Conductive Mechanical Isolators

Abstract

The disclosed inventive concept provides a conductive mechanical isolator for providing an electrical path between parts of a vehicle so as to reduce the need for a grounding busbar. The conductive isolator disclosed herein includes: an inner shell; an outer shell; an elastomer disposed therebetween; and a conductor interconnecting the inner shell and the outer shell to create an electrical path therebetween. In one embodiment, the conductor is at least one conductive wire having opposite ends electrically coupled to the inner shell and the outer shell. In another embodiment, the elastomer may include a plurality of conductive particles distributed throughout the elastomer. In yet another embodiment, the elastomer may include at least one channel formed in the elastomer and extending between the inner shell and the outer shell to store a conductive liquid therein. The conductive liquid is contained between the shells and provides an electrical path therebetween.

Description

Technical Field

[0001] The disclosed inventive concepts relate to components such as vehicle components. More particularly, the disclosed inventive concepts relate to mechanical isolators. More particularly, the disclosed inventive concepts relate to conductive mechanical isolators for providing an electrical path between a support structure and a mechanically isolated electrical component. Background Art

[0002] In a vehicle's DC system, electrons flow in a single direction to create a complete electrical path. In doing so, the electrons flow out of one of the battery's terminals, through the vehicle's electrical system, including the ignition system, lights, dashboard, and any other electrically powered components, and back into the battery at the battery's other terminal.

[0003] To avoid using excessive amounts of wire to place electrical components in direct connection with the battery, the components can be placed in electrical connection with a supporting structure such as the chassis, frame or engine block of the vehicle, which is in electrical communication with the battery. Thus, the amount of wire used in the process of manufacturing the vehicle is approximately halved.

[0004] Typically, multiple ground straps, cables, or wires are used in the process of creating this electrical path between the electrical components and the support structure associated therewith. The ground straps are typically braided steel straps that lack any kind of isolation. However, over time, due to the constant movement and vibration of the engine and overall degradation, the ground straps can wear and break. This causes the electrical path to be broken and the performance of any electrical components connected thereto to be affected.

[0005] Common troubles caused by a defective or damaged ground bus include dead battery, hard starting, cylinder misfires, poor fuel economy and an illuminated Check Engine Light, in addition to other problems affecting the starter motor, alternator, ignition system, and more.

[0006] Additionally, the ground strap and its associated fasteners add weight to the vehicle, as well as its cost, while also complicating the manufacturing process itself, which increases the likelihood of electrical failure.

[0007] Attempts have been made to provide alternatives to using a ground strap while still providing a complete circuit between the electrical components and the battery. Such devices are disclosed in U.S. Patent Nos. 4,222,029 and 9,548,144 and U.S. Patent Application Publication Nos. 2010 / 0130037 and 2015 / 0083456. Each of the devices disclosed therein teaches utilizing various vibration isolators located between components of the vehicle in order to provide an electrical path between them.

[0008] Vibration isolators such as bushings, engine mounts, motor mounts, battery mounts and other electric modules that need to be grounded in electric vehicles and the like are placed between two metal objects to minimize the transmission of noise and small vibrations throughout the vehicle. Vibration isolators generally include inner and outer metal sleeves, tubes or shells with a flexible medium such as rubber or polyurethane placed between them. Thus, movement between two metal objects contacting the vibration isolators is minimized because the flexible medium absorbs kinetic energy transmitted therefrom and prevents the kinetic energy from being transferred to the rest of the vehicle.

[0009] However, the devices disclosed in the above references are generally difficult to understand and overly complex. Therefore, in view of the prior art, it may be advantageous to provide a simple and cost-effective electrically conductive mechanical isolator for creating an electrical path between an electrical component and a support structure.

[0010] As in many areas of vehicle technology, there is always room for improvement related to vibration isolators and devices used to create electrical paths between various components of a vehicle. Summary of the invention

[0011] The disclosed inventive concepts overcome the problems associated with known electrical conductors and isolators by providing an electrically conductive mechanical isolator. In addition to the weight and cost of the vehicle itself, the disclosed inventive concepts also provide the significant general advantage of not requiring a ground strap, thereby reducing the cost of manufacturing and servicing the vehicle.

[0012] Specifically, the disclosed inventive concept provides a conductive isolator including an inner shell, an outer shell, and an elastic body disposed therebetween. Preferably, the inner shell and the outer shell each have a long axis and are coaxially aligned with each other along their long axes.

