U.S. patent application number 11/496098 was filed with the patent office on 2006-12-21 for sporting equipment manufactured from conductively doped resin-based materials.
Invention is credited to Thomas Aisenbrey.
Application Number | 20060287126 11/496098 |
Document ID | / |
Family ID | 37574126 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060287126 |
Kind Code |
A1 |
Aisenbrey; Thomas |
December 21, 2006 |
Sporting equipment manufactured from conductively doped resin-based
materials
Abstract
A sporting equipment device (10) includes an operator handle
(15) and a striking surface (12) operatively coupled to the
operator handle wherein the striking surface includes a
conductively doped, resin-based material including micron
conductive fiber in a base resin host. In addition, in one example,
the operator handle (15) includes a conductively doped, resin-based
material. In addition, in another example, a sporting equipment
device (140) includes a structure (142) adapted to covering at
least a part of a human body wherein the structure (142) includes
conductively doped resin-based material. In addition, in another
example, a sporting equipment device (180) includes a sheet (182)
of conductively doped resin-based material having a top surface
(185) and a bottom surface (187) wherein the top surface (185) is
adapted to support an operator and wherein the bottom surface (187)
is adapted for sliding.
Inventors: |
Aisenbrey; Thomas;
(Littleton, CO) |
Correspondence
Address: |
DOUGLAS SCHNABELL MICHIGAN
316 HART STREET
ESSEXVILLE
MI
48732
US
|
Family ID: |
37574126 |
Appl. No.: |
11/496098 |
Filed: |
July 29, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10877092 |
Jun 25, 2004 |
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11496098 |
Jul 29, 2006 |
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10309429 |
Dec 4, 2002 |
6870516 |
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10877092 |
Jun 25, 2004 |
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10075778 |
Feb 14, 2002 |
6741221 |
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10309429 |
Dec 4, 2002 |
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60704036 |
Jul 29, 2005 |
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60317808 |
Sep 7, 2001 |
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60269414 |
Feb 16, 2001 |
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60268822 |
Feb 15, 2001 |
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Current U.S.
Class: |
473/316 ; 2/425;
473/324; 473/349; 473/524 |
Current CPC
Class: |
A63B 2071/1208 20130101;
A63B 2209/02 20130101; A63B 67/14 20130101; A63B 2102/24 20151001;
A63B 2209/023 20130101; A01K 87/00 20130101; A63B 53/047 20130101;
A63B 59/70 20151001; A63B 60/002 20200801; A63B 2071/105 20130101;
A63B 60/08 20151001; A63B 69/02 20130101; A63B 49/08 20130101; A63B
53/0466 20130101; A63B 71/12 20130101; C08L 101/12 20130101; B29C
70/882 20130101; A63B 60/06 20151001; A63B 53/10 20130101; A63B
2225/50 20130101; A63B 2053/0491 20130101; A63B 2243/007 20130101;
A63B 59/50 20151001; A63B 49/02 20130101; B29L 2031/5227 20130101;
H01Q 1/276 20130101; A63B 2209/026 20130101; A63B 2102/065
20151001; A63B 2102/02 20151001; B29C 70/58 20130101; A63B 49/10
20130101; A63B 71/10 20130101; A63B 53/0487 20130101; A63B 60/10
20151001; A63B 2102/18 20151001; F41B 13/02 20130101; A63B 53/0416
20200801 |
Class at
Publication: |
473/316 ;
473/324; 473/349; 473/524; 002/425 |
International
Class: |
A63B 53/12 20060101
A63B053/12; A63B 53/00 20060101 A63B053/00; A63B 71/10 20060101
A63B071/10; A63B 49/02 20060101 A63B049/02 |
Claims
1. A sporting equipment device comprising: an operator handle; and
a striking surface operatively coupled to the operator handle
wherein the striking surface comprises a conductively doped,
resin-based material comprising micron conductive fiber in a base
resin host.
