Conductive Polymer Vehicle Component Using Carbon Nanotube Fillers

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Solution Overview

Problem

Polymeric compositions face challenges in achieving a desirable combination of stiffness, strength, and electrical conductivity, which are essential for vehicle components, leading to increased weight and complexity in wiring harnesses due to the need for metallic grounding.

Innovation Solution

A vehicle component comprising a polymeric material with a carbon-containing filler and carbon nanotubes extending from a substrate, which provides improved electrical conductivity and structural integrity, reducing the weight and complexity of wiring harnesses by allowing for more efficient grounding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If polymeric materials are used to replace metal components, then weight is reduced and corrosion resistance is improved, but electrical conductivity and structural strength deteriorate

Engineering Contradiction:

Improvevehicle component weightVSAvoidelectrical conductivity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent employs a composite material system consisting of polymeric matrix combined with conductive fillers (carbon black, graphite, carbon fiber, and/or metal particles). This composite structure allows the polymer to maintain its lightweight and corrosion-resistant properties while the conductive fillers provide the necessary electrical conductivity for vehicle grounding applications.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes parameter changes by adjusting the concentration, size, shape, and distribution of conductive fillers within the polymeric matrix. By varying these parameters, the material achieves optimal balance between electrical conductivity, mechanical strength, and weight reduction, enabling the polymer to replace metal components effectively.

Inventive Principle:

Principle #35Parameter changes

2Weight of moving object

If polymeric materials are used to replace metal components, then weight is reduced and corrosion resistance is improved, but structural strength deteriorates

Engineering Contradiction:

Improvevehicle component weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The composite structure combines the polymeric matrix with reinforcing fillers (carbon fiber, graphite, or metal particles) that provide structural strength. The synergistic interaction between the polymer matrix and filler particles creates a material that maintains both lightweight properties and adequate mechanical strength for vehicle components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent adjusts parameters such as filler concentration, particle size distribution, and aspect ratio to optimize structural strength. By controlling these parameters, the composite material achieves the necessary mechanical properties to replace metal components while maintaining weight reduction benefits.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional polymeric compositions are used, then manufacturing simplicity is maintained, but electrical conductivity and structural properties cannot achieve desirable combination

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcombination of electrical conductivity and structural properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs composite materials that can be processed using conventional polymer manufacturing techniques such as injection molding, extrusion, and compression molding. The conductive fillers are incorporated into the polymer matrix during standard manufacturing processes, maintaining ease of manufacture while achieving the desired combination of electrical conductivity and structural properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes parameters including filler loading concentration, particle size distribution, and processing conditions to achieve the desired property combination. By carefully controlling these parameters, the material attains both electrical conductivity and structural integrity without requiring complex or specialized manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution decreases the overall weight and manufacturing costs of vehicles while enhancing fuel efficiency by improving electrical conductivity and structural properties, allowing for shorter grounding wires and simplified wiring harnesses.

Implementation Method 1

The carbon nanotubes extend from a surface of the substrate... The first filler and the second filler interconnect with one another to provide conductive pathways within the polymeric material

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS11661493B2Electrically conductive, polymeric vehicle component

Publication Date: 2023.05.30 FORD GLOBAL TECH LLC

AI summary

A vehicle component includes a polymeric material, a first filler, and a second filler. The polymeric material can be present at a concentration of at least about 35% by weight of the vehicle component. The first filler can be a carbon-containing filler dispersed within the polymeric material. The carbon-containing filler can be present at a concentration of at least about 20% by weight of the vehicle component. The second filler includes a substrate and carbon nanotubes. The carbon nanotubes extend from a surface of the substrate.