[0013] In one embodiment, the conductor is an electrically conductive wire having opposite ends bonded to the inner housing and the outer housing. Thus, when the disclosed inventive concept is placed in place, such as between an electrical component and a vehicle support structure, an electrical path is created therebetween.

[0014] Preferably, the wire is coiled around and encircles the inner housing, wherein one end of the wire is electrically coupled to the inner housing and another end of the wire is electrically coupled to the outer housing.

[0015] Alternatively, the wire need not surround the inner housing and may be arranged in a coiled or non-coiled manner. The opposite ends of the wire are then attached to the inner housing and the outer housing by any suitable means to create an electrical path between them.

[0016] It should be understood that the wires may be partially or completely encapsulated in the elastomer. Alternatively, a region or space may be formed within the elastomer in which the wires are located.

[0017] Furthermore, the disclosed inventive concepts are not limited to utilizing a single conductor or wire. To this end, any number of wires, including a combination of both coiled wires and straight wires, may be employed to interconnect the inner housing and the outer housing. Doing so may increase the conductivity of the conductive isolator and the life of the conductive isolator.

[0018] In another embodiment, the elastomer itself can be used as a conductor, thereby eliminating the need for conductive wires. This embodiment is formed by providing a conductive elastomer by injecting conductive particles into the elastomer during manufacturing. Thus, the elastomer itself provides an electrical path between the inner housing and the outer housing.

[0019] In yet another embodiment, the disclosed inventive concept provides a conductive isolator comprising an elastomer disposed between an upper washer and a lower washer. Additionally, a conductor, such as a wire, extends within the elastomer to interconnect the upper washer and the lower washer at opposite ends of the conductor. Thus, an electrical path is created between the upper washer and the lower washer, similar to the electrical path discussed above with respect to the inner housing and the outer housing.

[0020] In yet another embodiment, the disclosed inventive concept provides a conductive isolator, comprising an inner housing, an outer housing, and an elastomer disposed therebetween. The elastomer has at least one through hole, the at least one through hole defining a channel or chamber formed therein, the channel or chamber extending between the inner housing and the outer housing. The conductive isolator further comprises a conductive liquid stored in the channel for creating an electrical path between the inner housing and the outer housing.

[0021] It should be appreciated that the elastomeric body may include any number of channels formed therein for increasing the amount of conductive liquid that may be stored between the inner housing and the outer housing.

[0022] The above advantages, in addition to other advantages and features, will also be apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] For a more complete understanding of the disclosed inventive concepts, reference should now be made to the embodiments illustrated in more detail in the accompanying drawings and described below by way of example of the disclosed inventive concepts, in which:

[0024] Figure 1 is an environmental view showing an electrically conductive mechanical isolator assembly located between a vehicle support structure and an engine according to the disclosed inventive concepts;

[0025] Figure 2 yes Figure 1A first side perspective view of a conductive isolator assembly including a bracket for mounting the conductive isolator to a vehicle support structure and an engine is shown in;

[0026] Figure 3 is with Figure 2 A second side perspective view of the conductive isolator assembly viewed opposite to the view of FIG.

[0027] Figure 4 yes Figure 1 A side view of a conductive isolator of the conductive isolator assembly;

[0028] Figure 5 yes Figure 1 A top view of a conductive isolator of the conductive isolator assembly;

[0029] Figure 6 is a perspective view of an electrically conductive mechanical isolator including a coiled conductive wire according to the disclosed inventive concepts;

[0030] Figure 7 is a bottom view of another embodiment of an electrically conductive mechanical isolator including a non-coiled electrically conductive wire according to the disclosed inventive concepts;

[0031] Figure 8 is a top view of yet another embodiment of an electrically conductive mechanical isolator including a pair of electrically conductive wires according to the disclosed inventive concepts;

[0032] Fig. 9 is a top view of yet another embodiment of a conductive mechanical isolator including a conductive elastomer according to the disclosed inventive concepts;

[0033] Fig.10 is a top view of yet another embodiment of an electrically conductive mechanical isolator including an electrically conductive liquid according to the disclosed inventive concepts;

[0034] Fig.11 is along Fig.10 A cross-sectional view of the conductive isolator taken along line 11-11;

[0035] Fig.12 is a perspective view of yet another embodiment of an electrically conductive mechanical isolator including a pair of washers according to the disclosed inventive concepts;

[0036] Fig.13 is along Fig.12 A cross-sectional view of the conductive isolator taken along line 13-13;

[0037] Fig.14 is an environmental view showing a conductive isolator located between a vehicle support structure and an electric vehicle battery; and

[0038] Fig.15is an environmental view showing a conductive isolator located between a vehicle support structure and an electric vehicle module. DETAILED DESCRIPTION

[0039] In the following figures, the same reference numerals will be used to represent the same components. In the following description, various operating parameters and components are described for different configurations of the embodiments. These specific parameters and components are included as examples and are not meant to be limiting.