2. The device according to claim 1 wherein the percent by weight of
the micron conductive fiber is between about 20% and about 50% of
the total weight of the conductively doped resin-based
material.
3. The device according to claim 1 wherein the conductively doped,
resin-based material further comprises conductive powder.
4. The device according to claim 1 wherein the micron conductive
fiber is metal.
5. The device according to claim 1 wherein the micron conductive
fiber is a non-metal material with metal plating.
6. The device according to claim 1 wherein the micron conductive
fiber is metal plated carbon micron fiber, stainless steel micron
fiber, copper micron fiber, silver micron fiber or combinations
thereof.
7. The device according to claim 1 further comprising a metal layer
overlying the conductively doped resin-based material.
8. The device according to claim 1 wherein the operator handle
comprises the conductively doped resin-based material.
9. A sporting equipment device comprising: an operator handle
wherein the operator handle comprises a conductively doped,
resin-based material comprising micron conductive fiber in a base
resin host; and a striking surface operatively coupled to the
operator handle.
10. The device according to claim 9 wherein the percent by weight
of the micron conductive fiber is between about 20% and about 50%
of the total weight of the conductively doped resin-based
material.
11. The device according to claim 9 wherein the conductively doped,
resin-based material further comprises conductive powder.
12. The device according to claim 9 wherein the micron conductive
fiber is metal.
13. The device according to claim 9 wherein the micron conductive
fiber is a non-metal material with metal plating.
14. The device according to claim 9 further comprising a metal
layer overlying the conductively doped resin-based material.
15. The device according to claim 9 wherein the conductive
materials are metal plated carbon micron fiber, stainless steel
micron fiber, copper micron fiber, silver micron fiber or
combinations thereof.
16. A sporting equipment device comprising a structure adapted to
covering at least a part of a human body wherein the structure
comprises conductively doped resin-based material comprising micron
conductive fiber in a base resin host.
17. The device according to claim 16 wherein the percent by weight
of the micron conductive fiber is between about 20% and about 50%
of the total weight of the conductively doped resin-based
material.
18. The device according to claim 16 wherein the conductively
doped, resin-based material further comprises conductive
powder.
19. The device according to claim 16 wherein the micron conductive
fiber is metal.
20. The device according to claim 16 wherein the micron conductive
fiber is a non-metal material with metal plating.
21. The device according to claim 16 further comprising a metal
layer overlying the conductively doped resin-based material.
22. The device according to claim 16 wherein the conductive
materials are metal plated carbon micron fiber, stainless steel
micron fiber, copper micron fiber, silver micron fiber or
combinations thereof.
23. The device according to claim 16 wherein the part of the human
body is the human head.
24. The device according to claim 16 further comprising an antenna
comprising the conductively doped resin-based material and
operatively coupled to the structure.
25. A sporting equipment device comprising a sheet of conductively
doped resin-based material comprising micron conductive fiber in a
base resin host and having a top surface and a bottom surface
wherein the top surface is adapted to support an operator and
wherein the bottom surface is adapted for sliding.
26. The device according to claim 25 wherein the percent by weight
of the micron conductive fiber is between about 20% and about 50%
of the total weight of the conductively doped resin-based
material.
27. The device according to claim 25 wherein the micron conductive
fiber is metal.
28. The device according to claim 25 wherein the micron conductive
fiber is a non-metal material with metal plating.
29. The device according to claim 25 further comprising a metal
layer overlying the conductively doped resin-based material.
30. The device according to claim 25 wherein the conductive
materials are metal plated carbon micron fiber, stainless steel
micron fiber, copper micron fiber, silver micron fiber or
combinations thereof.
31. The device according to claim 25 further comprising at least
one wheel operatively coupled to the sheet.
32. A sporting equipment device comprising: an operator handle
wherein the operator handle comprises a plurality of continuous
strands of micron conductive fiber molded into a resin-based
material; and a striking surface operatively coupled to the
operator handle.
