as a lubricant for the molding equipment. Carbon nano-tubes may be added to the conductive loaded resin-based material. The addition of conductive powder to the micron conductive fiber loading may increase the surface conductivity of the molded part, particularly in areas where a skinning effect occurs during molding.

The micron conductive fibers may be metal fiber or metal plated fiber. Further, the metal plated fiber may be formed by plating metal onto a metal fiber or by plating metal onto a non-metal fiber. Exemplary metal fibers include, but are not limited to, stainless steel fiber, copper fiber, nickel fiber, silver fiber, aluminum fiber, nichrome fiber, or the like, or combinations thereof. Exemplary metal plating materials include, but are not limited to, copper, nickel, cobalt, silver, gold, palladium, platinum, ruthenium, rhodium, and nichrome, and alloys of thereof. Any platable fiber may be used as the core for a non-metal fiber. Exemplary non-metal fibers include, but are not limited to, carbon, graphite, polyester, basalt, manmade and naturally-occurring materials, and the like. In addition, superconductor metals, such as titanium, nickel, niobium, and zirconium, and alloys of titanium, nickel, niobium, and zirconium may also be used as micron conductive fibers and/or as metal plating onto fibers in the present invention.

Where micron fiber is combined with base resin, the micron fiber may be pretreated to improve performance. According to one embodiment of the present invention, the fibers are subjected to any or several chemical modifications in order to improve the fibers interfacial properties. Fiber modification processes include, but are not limited to: mercerization; peroxide treatment; benzoylation; and amino, silane or other chemical or polymer treatments. The fiber modification processes are useful for improved the interfacial adhesion, improved wetting during homogenization and/or reduced oxide growth when compared to non-treated fiber.

The structural material may be any polymer resin or combination of polymer resins. Non-conductive resins or inherently conductive resins may be used as the structural material. Conjugated polymer resins, complex polymer resins, and/or inherently conductive resins may be used as the structural material. The dielectric properties of the resin-based material will have a direct effect upon the final electrical performance of the conductive loaded resin-based material. Many different dielectric properties are possible depending on the chemical makeup and/or arrangement, such as linking, cross-linking or the like, of the polymer, co-polymer, monomer, ter-polymer, or homo-polymer material. Structural material can be, here given as examples and not as an exhaustive list, polymer resins produced by GE PLASTICS, Pittsfield, Mass., a range of other plastics produced by GE PLASTICS, Pittsfield, Mass., a range of other plastics produced by other manufacturers, silicones produced by GE SILICONES, Waterford, N.Y., or other flexible resin-based rubber compounds produced by other manufacturers.

The resin-based structural material loaded with micron conductive powders, micron conductive fibers, or in combination thereof can be molded, using conventional molding methods such as injection molding or over-molding, or extrusion, or compression molding, or calendaring, to create desired shapes and sizes. The molded conductive loaded resin-based materials can also be stamped, cut or milled as desired to form create the desired shape form factor(s) of the components. The doping composition and directionality associated with the micron conductors within the loaded base resins can affect the electrical and structural characteristics of the components and can be precisely controlled by mold designs, gating and or protrusion design(s) and or during the molding process itself. In addition, the resin base can be selected to obtain the desired thermal characteristics such as very high melting point or specific thermal conductivity.

A resin-based sandwich laminate could also be fabricated with random or continuous webbed micron stainless steel fibers or other conductive fibers, forming a cloth like material. The webbed conductive fiber can be laminated or the like to materials such as Teflon, Polyesters, or any resin-based flexible or solid material(s), which when discretely designed in fiber content(s), orientation(s) and shape(s), will produce a very highly conductive flexible cloth-like material. Such a cloth-like material could also be used in forming motorcycle, marine, and racing components that could be embedded in other resin materials such as rubber(s) or plastic(s). When using conductive fibers as a webbed conductor as part of a laminate or cloth-like material, the fibers may have diameters of between about 3 and 12 microns, typically between about 8 and 12 microns or in the range of about 10 microns, with length(s) that can be seamless or overlapping.

The conductive loaded resin-based material may also be formed into a prepreg laminate, cloth, or webbing. A laminate, cloth, or webbing of the conductive loaded resin-based material is first impregnated with a resin-based material. In various embodiments, the conductive loaded resin-based material is dipped, coated, sprayed, and/or extruded with resin-based material to cause the laminate, cloth, or webbing to adhere together in a prepreg grouping that is easy to handle. This prepreg is placed, or laid up, onto a form and is then heated to form a permanent bond. In another embodiment, the prepreg is laid up onto the impregnating resin while the resin is still wet and is then cured by heating or other means. In another embodiment, the wet lay-up is performed by laminating the conductive loaded resin-based prepreg over a honeycomb structure. In yet another embodiment, a wet prepreg is formed by spraying, dipping, or coating the conductive loaded resin-based material laminate, cloth, or webbing in high temperature capable paint.

Carbon fiber and resin-based composites are found to display unpredictable points of failure. In carbon fiber systems there is no elongation of the structure. By comparison, in the present invention, the conductive loaded resin-based material displays greater strength in the direction of elongation. As a result a structure formed of the conductive loaded resin-based material of the present invention will hold together even if crushed while a comparable carbon fiber composite will break into pieces.

The conductive loaded resin-based material of the present invention can be made resistant to corrosion and/or metal electrolysis by selecting micron conductive fiber and/or micron conductive powder and base resin that are resistant to corrosion and/or metal electrolysis. For example, if a corrosion/electrolysis resistant base resin is combined with stainless steel fiber and carbon fiber/powder, then a corrosion and/or metal electrolysis resistant conductive loaded resin-based material is achieved. Another additional and important feature of the present invention is that the conductive loaded resin-based material of the present invention may be made flame retardant. Selection of a flame-retardant (FR) base resin material allows the resulting product to exhibit flame retardant capability. This is especially important in motorcycle, marine, and racing components as described herein.