[0040] According to the disclosed inventive concept and with reference to Figure 1 , an electrically conductive mechanical isolator assembly 10 is provided that is located between a vehicle support structure 12 and an engine 13 (or a motor if the vehicle is an electric vehicle or a hybrid vehicle). However, it should be understood that the disclosed inventive concepts are not limited to this particular location on a vehicle and may be relocated to any other suitable location where an electrical path may be required.

[0041] As described in more detail below, the conductive isolator assembly 10 has particular utility in providing an electrical path or continuity between an electrical component and a vehicle support structure 12. However, the conductive isolator assembly 10 is not limited to use in vehicles, and other uses requiring an electrical path are also within the scope of the disclosed inventive concepts.

[0042] like Figure 2 and Figure 3 , a conductive isolator assembly 10 is shown separated from a vehicle. The conductive isolator assembly 10 includes a conductive isolator 14, an engine attachment bracket 15, a first support bracket 16, and a second support bracket 17. The engine attachment bracket 15 surrounds an outer portion of the conductive isolator 14 and may be formed integrally therewith. The engine attachment bracket 15 is attached to an electrical component such as an engine 13 via a pair of mechanical fasteners such as a nut and stud arrangement. The first support bracket 16 includes a pair of spaced-apart attachment legs 18, 18'. The first support bracket 16 and the second support bracket 17 are also attached to the vehicle support structure 12 via a plurality of mechanical fasteners such as a nut and stud arrangement. It should be understood that the disclosed inventive concepts are not limited to use in conjunction with the specific brackets shown, but other suitable means for attaching the disclosed inventive concepts to a vehicle may also be utilized.

[0043] More specifically, if Figure 4 and Figure 5 As shown in FIG. 1 , the conductive isolator 14 includes an inner shell 19 , an outer shell 20 , and an elastic body 22 disposed therebetween. The engine attachment bracket 15 is shown to be integrally formed with the outer shell 20 .

[0044] In the following description, the conductive isolator 14 is shown as a bushing, which may also be referred to as a flexible mount or a vibration absorbing mount. However, it should be understood that the disclosed inventive concepts may be employed with any other suitable isolator mounts such as engine mounts, motor mounts, battery mounts, and any electric modules that need to be grounded in an electric vehicle.

[0045] The inner housing 19, also referred to as a "squeeze tube" in the bushing, protects the conductive isolator 14 from being crushed during use on a vehicle. The outer housing 20 acts as a sleeve for protecting the elastomer 22 from contact with surrounding components of the vehicle.

[0046] For reasons discussed below, the material used to make the inner housing 19 and the outer housing 20 is a conductive metal material. Therefore, the inner housing 19 and the outer housing 20 are made of any suitable material such as iron, steel (including stainless steel), copper, aluminum, chromate, nickel, etc. The inner housing 19 and the outer housing 20 both have a long axis. Preferably, the long axis of the inner housing 19 and the long axis of the outer housing 20 are coaxial with each other.

[0047] The elastomer 22 maintains the spacing between the inner housing 19 and the outer housing 20 while reducing the energy transmitted through the conductive isolator 14 during use. The elastomer 22 can be selected from any material with high resistivity, such as silicone, rubber, polyurethane, fluoropolymer, etc. Suitable rubbers include natural rubber, synthetic rubber, black rubber, butyl rubber, ethylene propylene diene monomer (EPDM) rubber, etc.

[0048] As mentioned above, the conductive isolator 14 herein is shown as a bushing or other flexible mounting for reducing vibration between vehicle components. To this end, it is desirable that the conductive isolator 14 can provide an electrical path between surrounding components so as to reduce the need for a grounding strap. Figure 6 As shown in , the conductive isolator 14 is shown without the brackets 15 , 16 , 17 , and further includes a conductor interconnecting the inner housing 19 and the outer housing 20 .

[0049] In one embodiment, the conductor is a conductive wire 24 and is shown by removing a portion of the outer housing 20. The conductive wire 24 is made of any conductive metal material such as iron, steel (including stainless steel), copper, aluminum, chromate, nickel, etc. The wire 24 can also be made of any combination thereof when the wire 24 is surface treated, coated or electroplated. For example, the material construction of the wire 24 can include: a copper structure surface treated with aluminum or chromate, a copper structure electroplated with nickel or electroless nickel, a stainless steel structure electroplated with nickel or electroless nickel, etc.

