Low cost vehicle electrical and electronic components and systems manufactured from conductive loaded resin-based materials

• US 20050224280A1
• Filed: 06/08/2005
• Published: 10/13/2005
• Est. Priority Date: 02/15/2001
• Status: Active Grant

• Current Assignee: Integral Technologies, Inc. (Schneider Electric SE)
• Original Assignee: Integral Technologies, Inc. (Schneider Electric SE)
• Inventors: Aisenbrey, Thomas
• Granted Patent: US 7,726,440 B2
• Time in Patent Office: Days
• US Class Current: 181/148
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 45/0013 using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2031/3456 Antennas, e.g. radomes
• CPC Class Codes: H01B 1/22 the conductive material comprising metals or alloys
• CPC Class Codes: H01B 1/24 the conductive material comprising carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01Q 1/3291 mounted in or on other locations inside the vehicle or vehicle body
• CPC Class Codes: H01R 4/58 characterised by the form or material of the contacting members H01R4/01 takes precedence

Abstract

Vehicle electrical and electronic components are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are metals or conductive non-metals or metal plated non-metals. 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. Any platable fiber may be used as the core for a non-metal fiber. Superconductor metals may also be used as micron conductive fibers and/or as metal plating onto fibers in the present invention.

Claims

1. A vehicle electrical component device comprising a conductive loaded, resin-based material comprising conductive materials in a base resin host wherein the percent by weight of said conductive materials is between about 20% and about 50% of the total weight of said conductive loaded resin-based material.

2. The device according to claim 1 wherein the percent by weight of said conductive materials is between about 20% and about 40% of the total weight of said conductive loaded resin-based material.

3. The device according to claim 1 wherein said conductive materials comprise micron conductive fiber.

4. The device according to claim 2 wherein said conductive materials further comprise conductive powder.

5. The device according to claim 1 wherein said conductive materials are metal.

6. The device according to claim 1 wherein said conductive materials are non-conductive materials with metal plating.

7. The device according to claim 1 wherein said component is an enclosure for an electronic device.

8. The device according to claim 1 wherein said component is a signal wire wherein said conductive loaded resin-based material is the signal conductor.

9. The device according to claim 1 wherein said component is a heating element.

10. A vehicle electrical component device comprising a conductive loaded, resin-based material comprising conductive materials in a base resin host wherein the percent by weight of said conductive materials is between about 20% and about 40% of the total weight of said conductive loaded resin-based material.

11. The device according to claim 10 wherein said conductive materials are nickel plated carbon micron fiber, stainless steel micron fiber, copper micron fiber, silver micron fiber or combinations thereof.

12. The device according to claim 10 wherein said conductive materials comprise micron conductive fiber and conductive powder.

13. The device according to claim 12 wherein said conductive powder is nickel, copper, or silver.

14. The device according to claim 12 wherein said conductive powder is a non-metallic material with a metal plating.

15. The device according to claim 10 wherein said component is an electrical connector.

16. The device according to claim 10 wherein said component is an electrical fuse.

17. The device according to claim 10 wherein said component is an antenna.

18. The device according to claim 10 wherein said component is a heat sink or heat pipe.

19. A vehicle electrical component device comprising a conductive loaded, resin-based material comprising micron conductive fiber in a base resin host wherein the percent by weight of said micron conductive fiber is between about 20% and about 50% of the total weight of said conductive loaded resin-based material.

20. The device according to claim 19 wherein said micron conductive fiber is stainless steel.

21. The device according to claim 19 wherein said micron conductive fiber has a diameter of between about 3 μ

m and about 12 μ

m and a length of between about 2 mm and about 14 mm.

22. The device according to claim 19 wherein said component is an enclosure for an electronic device.

23. The device according to claim 19 wherein said component is a signal wire wherein said conductive loaded resin-based material is the signal conductor.

24. The device according to claim 19 wherein said component is a heating element.

25. The device according to claim 19 wherein said component is an antenna.