The substantially homogeneous mixing of micron conductive fiber and/or micron conductive powder and base resin described in the present invention may also be described as doping. That is, the substantially homogeneous mixing converts the typically non-conductive base resin material into a conductive material. This process is analogous to the doping process whereby a semiconductor material, such as silicon, can be converted into a conductive material through the introduction of donor/acceptor ions as is well known in the art of semiconductor devices. Therefore, the present invention uses the term doping to mean converting a typically non-conductive base resin material into a conductive material through the substantially homogeneous mixing of micron conductive fiber and/or micron conductive powder into a base resin.

As an additional and important feature of the present invention, the molded conductor loaded resin-based material exhibits excellent thermal dissipation characteristics. Therefore, motorcycle, marine, and racing components manufactured from the molded conductor loaded resin-based material can provide added thermal dissipation capabilities to the application. For example, heat can be dissipated from electrical devices physically and/or electrically connected to a component of the present invention.

As a significant advantage of the present invention, motorcycle, marine, and racing components constructed of the conductive loaded resin-based material can be easily interfaced to an electrical circuit or grounded. In one embodiment, a wire can be attached to a conductive loaded resin-based component via a screw that is fastened to the component. For example, a simple sheet-metal type, self tapping screw, when fastened to the material, can achieve excellent electrical connectivity via the conductive matrix of the conductive loaded resin-based material. To facilitate this approach a boss may be molded into the conductive loaded resin-based material to accommodate such a screw. Alternatively, if a solderable screw material, such as copper, is used, then a wire can be soldered to the screw that is embedded into the conductive loaded resin-based material. In another embodiment, the conductive loaded resin-based material is partly or completely plated with a metal layer. The metal layer forms excellent electrical conductivity with the conductive matrix. A connection of this metal layer to another circuit or to ground is then made. For example, if the metal layer is solderable, then a soldered connection may be made between the component and a grounding wire.

Where a metal layer is formed over the surface of the conductive loaded resin-based material, any of several techniques may be used to form this metal layer. This metal layer may be used for visual enhancement of the molded conductive loaded resin-based material article or to otherwise alter performance properties. Well-known techniques, such as electroless metal plating, electrolytic metal plating, sputtering, metal vapor deposition, metallic painting, or the like, may be applied to the formation of this metal layer. If metal plating is used, then the resin-based structural material of the conductive loaded, resin-based material is one that can be metal plated. There are many of the polymer resins that can be plated with metal layers. For example, GE Plastics, SUPEC, VALOX, ULTEM, CYCOLAC, UGIKRAL, STYRON, CYCOLOY are a few resin-based materials that can be metal plated. Electroless plating is typically a multiple-stage chemical process where, for example, a thin copper layer is first deposited to form a conductive layer. This conductive layer is then used as an electrode for the subsequent plating of a thicker metal layer.

A typical metal deposition process for forming a metal layer onto the conductive loaded resin-based material is vacuum metallization. Vacuum metallization is the process where a metal layer, such as aluminum, is deposited on the conductive loaded resin-based material inside a vacuum chamber. In a metallic painting process, metal particles, such as silver, copper, or nickel, or the like, are dispersed in an acrylic, vinyl, epoxy, or urethane binder. Most resin-based materials accept and hold paint well, and automatic spraying systems apply coating with consistency. In addition, the excellent conductivity of the conductive loaded resin-based material of the present invention facilitates the use of extremely efficient, electrostatic painting techniques.

The conductive loaded resin-based material can be contacted in any of several ways. In one embodiment, a pin is embedded into the conductive loaded resin-based material by insert molding, ultrasonic welding, pressing, or other means. A connection with a metal wire can easily be made to this pin and results in excellent contact to the conductive loaded resin-based material. In another embodiment, a hole is formed in to the conductive loaded resin-based material either during the molding process or by a subsequent process step such as drilling, punching, or the like. A pin is then placed into the hole and is then ultrasonically welded to form a permanent mechanical and electrical contact. In yet another embodiment, a pin or a wire is soldered to the conductive loaded resin-based material. In this case, a hole is formed in the conductive loaded resin-based material either during the molding operation or by drilling, stamping, punching, or the like. A solderable layer is then formed in the hole. The solderable layer is preferably formed by metal plating. A conductor is placed into the hole and then mechanically and electrically bonded by point, wave, or reflow soldering.

Another method to provide connectivity to the conductive loaded resin-based material is through the application of a solderable ink film to the surface. One exemplary solderable ink is a combination of copper and solder particles in an epoxy resin binder. The resulting mixture is an active, screen-printable and dispensable material. During curing, the solder reflows to coat and to connect the copper particles and to thereby form a cured surface that is directly solderable without the need for additional plating or other processing steps. Any solderable material may then be mechanically and/or electrically attached, via soldering, to the conductive loaded resin-based material at the location of the applied solderable ink. Many other types of solderable inks can be used to provide this solderable surface onto the conductive loaded resin-based material of the present invention. Another exemplary embodiment of a solderable ink is a mixture of one or more metal powder systems with a reactive organic medium. This type of ink material is converted to solderable pure metal during a low temperature cure without any organic binders or alloying elements.

A ferromagnetic conductive loaded resin-based material may be formed of the present invention to create a magnetic or magnetizable form of the material. Ferromagnetic micron conductive fibers and/or ferromagnetic conductive powders are mixed with the base resin. Ferrite materials and/or rare earth magnetic materials are added as a conductive loading to the base resin. With the substantially homogeneous mixing of the ferromagnetic micron conductive fibers and/or micron conductive powders, the ferromagnetic conductive loaded resin-based material is able to produce an excellent low cost, low weight magnetize-able item. The magnets and magnetic devices of the present invention can be magnetized during or after the molding process. The magnetic strength of the magnets and magnetic devices can be varied by adjusting the amount of ferromagnetic micron conductive fibers and/or ferromagnetic micron conductive powders that are incorporated with the base resin. By increasing the amount of the ferromagnetic doping, the strength of the magnet or magnetic devices is increased. The substantially homogenous mixing of the conductive fiber network allows for a substantial amount of fiber to be added to the base resin without causing the structural integrity of the item to decline. The ferromagnetic conductive loaded resin-based magnets display the excellent physical properties of the base resin, including flexibility, moldability, strength, and resistance to environmental corrosion, along with excellent magnetic ability. In addition, the unique ferromagnetic conductive loaded resin-based material facilitates formation of items that exhibit excellent thermal and electrical conductivity as well as magnetism.