[0050] The conductive wire 24 includes a body 26 having a first end 28 and a second end 30. The first end 28 and the second end 30 of the wire 24 are respectively coupled to the inner housing 19 and the outer housing 20 by any suitable means such as welding, ultrasonic welding, crimping, or by using rivets, bolts, etc. As shown, the first end 28 of the wire 24 is coupled to the inner housing 19 at a first contact point 29, and the second end 30 of the wire 24 is coupled to the outer housing 20 at a second contact point 31.

[0051] However, it should be understood that the first end 28 and the second end 30 of the wire 24 can be coupled to the inner housing 19 or the outer housing 20 without limiting the scope of the disclosed inventive concept. In addition, the first end 28 and the second end 30 can be electrically coupled to any suitable position on the inner housing 19 and the outer housing 20.

[0052] In the process of electrically coupling the first end 28 and the second end 30 of the wire 24 to the conductive inner housing 19 and the outer housing 20, an electrical path is thereby created. Thus, the electrical path flows between an electrical component such as the engine 14 and a vehicle support structure 12 such as a chassis or frame. In doing so, it should be understood that the engine 14 is in direct or indirect contact with the outer housing 20, and the vehicle support structure 12 is in direct contact with the inner housing 19. Alternatively, the engine 14 and the vehicle support structure 12 may be rearranged so that the engine 14 contacts the inner housing 19 and the vehicle support structure 12 contacts the outer housing 20. It should be understood that the relationship between the various vehicle parts that form the complete electrical path is for exemplary purposes only, and any other desired components may be placed in contact with the inner housing 19 and the outer housing 20 to provide an electrical path therebetween.

[0053] like Figure 6 , the body 26 of the conductive wire 24 is repeatedly wrapped around and around the exterior of the inner housing 19 to provide a plurality of windings 32 formed therein. In this coiled configuration, the wire 24 surrounds the inner housing 19 and extends along at least a portion of its length. This allows the wire 24 to withstand vibrations present within the conductive isolator 14 during use by allowing the wire 24 to move in all three axes without restricting or interfering with the electrical path created.

[0054] As shown, each of the windings 32 has a substantially similar diameter. However, it should be understood that the diameter of one end of the winding 32 near the wire 24 may be larger than the diameter of the other end of the winding 32 near the wire 24 so as to be closer to the outer housing 20.

[0055] In another embodiment of the disclosed inventive concept, the conductive isolator 50 is Figure 7The conductive isolator 50 includes an inner shell 54, an outer shell 56, and an elastic body 58 disposed therebetween. It should be understood that the inner shell 54, the outer shell 56, and the elastic body 58 are the same as the similar components described above.

[0056] Similarly, the conductive isolator 50 includes a conductor, such as a conductive wire 60 having a body 62, a first end 64, and a second end 66. However, unlike the coiled body 26 of the wire 24 discussed above, the body 62 is an arcuate member without any windings formed therein. Moreover, the first end 64 and the second end 66 are electrically coupled to the inner housing 54 and the outer housing 56, respectively, in any suitable manner to create an electrical path therebetween.

[0057] The conductive wires 60 may be at least partially encapsulated in the elastomer 58, or a space or region 68 may be formed within the elastomer 58 and the wires 60 located therein. It should be understood that the region 68 may be provided in the elastomer of any of the embodiments discussed herein.

[0058] Additionally, the body 62 of the wire 60 is flexible and has sufficient slack between its first and second ends 64, 66 so that the first and second ends 64, 66 do not become separated from the inner and outer housings 54, 56 when the conductive isolator 50 is operated through its full range of motion.

[0059] In yet another embodiment of the disclosed inventive concept, the conductive isolator 80 is Figure 8 The conductive isolator 80 includes an inner shell 84, an outer shell 86, and an elastic body 88 disposed therebetween. It should be understood that the inner shell 84, the outer shell 86, and the elastic body 88 are the same as the similar components described above.

[0060] Similarly, the conductive isolator 80 includes a conductor, such as a conductive wire 90 having a body 92, a first end 94, and a second end 96. Here, the body 92 is coiled, similar to the wire 24 discussed above, and includes a plurality of windings 98 formed therein. However, the coiled body 92 does not wrap around the inner housing 19, but is located on one side of the inner housing 84.

[0061] As with the coiled wire 24 described above, the first end 94 and the second end 96 are electrically coupled between the inner housing 84 and the outer housing 86 in any suitable manner to create an electrical path therebetween. Additionally, the winding 98 allows the wire 90 to withstand movement of the conductive isolator 80 when in use and prevents the first end 94 and the second end 96 from becoming separated from the inner housing 84 and the outer housing 86.

[0062] It should be understood that the conductive isolator 80 herein may include any number of conductors or wires. As shown, the conductive isolator 80 includes a pair of conductive wires 90, 90' located on opposite sides of the inner housing 84. Each wire 90, 90' is individually connected to opposite ends 94, 96, 94', 96' of the inner housing 84 and the outer housing 86. This provides improved conductivity between the inner housing 84 and the outer housing 86, and further increases the life of the conductive isolator 80 by avoiding repair in the event of a possible failure of one of the wires 90, 90'.

[0063] Furthermore, each wire 90, 90' is shown positioned within a respective region 97, 97' formed in the elastomeric body 88. However, it should be understood that one or both of the wires 90, 90' may also be partially or fully enclosed therein.

[0064] In yet another embodiment of the disclosed inventive concept, the conductive isolator 110 is Fig. 9 The conductive isolator 110 includes an inner housing 114, an outer housing 116, and an elastic body 118 disposed therebetween. Here, instead of providing a conductor extending through the elastic body 118 as discussed in the above embodiments, the elastic body 118 itself is used as a conductor.

[0065] Conductive elastomers reduce or eliminate electromagnetic interference (EMI) and radio frequency interference (RFI) commonly associated with electronic devices. In the process of making conductive elastomers, conductive solid particles are finely distributed and evenly dispersed throughout the polymer or elastomeric material. Therefore, the conductivity of the elastomer extends as a property of the entire material of manufacture, rather than just surface conductivity or antistatic surface treatment.

[0066] The elastomer 118 is a conductive elastomer including a mixture of a base material and a conductive material. The conductive material includes a plurality of conductive particles 120, such as carbon, silver aluminum, silver glass, silver copper, nickel graphite, etc., or any combination thereof.

[0067] The volume percentage concentration of the conductive particles 120 in the conductive elastomer 18 is directly based on the type of base material used. In silicone elastomers, the preferred volume percentage of the conductive particles 120 is about 10% to about 25%, and more preferably about 15% to about 22%. In thermoplastic elastomers, the preferred volume percentage of the conductive particles 120 is about 5% to about 30%, and more preferably about 7% to about 25%. In polyurethane elastomers, the preferred volume percentage of the conductive particles 120 is about 5% to about 30%, and more preferably about 10% to about 25%. By utilizing the conductive elastomer 118, an electrical path is provided between the inner housing 114 and the outer housing 116 without the use of additional wires or other conductive elements.

[0068] In yet another embodiment of the disclosed invention, the conductive isolator 130 is Fig.10 and Fig.11 The conductive isolator 130 includes an inner shell 134, an outer shell 136, and an elastic body 138 disposed therebetween. The elastic body 138 includes at least one through hole formed therein, which defines a chamber or channel 140A extending between the inner shell 134 and the outer shell 136.

[0069] The conductive isolator 130 further includes a conductive liquid 142 stored within the channel 140A for providing an electrical path between the inner housing 134 and the outer housing 136. When the sides of the elastomer are compressed against the inner and outer housings 136, the conductive liquid 142 is retained within the channel 140A.

[0070] The conductive liquid may include any suitable liquid metal such as mercury, or a water-based slurry mixed with conductive particles or powders such as silver, copper, gold, aluminum, brass, nickel, iron, bronze, Inconel, molybdenum, molybdenum carbide, monel, steel (including stainless steel), etc., or any combination thereof. Alternatively, a base liquid such as a mineral liquid, a silicone liquid, an ester liquid, a petroleum hydrocarbon liquid, a synthetic hydrocarbon liquid, a phenyl ether, a polyethylene glycol, a polydimethyl silicone fluid, a polydimethylsiloxane polymer, a fluorosilicone liquid, a polyalphaolefin, a diester, a ball ester, an alkyl naphthalene, an alkyl benzene, a polyoxyalkylene glycol, a polyphenylene ether, a dialkyl diphenyl ether, a castor oil liquid, etc., or any combination thereof, may be used in place of water. The base liquid or water is used to fully distribute the conductive particles throughout the conductive liquid 142.