A high aspect ratio magnet is easily achieved through the use of ferromagnetic conductive micron fiber or through the combination of ferromagnetic micron powder with conductive micron fiber. The use of micron conductive fiber allows for molding articles with a high aspect ratio of conductive fiber to cross sectional area. If a ferromagnetic micron fiber is used, then this high aspect ratio translates into a high quality magnetic article. Alternatively, if a ferromagnetic micron powder is combined with micron conductive fiber, then the magnetic effect of the powder is effectively spread throughout the molded article via the network of conductive fiber such that an effective high aspect ratio molded magnetic article is achieved. The ferromagnetic conductive loaded resin-based material may be magnetized, after molding, by exposing the molded article to a strong magnetic field. Alternatively, a strong magnetic field may be used to magnetize the ferromagnetic conductive loaded resin-based material during the molding process.

The ferromagnetic conductive loading is in the form of fiber, powder, or a combination of fiber and powder. The micron conductive powder may be metal fiber or metal plated fiber. If metal plated fiber is used, then the core fiber is a platable material and may be metal or non-metal. Exemplary ferromagnetic conductive fiber materials include ferrite, or ceramic, materials as nickel zinc, manganese zinc, and combinations of iron, boron, and strontium, and the like. In addition, rare earth elements, such as neodymium and samarium, typified by neodymium-iron-boron, samarium-cobalt, and the like, are useful ferromagnetic conductive fiber materials. Exemplary ferromagnetic micron powder leached onto the conductive fibers include ferrite, or ceramic, materials as nickel zinc, manganese zinc, and combinations of iron, boron, and strontium, and the like. In addition, rare earth elements, such as neodymium and samarium, typified by neodymium-iron-boron, samarium-cobalt, and the like, are useful ferromagnetic conductive powder materials. A ferromagnetic conductive loading may be combined with a non-ferromagnetic conductive loading to form a conductive loaded resin-based material that combines excellent conductive qualities with magnetic capabilities.

According to the present invention, a wide variety of motorcycle, marine, and racing vehicle components are formed, at least in part, of conductive loaded resin-based materials. The vehicle components described in the present invention take advantage of the novel characteristics of the conductive loaded resin-based material. Component cases and housings take advantage of low material weight, high strength, high conductivity, and ease of formation via molding. Fluid lines, hoses, and pipes benefit from the non-reactive, high temperature capability of the base resin combined with the high conductivity of the conductive loaded resin-based material. Electronics enclosures take advantage of the excellent electromagnetic energy absorption of the conductive loaded resin-based material.

Components include, but are not limited to, oil pans, oil coolers, oil tube coolers, radiators, fan shrouds, radiator hoses, coolant lines, water pumps, power steering cooler and hoses, heater coils, heater motors, fuel pumps, lines, tanks, fillers, injectors, and dump cans, exhaust manifolds, headers, mufflers, and pipes, starters, radio enclosures, control module covers, computer enclosures, voltage regulators, distributors, rotors, antennas, telemetry devices, LED lighting and circuits, other lighting circuits, lighting terminals, wiring harnesses and conduit, fuses, gauges, sensors, switches, oil, air, and fuel filters, air hoses, brake pads, lines, master cylinders, and wheel cylinders, clutch disks, spark plugs and plug wires, valve covers, intake manifolds, transmission cases, coolers, and lines, bell housings, torque converters, body panels, alternators, and the like. Numerous exemplary embodiments of the above vehicle racing components are illustrated.

Referring now to FIG. 1, a first preferred embodiment of the present invention is illustrated. A representative motorcycle 10 is shown. In the embodiment, any component, or several components, of the motorcycle 10 comprise the conductive loaded resin-based material of the present invention. In various embodiments, the front and rear fenders 12, the gas tank 14, the frame 16, the engine housing covers 18, the headlight assembly 13, and the turn signal assembly 15 are formed of the conductive loaded resin-based material of the present invention. By forming the fenders 12, frame 16, gas tank 14, engine housing covers 18, or exhaust pipes 19 of the conductive loaded resin-based material of the present invention the need for drilling the mounting holes can be eliminated by forming them in the molding process. In addition, more intricate designs can be realized over traditional sheet metal bending and forming. The conductive loaded resin-based material of the present invention also offers the advantages of a less complex manufacturing processes and lower weight when compared to metal-based components. In addition, the conductive loaded resin-based material is compatible with electrostatic painting methods, exhibits excellent heat dissipation due to its thermal conductive properties, exhibits excellent electrical conductivity and electromagnetic energy absorption. These features are not typical to prior resin-based products. The engine housing covers 18 are representative. Other housings, or shields, for the engine or drive train assemblies benefit from the physical properties of the conductive loaded resin-based material of the present invention and are envisioned as additional embodiments.

In yet other embodiments, the motorcycle electrical system contains various components comprising the conductive loaded resin-based material of the present invention. Electrical wiring, wiring harnesses, switches, lighting components, electromagnetic absorbing, connectors, circuit boards, heat sinks, and the like, are formed of the conductive loaded resin-based material of the present invention. In another embodiment, fuel delivery systems, including gas tanks, fuel pumps, and fuel lines, comprise the conductive loaded resin-based material. In another embodiment, hydraulic systems, including pumps and lines, brake lines, master cylinders, and the like, comprise the conductive loaded resin-based material. In another embodiment, oil handling devices, such as oil coolers, oil pans and tanks, oil tubes, and the like comprise conductive loaded resin-based material. High conductivity combined with resistance to corrosive chemicals and less weight, makes the conductive loaded resin-based material an ideal choice for these applications where elimination of electrostatic discharge is required. In yet another embodiment, the conductive loaded resin-based material is used to form spark plug electrodes. The network of conductive fibers creates a very unique and useful fuel ignition device.

In addition to street motorcycles, like that shown in FIG. 1, any other type of motorcycle vehicle may be manufactured with the conductive loaded resin-based material of the present invention. Other types of motorcycle vehicles include, but are not limited to, off-road or “dirt” motorcycles; scooter, mopeds, and go-peds; mini-bikes; three wheeled and four wheeled all-terrain vehicle (ATV); and choppers.