[0071] It should be understood that any number of channels may be formed within the elastomer 138 to increase the amount of conductive liquid 142 that can be stored therein. Fig.10 As shown in FIG. 1 , a pair of channels 140A, 140B are shown.

[0072] from Fig.11 In the cross-sectional side view shown in FIG. 1 , a plurality of channels 140A-F are shown and formed within the elastomeric body 138 at any suitable location along its length. Although the channels 140A-F are shown as being generally horizontal, it should be understood that the channels 140A-F may extend at any suitable angle between the inner housing 134 and the outer housing 136. In addition, the channels 140A-F are not limited to being parallel to each other. Therefore, each of the channels 140A-F may be oriented in any suitable manner without being relative to the other channels 140A-F.

[0073] In yet another embodiment, Figures 12 to 15As shown in , the disclosed inventive concept provides a conductive isolator 160, which includes an elastomer 162 disposed between an upper plate or upper gasket 164 and a lower plate or lower gasket 166. The elastomer 162 is the same as the elastomer described in the above embodiments, and therefore, can be made of silicone, rubber, polyurethane, fluoropolymer, etc.

[0074] It should be understood that the washers 164, 166 are used to replace the housings 18, 20 disclosed in the above embodiments. However, the washers 164, 166 still serve as the opposite ends of the electrical path. Therefore, the washers 164, 166 are formed of conductive metal materials such as iron, steel (including stainless steel), copper, aluminum, chromate, nickel, etc. The washers 164, 166 can be bonded to the opposite ends of the elastomer 162 by any suitable means, such as by using an adhesive, epoxy resin, silicone resin compound, etc.

[0075] As shown, a channel 168 is formed that extends completely through the washers 164, 166 and the elastomer 162. As discussed below, the channel 168 facilitates mounting the conductive isolator 160 to the electric component and the vehicle support structure using any suitable means, such as fasteners.

[0076] The conductive isolator 160 further includes at least one conductor 170, such as a spring, having a first end 172 and a second end 174. The conductor 170 extends through the elastomeric body 162 so as to interconnect the washers 164, 166 at their opposite ends 172, 174. This creates an electrical path between the washers 164, 166 for grounding the electrical component. As discussed above, and in Fig.13 As shown in , the conductor 170 may optionally include at least one winding formed in its body to define a coil. This allows the conductor 170 to withstand movement between the washers 164, 166 and prevents its ends 172, 174 from being separated from the washers 164, 166.

[0077] like Fig.13 As shown in FIG, the conductive isolator 160 includes a pair of conductors 170, 170' disposed within regions 176, 176' respectively formed within the elastomer 162. Utilizing more than one conductor increases the conduction between the washers 164, 166 and further improves the life of the conductive isolator 160 in the event of a possible failure of one of the conductors 170, 170'.

[0078] As described above, the disclosed inventive concepts may be utilized in any suitable location on a vehicle to provide an electrical path between an electrical component and a vehicle support structure and to facilitate grounding of the electrical component. Fig.14As shown in FIG, a plurality of conductive isolators 160 are located between a vehicle support structure 178 and an electric vehicle battery 180 for absorbing vibrations and grounding the battery 180. The conductive isolators 160 are mounted to the battery 180 and the vehicle support structure 178 by any suitable means such as mounting brackets 182 and fastener arrangements that engage channels 164 formed in the conductive isolators 160.

[0079] Similarly, if Fig.15 As shown in , a plurality of conductive isolators 160 are located and mounted between a vehicle support structure 178 and a vehicle module 184 for absorbing vibrations and grounding the module 184. Such vehicle modules may include an electronic / engine control module (ECM), a powertrain control module (PCM), a transmission control module (TCM), a brake control module (BCM), a central control module (CCM), a central timing module (CTM), a general electronic module (GEM), a body control module (BCM), a suspension control module (SCM), etc. It should be understood that the use and location of the disclosed inventive concepts shown herein are not limiting, and a person of ordinary skill in the art will understand other suitable uses.

[0080] From the foregoing it will be appreciated that defined herein is a new and unique electrically conductive mechanical isolator for providing an electrical path between various parts of a vehicle.

[0081] One skilled in the art will readily recognize from the discussion as well as from the drawings and claims that various changes, modifications and other variations may be made to the present invention without departing from the spirit and fair scope of the disclosed inventive concept as defined by the following claims.

[0082] According to the present invention, a conductive isolator used in a vehicle to provide electrical continuity between an electrical component and a supporting structure is provided with: an inner shell, the inner shell being attached to one of the component or the structure; an outer shell, the outer shell being attached to the other of the component or the structure; an elastomer between the shells; and a conductor, one end of the conductor being attached to one of the shells and the other end being attached to the other of the shells.