Referring now to FIGS. 7 and 8, second and third preferred embodiments of the present invention are illustrated showing embodiments of marine applications. FIG. 7 illustrates a military war ship 100, and FIG. 8 illustrates a recreational or commercial boating vehicle 120. Referring particularly now to FIG. 7, the military war ship 100 is formed with an external body structure 106 and the cannon barrels 104 are covered with an outer skin or sheathing of the conductive loaded resin-based material of the present invention. By fabricating the components of the conductive loaded resin-based material, a military war ship 100 with a very small radar profile is derived. The conductive loaded resin-based material comprises a network of conductive fibers and/or powders in a polymer matrix. This material exhibits excellent absorption of RF energy across a wide bandwidth. As a result, the war ship 100 reflects very little RF energy back to a radar detection system. The war ship 100 is therefore much harder to detect using radar. As a further advantage, the conductive loaded resin-based material provides a significant weight reduction over metal sheeting. Conductive loaded resin-based material can be used in areas of the war ship 100 that are less critical to armor protection. As a result, the steel and other armoring materials can be concentrated in areas of maximum vessel and/or occupant protection. Alternately, a reduced weight war ship 100 is derived resulting in greater marine performance and range of operation.

The above-described embodiments are derived in several ways. First, conductive loaded resin-based panels 106, and the like, are easily injection molded. Second, where an outer layer, or skin, of the conductive loaded resin-based material is used, this outer layer is formed by over molding the conductive loaded resin-based material onto a previously stamped metal panel. In an additional embodiment, the conductive loaded resin-based material is in applied to metal panels, and the like, in the form of a layered fabric. If the base resin of the conductive loaded resin-based material is one that is useful for dissipating bullet energy, such as polyparaphenylene terephthalamide, then the conductive loaded resin-based material acts as additional armor reinforcement as well as a radar shield.

The conductive loaded resin-based material sheathing provides several important advantages to the war ship 100. First, the conductive loaded resin-based material sheathing reduces the RF emissions from the war ship 100 to thereby make it difficult to detect with radar. Second, the conductive loaded resin-based material exhibits excellent heat transfer properties and aids in removing heat from the cannon barrels 14, the engine room, and other heat generating sources onboard. Third, the advantages in reduced electromagnetic energy emission and in better heat transfer are realized with a material that is significantly lighter than steel or other metal materials.

Referring particularly now to FIG. 8, a third preferred embodiment of the present invention is illustrated. A recreational or commercial boating vehicle 120 is shown. In particular, a personal watercraft vehicle 120 is shown. In the embodiment, any component, or several components, of the personal watercraft vehicle 120 comprise the conductive loaded resin-based material of the present invention. In various embodiments, the gas tank, the frame, and/or the engine housing covers 124 are formed of the conductive loaded resin-based material of the present invention. By forming the gas tank, the frame, and/or the engine housing covers 124 of the conductive loaded resin-based material of the present invention the need for drilling the mounting holes can be eliminated by forming them in the molding process. In addition, more intricate designs can be realized over traditional sheet metal bending and forming. The conductive loaded resin-based material of the present invention also offers the advantages of a less complex manufacturing processes and lower weight when compared to metal-based components. In addition, the conductive loaded resin-based material is compatible with electrostatic painting methods, exhibits excellent heat dissipation due to its thermal conductive properties, exhibits excellent electrical conductivity and electromagnetic energy absorption. These features are not typical to prior resin-based products. The engine housing covers 124 are representative. Other housings, or shields, for the engine or drive train assemblies benefit from the physical properties of the conductive loaded resin-based material of the present invention and are envisioned as additional embodiments.

In yet other embodiments, the personal watercraft vehicle electrical system contains various components comprising the conductive loaded resin-based material of the present invention. Electrical wiring, connectors, circuit boards, heat sinks, and like, are formed of the conductive loaded resin-based material of the present invention. In another embodiment, fuel delivery systems, including gas tanks, fuel pumps, and fuel lines, comprise the conductive loaded resin-based material. In another embodiment, hydraulic systems, including pumps and lines, comprise the conductive loaded resin-based material. High conductivity combined with resistance to corrosive chemicals and less weight, makes the conductive loaded resin-based material an ideal choice for these applications where elimination of electrostatic discharge is required. In yet another embodiment, the conductive loaded resin-based material is used to form spark plug electrodes. The network of conductive fibers creates a very unique and useful fuel ignition device.

In addition to military warships, like that shown in FIG. 7, any other type of military marine vehicle may be manufactured with the conductive loaded resin-based material of the present invention. Other types of military marine vehicles include, but are not limited to, cruisers, battleships, aircraft carriers, mine sweepers, reconnaissance boats, gun boats, submersible vehicles, and hydrofoils. Other types of recreational or commercial marine vehicles include, but are not limited to, powered and un-powered boats, fishing boats, pontoon boats, sail boats, ski boats, tug boats, barges, cargo boats, ferry boats, and jet skis.

Referring now to FIG. 9, a fourth preferred embodiment of the present invention is illustrated. A representative racing vehicle 150 is shown. In the embodiment, any component, or several components, of the racing vehicle 150 comprise the conductive loaded resin-based material of the present invention. In various embodiments, the front and rear fenders 152, the gas tank, the frame 154, and the engine housing covers are formed of the conductive loaded resin-based material of the present invention. By forming the fenders 152, frame 154, gas tank, engine housing covers, or exhaust pipes of the conductive loaded resin-based material of the present invention the need for drilling the mounting holes can be eliminated by forming them in the molding process. In addition, more intricate designs can be realized over traditional sheet metal bending and forming. The conductive loaded resin-based material of the present invention also offers the advantages of a less complex manufacturing processes and lower weight when compared to metal-based components. In addition, the conductive loaded resin-based material is compatible with electrostatic painting methods, exhibits excellent heat dissipation due to its thermal conductive properties, exhibits excellent electrical conductivity and electromagnetic energy absorption. These features are not typical to prior resin-based products. The engine housing covers are representative. Other housings, or shields, for the engine or drive train assemblies benefit from the physical properties of the conductive loaded resin-based material of the present invention and are envisioned as additional embodiments.

In yet other embodiments, the racing vehicle electrical system contains various components comprising the conductive loaded resin-based material of the present invention. Electrical wiring, wiring harnesses, switches, lighting components, electromagnetic absorbing, connectors, circuit boards, heat sinks, and the like, are formed of the conductive loaded resin-based material of the present invention. In another embodiment, fuel delivery systems, including gas tanks, fuel pumps, and fuel lines, comprise the conductive loaded resin-based material. In another embodiment, hydraulic systems, including pumps and lines, brake lines, master cylinders, and the like, comprise the conductive loaded resin-based material. In another embodiment, oil handling devices, such as oil coolers, oil pans and tanks, oil tubes, and the like comprise conductive loaded resin-based material. High conductivity combined with resistance to corrosive chemicals and less weight, makes the conductive loaded resin-based material an ideal choice for these applications where elimination of electrostatic discharge is required. In yet another embodiment, the conductive loaded resin-based material is used to form spark plug electrodes. The network of conductive fibers creates a very unique and useful fuel ignition device.

In addition to stock cars, like that shown in FIG. 9, any other type of racing vehicle may be manufactured with the conductive loaded resin-based material of the present invention. Other types of racing vehicles include, but are not limited to, off-road vehicles such as dune buggies and 4×4 trucks; formula and “indy” cars; sprint and midget racers; go-carts; drag racing vehicles; and ultra-light vehicles.

A variety of embodiments of motorcycle, marine, and racing vehicle components are illustrated in FIGS. 10-53. Each is exemplary of the type of component that is manufactured, in part or in whole, of the conductive loaded resin-based material of the present invention. Illustrated components are applicable to motorcycle, marine, or racing applications unless otherwise indicated.

Referring now to FIG. 10, a fifth preferred embodiment of the present invention is illustrated. An electronic ignition switch 200 is shown. In the embodiment, any component, or several components, of the ignition switch 200 comprise the conductive loaded resin-based material of the present invention. In this embodiment the outside casing 200 and the electrical contact points (not shown) are formed of the conductive loaded resin-based material of the present invention. Preferably, the casing 200 and contact points are injection molded of the conductive loaded resin-based material.

Referring now to FIG. 11, a sixth preferred embodiment of the present invention is illustrated. An electrical connector is shown. In the embodiment, any or all of several components comprise the conductive loaded resin-based material: the external conduit 210, individual conductors 212, and the connector 214. Preferably, the external conduit 210 and conductors 212 are extrusion molded of the conductive loaded resin-based material, while the connector 214 is injection molded of the conductive loaded resin-based material.

Referring now to FIG. 12, a seventh preferred embodiment of the present invention is illustrated. An electrical fuse box is shown. In the embodiment, any component, or several components, of the electrical fuse box comprise the conductive loaded resin-based material of the present invention. In this embodiment the outside casing 220 and the electrical contact points (not shown) are formed of the conductive loaded resin-based material of the present invention. Preferably, the casing 220 and contact points are injection molded of the conductive loaded resin-based material.

Referring now to FIG. 13, an eighth preferred embodiment of the present invention is illustrated. A flexible electromagnetic energy absorbing conduit 230 is shown. The conductive loaded resin-based material of the present invention offers the advantages of a less complex manufacturing processes and lower weight when compared to metal-based components. In addition, the conductive loaded resin-based material is compatible with electrostatic painting methods, exhibits excellent heat dissipation due to its thermal conductive properties, exhibits excellent electrical conductivity and electromagnetic energy absorption. These features are not typical to prior resin-based products. Preferably, the conduit is extrusion molded from the conductive loaded resin-based material.

Referring now to FIG. 14, a ninth embodiment of the present invention is illustrated. An electronic ignition module 240 is shown. In the embodiment, any component, or several components, of the electronic ignition module 240 comprise the conductive loaded resin-based material of the present invention. In this embodiment the outside casing 242 and the electrical contact points 244 are formed of the conductive loaded resin-based material of the present invention. Preferably, the casing 242 and contact points 244 are injection molded from the conductive loaded resin-based material.

Referring now to FIG. 15, a tenth preferred embodiment of the present invention is illustrated. A rocker switch 250 is shown. In the embodiment, any component, or several components, of the rocker switch 250 comprise the conductive loaded resin-based material of the present invention. In this embodiment the outside casing and the electrical contact points (not shown) are formed of the conductive loaded resin-based material of the present invention. Preferably, the casing 250 and contact points are injection molded from the conductive loaded resin-based material.

Referring now to FIG. 16, an eleventh preferred embodiment of the present invention is illustrated. A toggle switch 260 is shown. In the embodiment, any component, or several components, of the toggle switch 260 comprise the conductive loaded resin-based material of the present invention. In this embodiment the outside casing 262 and the electrical contact points 264 are formed of the conductive loaded resin-based material of the present invention. Preferably, the casing 262 and contact points 264 are injection molded from the conductive loaded resin-based material.

Referring now to FIG. 17, a twelfth preferred embodiment of the present invention is illustrated. An electronics enclosure 270 is shown. The conductive loaded resin-based material exhibits a novel combination of structural strength, electrical conductivity, thermal conductivity, and electromagnetic absorption that makes this material ideal for various electronic applications in the racing environment. Any of various types of electronics devices, such as radios, electronic climate controls, electronic engine controls, and electronic displays, may be formed into a housing comprising the conductive loaded resin-based material. Preferably, the enclosure 270 is injection molded from the conductive loaded resin-based material.

Referring now to FIG. 18, a thirteenth preferred embodiment of the present invention is illustrated. Spark plug wires 280 are shown. A spark plug wire 280 comprises the conductive loaded resin-based material of the present invention. In one embodiment, the plug wire 280 comprises an inner conductor of the conductive loaded resin-based material. In another embodiment, a shielding layer is formed of the conductive loaded resin-based material. In another embodiment, the connector interface to the spark plug comprises the conductive loaded resin-based material. Preferably, the inner conductor and shield are extrusion molded while the connector is injection molded.