[0083] According to one embodiment, the inner housing and the outer housing are manufactured from a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

[0084] According to one embodiment, the elastomer is made of a material selected from the group consisting of: silicone, rubber, polyurethane and fluoropolymer.

[0085] According to one embodiment, the conductor is an electrically conductive wire made of a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate and nickel.

[0086] According to one embodiment, the conductor is an electrically conductive wire having a body, a first end and a second end, the first end being electrically coupled to the inner housing and the second end being electrically coupled to the outer housing.

[0087] According to one embodiment, the body of the electrically conductive wire comprises a plurality of windings defining a coil.

[0088] According to one embodiment, the above invention is further characterized in that the plurality of windings surround the inner housing.

[0089] According to one embodiment, the conductor comprises a pair of conductive wires, each conductive wire interconnecting the inner housing and the outer housing at opposite ends of the conductive wires.

[0090] According to one embodiment, the inner housing has a major axis and the outer housing has a major axis, the major axis of the inner housing being coaxial with the major axis of the outer housing.

[0091] According to one embodiment, the conductive isolator is selected from the group consisting of a flexible bushing and an engine mount.

[0092] According to the present invention, a conductive isolator used in a vehicle to provide electrical continuity between an electrical component and a supporting structure is provided with: an inner shell, the inner shell being attached to one of the component or the structure; an outer shell, the outer shell being attached to the other of the component or the structure; and an elastomer between the shells, the elastomer being a conductive elastomer including a base material and a conductive material.

[0093] According to one embodiment, the inner housing and the outer housing are manufactured from a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

[0094] According to one embodiment, the above invention is further characterized in that the base material is selected from the group consisting of: silicone, rubber, polyurethane and fluoropolymer elastomer.

[0095] According to one embodiment, the above invention is further characterized in that the conductive material is selected from the group consisting of: carbon, silver aluminum, silver glass, silver copper and nickel graphite.

[0096] According to one embodiment, the conductive isolator is a flexible bushing.

[0097] According to one embodiment, the conductive isolator is an engine mount.

[0098] According to the present invention, a conductive isolator used in a vehicle to provide electrical continuity between an electrical component and a supporting structure, the isolator being provided with: an inner shell attached to one of the component or the structure; an outer shell attached to the other of the component or the structure; an elastomer between the shells, the elastomer having at least one channel formed between the shells; and a conductive liquid disposed in the at least one channel.

[0099] According to one embodiment, the elastomeric body comprises a plurality of channels, each of the plurality of channels extending between the inner shell and the outer shell.

[0100] According to one embodiment, the conductive liquid is a water-based slurry mixed with conductive particles selected from the group consisting of: silver, copper, gold, aluminum, brass, nickel, iron, bronze, Inconel, molybdenum, molybdenum carbide, monel, and stainless steel.

[0101] According to one embodiment, the above invention is further characterized in that the inner shell and the outer shell are made of a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate and nickel.

[0102] Reference numerals list

[0103] 10 Conductive isolator assembly

[0104] 12 Support structure

[0105] 13 Engine

[0106] 14 Conductive Isolator

[0107] 15 Engine attachment bracket

[0108] 16 First support bracket

[0109] 17 Second support bracket

[0110] 18 Attachment foot for first support bracket

[0111] 18' Attachment feet for first support bracket

[0112] 19 Inner shell

[0113] 20 External housing

[0114] 22 Elastomer

[0115] 24 Conductive thread

[0116] 26 Main body of conductor

[0117] 28 First end of conductor

[0118] 29 First point of contact

[0119] 30 Second end of conductor

[0120] 31 Second contact point

[0121] 32 Conductor windings in the body

[0122] 50 Conductive isolator (second embodiment)

[0123] 54 Inner shell

[0124] 56 External housing

[0125] 58 Elastomer

[0126] 60 Conductive thread

[0127] 62 Conductor body

[0128] 64 First end of conductor

[0129] 66 Second end of conductor

[0130] 68 Area

[0131] 80 Conductive isolator (third embodiment)

[0132] 84 Inner shell

[0133] 86 External housing

[0134] 88 Elastomer

[0135] 90 Conductive Thread

[0136] 90' Conductive Cord

[0137] 92 Conductor body

[0138] 94 First end of conductor

[0139] 94' First end of conductor

[0140] 96 Second end of conductor

[0141] 96' Second end of conductor

[0142] 97 Area

[0143] 97' Area

[0144] 98 Windings in the body of the conductor

[0145] 110 Conductive Isolator (Fourth Embodiment)

[0146] 114 Inner shell

[0147] 116 External housing

[0148] 118 Elastomer

[0149] 120 Conductive particles

[0150] 130 Conductive Isolator (Fifth Embodiment)

[0151] 134 Inner shell

[0152] 136 External housing

[0153] 138 Elastomer

[0154] 140A Channel

[0155] 140B Channel

[0156] 140C Channel

[0157] 140D Channel

[0158] 140E Channel

[0159] 140F Channel

[0160] 142 Conductive liquid

[0161] 160 Conductive Isolator (Sixth Embodiment)

[0162] 162 Elastomer

[0163] 164 Upper washer

[0164] 166 Lower washer

[0165] 168 channels

[0166] 170 Conductor

[0167] 170' conductor

[0168] 172 First end of conductor

[0169] 174 Second end of conductor

[0170] 176 Area

[0171] 176' Area

[0172] 178 Support structure

[0173] 180 Batteries

[0174] 182 Battery mounting bracket

[0175] 184 modules

[0176] 186 Module Mounting Bracket

Claims

1. A conductive isolator for use in a vehicle to provide electrical continuity between an electrical component and a supporting structure, the isolator comprising: a hollow inner housing attached to one of the electrical component or the support structure; an external housing attached to the other of the electrical component or the support structure; an elastomer between the shells, wherein the outer shell serves as a sleeve for protecting the elastomer from contact with surrounding components of the vehicle; as well as A conductor having one end attached to one of the housings and another end attached to the other of the housings.

2. The conductive isolator of claim 1, wherein the inner housing and the outer housing are fabricated from a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

3. The conductive isolator of claim 1, wherein the elastomer is made of a material selected from the group consisting of silicone, rubber, polyurethane, and fluoropolymer.

4. The conductive isolator of claim 1, wherein the conductor is a conductive wire made of a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

5. The conductive isolator of claim 1, wherein the conductor is an electrically conductive wire having a body, a first end, and a second end, the first end being electrically coupled to the inner housing, and the second end being electrically coupled to the outer housing.

6. The conductive isolator of claim 5, wherein the body of the conductive wire includes a plurality of windings defining a coil.

7. The conductive isolator of claim 6, wherein the plurality of windings surround the inner housing.

8. The conductive isolator of claim 1, wherein the conductor comprises a pair of conductive wires, each conductive wire interconnecting the inner housing and the outer housing at opposite ends of the conductive wires.

9. A conductive isolator for use in a vehicle to provide electrical continuity between an electrical component and a supporting structure, the isolator comprising: a hollow inner housing attached to one of the electrical component or the support structure; an external housing attached to the other of the electrical component or the support structure; as well as The elastic body between the shells is a conductive elastic body including a base material and a conductive material, wherein the outer shell serves as a sleeve for protecting the elastic body from contact with surrounding parts of the vehicle.

10. The conductive isolator of claim 9, wherein the inner housing and the outer housing are fabricated from a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

11. The conductive isolator of claim 9, wherein the base material is selected from the group consisting of silicone, rubber, polyurethane, and fluoropolymer elastomer.

12. The conductive isolator of claim 9, wherein the conductive material is selected from the group consisting of carbon, silver aluminum, silver glass, silver copper, and nickel graphite.

13. An electrically conductive isolator for use in a vehicle to provide electrical continuity between an electrical component and a supporting structure, the isolator comprising: a hollow inner housing attached to one of the electrical component or the support structure; an external housing attached to the other of the electrical component or the support structure; an elastic body between the shells, the elastic body having a plurality of channels formed between the shells, each of the plurality of channels extending between the inner shell and the outer shell; as well as a conductive liquid disposed in each of the plurality of channels, The positions of the inner shell and the outer shell relative to each other are maintained in a relatively fixed position during use, wherein the elastomer absorbs movement energy and vibration between the inner shell and the outer shell.

14. The conductive isolator of claim 13, wherein the inner shell and the outer shell are made of a material selected from the group consisting of: iron, steel, stainless steel, copper, aluminum, chromate, and nickel.

15. The conductive isolator of claim 13, wherein the conductive liquid is a water-based slurry mixed with conductive particles selected from the group consisting of: silver, copper, gold, aluminum, brass, nickel, iron, bronze, Inconel, molybdenum, molybdenum carbide, monel, and stainless steel.

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