Referring now to FIG. 19, a fourteenth preferred embodiment of the present invention is illustrated. An air hose 290 is shown. In the embodiment, the air hose is constructed of the conductive loaded resin-based material of the present invention. Preferably, the hose is extrusion molded from the conductive loaded resin-based material.

Referring now to FIG. 20, a fifteenth preferred embodiment of the present invention is illustrated. A fuel line 300 is shown. In the embodiment, a fuel line 300 is formed of the conductive loaded resin-based material of the present invention. In one embodiment, the fuel line 300 is color coded. In another embodiment, the line is braided, or plated, with a metal layer. Preferably, the fuel line is extrusion molded from the conductive loaded resin-based material.

Referring now to FIG. 21, a sixteenth preferred embodiment of the present invention is illustrated. A fuel filter 310 is shown. In the embodiment, the fuel filter 310 comprises the conductive loaded resin-based material of the present invention. Preferably, the filter is extrusion molded from the conductive loaded resin-based material.

Referring now to FIG. 22, a seventeenth preferred embodiment of the present invention is illustrated. An oil pan 180 is shown. In the embodiment, any component, or several components, of the oil pan 320 comprise the conductive loaded resin-based material of the present invention. The structural stability, strength, and heat conductivity or the conductive loaded resin-based material yield an oil pan of excellent performance and low weight. Preferably, the filter is injection molded from the conductive loaded resin-based material.

Referring now to FIG. 23, an eighteenth preferred embodiment of the present invention is illustrated. A brake system 330 is shown comprising a brake drum 334 and brake pads 332. In the embodiment, brake pads 332 comprise abrasive pads and pad brackets. The brake pads 332 are constructed of the conductive loaded resin-based material of the present invention. Preferably, the pads 332 are injection molded.

Referring now to FIG. 24, a nineteenth preferred embodiment of the present invention is illustrated. An engine exhaust pipe 340 is shown. The exhaust pipe 340 comprises the conductive loaded resin-based material of the present invention. Preferably, the exhaust pipe 340 is extrusion molded from the conductive loaded resin-based material.

Referring now to FIG. 25, a twentieth preferred embodiment of the present invention is illustrated. A horn conductive ring assembly 350 for a steering column is shown. The horn conductive ring 350 for a steering column comprises the conductive loaded resin-based material of the present invention. The horn conductive ring assembly 370 for a steering column comprises a horn cup 352, a contact ring 354, and a spacer 356. Preferably, the contact ring 354 is injection molded.

Referring now to FIG. 26, a twenty first preferred embodiment of the present invention is illustrated. A kill switch system 370 is shown. The kill switch system 370 comprises the conductive loaded resin-based material of the present invention. The kill switch system 370 comprises a lanyard 372, a momentary switch 376, and contacts 374. Preferably, the momentary switch 376 and contacts 374 are injection molded.

Referring now to FIG. 27, a twenty second preferred embodiment of the present invention is illustrated. A grip control system 380 with a horn switch 382 is shown. The grip control system 380 with a horn switch 392 comprises the conductive loaded resin-based material of the present invention.

Referring now to FIG. 28, a twenty third preferred embodiment of the present invention is illustrated. A pop-up bow-mounted navigation light 390 is shown. In the embodiment, any component, or several components, of the pop-up bow-mounted navigation light 390 comprise the conductive loaded resin-based material of the present invention. In this embodiment the bulb fixture (not shown) and the electrical contact points (not shown) are formed of the conductive loaded resin-based material of the present invention. The pop-up bow-mounted navigation light 390 is representative. In other embodiments the light fixture would be a modular plug-in mast design. The conductive loaded resin-based material of the present invention offers the advantages of a less complex manufacturing processes and lower weight when compared to metal-based components. In addition, the conductive loaded resin-based material is compatible with electrostatic painting methods, exhibits excellent heat dissipation due to its thermal conductive properties, exhibits excellent electrical conductivity and electromagnetic energy absorption. These features are not typical to prior resin-based products.

Referring now to FIG. 29, a twenty fourth preferred embodiment of the present invention is illustrated. A distributor cap assembly 400 is shown. In the embodiment, any component, or several components, of the distributor cap assembly 400 comprise the conductive loaded resin-based material of the present invention. In this embodiment the electrical connectors 402, the contact pins 404, the electronic module cover 406, and the outside casing 408, are formed of the conductive loaded resin-based material of the present invention. Preferably, the electrical connectors 402, the contact pins 404, the electronic module cover 406, and the outside casing 408 are injection molded.

Referring now to FIG. 30, a twenty fifth preferred embodiment of the present invention is illustrated. An alternator 410 is shown. In the embodiment, any component, or several components, of the alternator 410 comprise the conductive loaded resin-based material of the present invention. In this embodiment electrical connectors, magnets, wire coils, and the outside casing 410 are formed of the conductive loaded resin-based material of the present invention. Preferably, the outside casing 410 is injection molded.

Referring now to FIG. 31, a twenty sixth preferred embodiment of the present invention is illustrated. A starter 420 is shown. In the embodiment, any component, or several components, of the starter 420 comprise the conductive loaded resin-based material of the present invention. In this embodiment the electrical connectors and the outside casing are injection molded from the conductive loaded resin-based material of the present invention.

Referring now to FIG. 31, a twenty seventh preferred embodiment of the present invention is illustrated. A fuel rail 430 is shown. In the embodiment, the fuel rail 430 comprises fuel lines and fuel injectors. Any, or all, of these components is constructed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 33, a twenty eighth preferred embodiment of the present invention is illustrated. An automatic transmission torque converter 440 is shown. In the embodiment, any component, or several components, of the torque converter 440 comprise the conductive loaded resin-based material of the present invention. In this embodiment, any or all of the components of the impeller pump 448, stator 442, the turbine 444, and the cover 446 of the conductive loaded resin-based material of the present invention. In this embodiment the impeller pump 448, stator 442, the turbine 444, and/or the cover 446 are injection molded from the conductive loaded resin-based material of the present invention.

Referring now to FIG. 34, a twenty ninth preferred embodiment of the present invention is illustrated. A cooling water pump 450 is shown. In the embodiment, the cooling water pump housing 450 and/or drive pump comprise the conductive loaded resin-based material of the present invention. In this embodiment the pump housing 450 and/or drive pump are injection molded from the conductive loaded resin-based material of the present invention.

Referring now to FIG. 35, a thirtieth preferred embodiment of the present invention is illustrated. An engine head cover 460 is shown. In the embodiment, the head covers 460 comprise the conductive loaded resin-based material of the present invention and are formed by injection molding.

Referring now to FIG. 36, a thirty first preferred embodiment of the present invention is illustrated. Radiator hoses 470 are shown. In the embodiment, any component, or several components, of the radiator hoses 470 comprise the conductive loaded resin-based material of the present invention. In this embodiment the radiator hoses 470 are extrusion molded from the conductive loaded resin-based material of the present invention.

Referring now to FIG. 37, a thirty third preferred embodiment of the present invention is illustrated. A radiator shroud assembly is shown. The assembly comprises a shroud 480 and fan 484. Either or both of these components are constructed of the conductive loaded resin-based material of the present invention. In this embodiment the shroud 480 and fan 484 are injection molded from the conductive loaded resin-based material of the present invention.

Referring now to FIG. 38, a thirty second preferred embodiment of the present invention is illustrated. A radiator 490 is shown. In the embodiment, any component, or several components, of the radiator comprise the conductive loaded resin-based material of the present invention. In this embodiment the cooling fins 492, the fill spout 496, and the outlet and inlet 494 are formed of the conductive loaded resin-based material of the present invention. In this embodiment the fill spout 496 and the outlet and inlet 494 are injection molded while the cooling fins are extrusion molded.

Referring now to FIG. 39, a thirty fourth preferred embodiment of the present invention is illustrated. An automotive brake pedal assembly 500 is shown. In the embodiment, any component, or several components, of the automotive brake pedal assembly 500 comprise the conductive loaded resin-based material of the present invention. In this embodiment the fluid reservoirs 502, the fluid reservoir covers 504, and the master cylinders 506 are formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 40, a thirty fifth preferred embodiment of the present invention is illustrated. An automotive clutch assembly 510 is shown. In the embodiment, any component, or several components, of the automotive clutch assembly 510 comprise the conductive loaded resin-based material of the present invention. In this embodiment the clutch housing 512, and the clutch plate 514 are formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 41, a thirty sixth preferred embodiment of the present invention is illustrated. A transmission cooler 520 is shown. In the embodiment, any component, or several components, of the transmission cooler 520 comprise the conductive loaded resin-based material of the present invention.

Referring now to FIG. 42, a thirty seventh preferred embodiment of the present invention is illustrated. High performance headers 530 are shown. In the embodiment, any component, or several components, of the high performance headers comprise the conductive loaded resin-based material of the present invention.

Referring now to FIG. 43, a thirty eighth preferred embodiment of the present invention is illustrated. An intake manifold 540 is shown. In the embodiment, any component, or several components of the intake manifold 540 comprise the conductive loaded resin-based material of the present invention.

Referring now to FIG. 44, a thirty ninth preferred embodiment of the present invention is illustrated. An engine oil cooler 550 is shown. In the embodiment, any component, or several components, of the engine oil cooler 550 comprise the conductive loaded resin-based material of the present invention. In this embodiment, the cooling fins 558, the outlet 554, and the inlet 552 are formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 45, a fortieth preferred embodiment of the present invention is illustrated. A power steering cooler 560 is shown. In the embodiment, any component, or several components, of the power steering cooler 560 comprise the conductive loaded resin-based material of the present invention. In this embodiment, the cooling fins 562, the outlet 564, and the inlet 566 are formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 46, a forty first preferred embodiment of the present invention is illustrated. An oil tube cooler 570 is shown. In the embodiment, any component, or several components, of the oil tube cooler 570 comprise the conductive loaded resin-based material of the present invention. In this embodiment the cooling fins 572 and the milled slot 574 can be extruded at one time and are formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 47, a forty second preferred embodiment of the present invention is illustrated. A transmission 580 is shown. In the embodiment, any component, or several components, of the transmission 580 comprise the conductive loaded resin-based material of the present invention. In this embodiment the housing cover 580 is formed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 48, a forty third preferred embodiment of the present invention is illustrated. A fuel tank 590 is shown. In the embodiment, any component, or several components, of the fuel tank 590 comprise the conductive loaded resin-based material of the present invention.

Referring now to FIG. 49, a forty fourth preferred embodiment of the present invention is illustrated. A power steering pump 600 is shown. In the embodiment, the power steering pump 600 comprises a fluid reservoir 604, a filler cap 606, a pulley 602, and an internal pumping mechanism. Any, or all, of these components is constructed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 50, a forty fifth preferred embodiment of the present invention is illustrated. A fuel pump 610 is shown. In modern vehicles, the fuel pump is typically packaged inside the fuel tank. The fuel pump 610 is used to pump fuel from the fuel tank to the other components of the fuel system. Conductive loaded resin-based material of the present invention is used to form any or all of the components of the fuel pump 610. The conductive loaded resin-based material components include, but are not limited to, the housing 612, the stem 614, and other interior components. Again, conductive loaded resin-based material provides advantageous cost, weight, static electricity discharge and other performance characteristics for this and other vehicle fuel system components.

Referring now to FIG. 51, a forty sixth preferred embodiment of the present invention is illustrated. A brake, or hydraulic, line 620 is shown. In the embodiment, the brake, or hydraulic, line 620 comprises connectors 622 and tubing 624. Any, or all, of these components is constructed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 52, a forty seventh preferred embodiment of the present invention is illustrated. A fuel dump can 630, as is compatible with rapid fueling during competition, is constructed of the conductive loaded resin-based material of the present invention.

Referring now to FIG. 53, a forty eighth preferred embodiment of the present invention is illustrated. A wheel brake cylinder 640 is shown. The wheel brake cylinder 480 comprises the conductive loaded resin-based material of the present invention.

The conductive loaded resin-based material of the present invention typically comprises a micron powder(s) of conductor particles and/or in combination of micron fiber(s) substantially homogenized within a base resin host. FIG. 2 shows cross section view of an example of conductor loaded resin-based material 32 having powder of conductor particles 34 in a base resin host 30. In this example the diameter D of the conductor particles 34 in the powder is between about 3 and 12 microns.

FIG. 3 shows a cross section view of an example of conductor loaded resin-based material 36 having conductor fibers 38 in a base resin host 30. The conductor fibers 38 have a diameter of between about 3 and 12 microns, typically in the range of 10 microns or between about 8 and 12 microns, and a length of between about 2 and 14 millimeters. The micron conductive fibers 38 may be metal fiber or metal plated fiber. Further, the metal plated fiber may be formed by plating metal onto a metal fiber or by plating metal onto a non-metal fiber. Exemplary metal fibers include, but are not limited to, stainless steel fiber, copper fiber, nickel fiber, silver fiber, aluminum fiber, nichrome fiber, or the like, or combinations thereof. Exemplary metal plating materials include, but are not limited to, copper, nickel, cobalt, silver, gold, palladium, platinum, ruthenium, rhodium, and nichrome, and alloys of thereof. Any platable fiber may be used as the core for a non-metal fiber. Exemplary non-metal fibers include, but are not limited to, carbon, graphite, polyester, basalt, man-made and naturally-occurring materials, and the like. In addition, superconductor metals, such as titanium, nickel, niobium, and zirconium, and alloys of titanium, nickel, niobium, and zirconium may also be used as micron conductive fibers and/or as metal plating onto fibers in the present invention.

These conductor particles and/or fibers are substantially homogenized within a base resin. As previously mentioned, the conductive loaded resin-based materials have a sheet resistance between about 5 and 25 ohms per square, though other values can be achieved by varying the doping parameters and/or resin selection. To realize this sheet resistance the weight of the conductor material comprises between about 20% and about 50% of the total weight of the conductive loaded resin-based material. More preferably, the weight of the conductive material comprises between about 20% and about 40% of the total weight of the conductive loaded resin-based material. More preferably yet, the weight of the conductive material comprises between about 25% and about 35% of the total weight of the conductive loaded resin-based material. Still more preferably yet, the weight of the conductive material comprises about 30% of the total weight of the conductive loaded resin-based material. Stainless Steel Fiber of 6-12 micron in diameter and lengths of 4-6 mm and comprising, by weight, about 30% of the total weight of the conductive loaded resin-based material will produce a very highly conductive parameter, efficient within any EMF, thermal, acoustic, or electronic spectrum. Referring now to FIG. 4, another preferred embodiment of the present invention is illustrated where the conductive materials comprise a combination of both conductive powders 34 and micron conductive fibers 38 substantially homogenized together within the resin base 30 during a molding process.

Referring now to FIGS. 5a and 5b, a preferred composition of the conductive loaded, resin-based material is illustrated. The conductive loaded resin-based material can be formed into fibers or textiles that are then woven or webbed into a conductive fabric. The conductive loaded resin-based material is formed in strands that can be woven as shown. FIG. 5a shows a conductive fabric 42 where the fibers are woven together in a two-dimensional weave 46 and 50 of fibers or textiles. FIG. 5b shows a conductive fabric 42′ where the fibers are formed in a webbed arrangement. In the webbed arrangement, one or more continuous strands of the conductive fiber are nested in a random fashion. The resulting conductive fabrics or textiles 42, see FIG. 5a, and 42′, see FIG. 5b, can be made very thin, thick, rigid, flexible or in solid form(s).

Similarly, a conductive, but cloth-like, material can be formed using woven or webbed micron stainless steel fibers, or other micron conductive fibers. These woven or webbed conductive cloths could also be sandwich laminated to one or more layers of materials such as Polyester(s), Teflon(s), Kevlar(s) or any other desired resin-based material(s). This conductive fabric may then be cut into desired shapes and sizes.

Motorcycle, marine, and racing components formed from conductive loaded resin-based materials can be formed or molded in a number of different ways including injection molding, extrusion, calendaring, or chemically induced molding or forming. FIG. 6a shows a simplified schematic diagram of an injection mold showing a lower portion 54 and upper portion 58 of the mold 50. Conductive loaded blended resin-based material is injected into the mold cavity 64 through an injection opening 60 and then the substantially homogenized conductive material cures by thermal reaction. The upper portion 58 and lower portion 54 of the mold are then separated or parted and the component is removed.

FIG. 6
b shows a simplified schematic diagram of an extruder 70 for forming motorcycle, marine, and racing components using extrusion. Conductive loaded resin-based material(s) is placed in the hopper 80 of the extrusion unit 74. A piston, screw, press or other means 78 is then used to force the thermally molten or a chemically induced curing conductive loaded resin-based material through an extrusion opening 82 which shapes the thermally molten curing or chemically induced cured conductive loaded resin-based material to the desired shape. The conductive loaded resin-based material is then fully cured by chemical reaction or thermal reaction to a hardened or pliable state and is ready for use. Thermoplastic or thermosetting resin-based materials and associated processes may be used in molding the conductive loaded resin-based articles of the present invention.

The advantages of the present invention may now be summarized. An effective motorcycle vehicle component is achieved. Effective marine, racing, and motorcycle vehicle components are achieved. Methods to form a motorcycle, marine, or racing vehicle components comprising conductive loaded resin-based material are achieved. The motorcycle, marine, or racing vehicle components are formed by a molding processes. A replacement for metal in motorcycle, marine, or racing vehicle components is achieved. The electric or thermal characteristics can be altered or the visual characteristics can be altered by forming a metal layer over the conductive loaded resin-based material.

As shown in the preferred embodiments, the novel methods and devices of the present invention provide an effective and manufacturable alternative to the prior art.

While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.

Number	Date	Country
60628807	Nov 2004	US
60630562	Nov 2004	US
60625822	Nov 2004	US

Low cost components for use in motorcycle, marine, and racing applications manufactured from conductive loaded resin-based materials

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