33. The device according to claim 34 wherein the micron conductive
fiber is metal.
34. The device according to claim 34 wherein the micron conductive
fiber is a non-metal material with metal plating.
35. The device according to claim 34 wherein the plurality of
continuous strands of micron conductive fiber are webbed or woven
together.
36. The device according to claim 34 wherein the plurality of
continuous strands of micron conductive fiber are oriented in the
longitudinal direction of the operator handle.
37. The device according to claim 34 wherein the operator handle
further comprises a core portion wherein the plurality of
continuous strands of micron conductive fiber surround the core
portion.
38. The device according to claim 34 wherein the operator handle
further comprises a second plurality of continuous strands of
micron conductive fiber surrounding the plurality of continuous
strands of micron conductive fiber molded into a resin-based
material.
Description
RELATED PATENT APPLICATIONS
[0001] This Patent Application claims priority to the U.S.
Provisional Patent Application 60/704,036, filed on Jul. 29, 2005,
which is herein incorporated by reference in its entirety.
[0002] This Patent Application is a Continuation-in-Part of
INT01-002CIPC, filed as U.S. patent application Ser. No.
10/877,092, filed on Jun. 25, 2004, which is a Continuation of
INT01-002CIP, filed as U.S. patent application Ser. No. 10/309,429,
filed on Dec. 4, 2002, now issued as U.S. Pat. No. 6,870,516, also
incorporated by reference in its entirety, which is a
Continuation-in-Part application of docket number INT01-002, filed
as U.S. patent application Ser. No. 10/075,778, filed on Feb. 14,
2002, now issued as U.S. Pat. No. 6,741,221, which claimed priority
to U.S. Provisional Patent Applications Ser. No. 60/317,808, filed
on Sep. 7, 2001, Ser. No. 60/269,414, filed on Feb. 16, 2001, and
Ser. No. 60/268,822, filed on Feb. 15, 2001, all of which are
incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0003] This invention relates to articles for use in sporting and
recreational activities and, more particularly, to sporting
equipment articles molded of conductively doped 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).
BACKGROUND OF THE INVENTION
[0004] By way of example, modern golf clubs are carefully designed
to provide maximum performance. For example, when a golf club head
comes in contact with a golf ball, the face of the club is designed
to flex inward and spring back in what is known as a "trampoline
effect". The trampoline effect helps to propel the ball great
distances. The club face may be manufactured from an expensive and
exotic material, such as titanium, that exhibits the desired reflex
action. Likewise, golf club shafts are designed to flex such that
the golfer's swing speed is increased via whipping action. Shaft
materials and dimensions are carefully chosen to achieve a whipping
action that is predictable and controlled. Similarly, other sports
striking equipment, such as baseball bats, hockey sticks, and
tennis racquets, use selected materials to reduce weight and to
improve impact response. However, it is difficult to tune optimum
frequency response with materials typically used.
[0005] Protection equipment, such as helmets, face masks, shields,
and fencing lame, and is also carefully designed to provide player
protection while minimizing weight. For example, typical protection
equipment is manufactured from rigid plastics. While these plastic
materials may provide protection, the materials typically do not
provide a tunable response to impacts. As a result, the ability of
the materials to protect against concussive injury may not be
optimized. In addition, since most plastics exhibit high intrinsic
resistivity, protection equipment is typically non-conductive. It
is difficult, therefore, the integrated devices, such as antennas
and sensors, in typical protection devices.
[0006] Sporting boards, such as snow boards, surf boards, skate
boards, and skis, are also designed to meet stringent performance
requirements. For example, typical boards are manufactured from
fiberglass composites. While fiberglass composites may provide high
strength, these materials typically do not provide a tunable
flexing response. As a result, the ability of the materials to
provide optimum performance is limited.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention and the corresponding advantages and
features provided thereby will be best understood and appreciated
upon review of the following detailed description of the invention,
taken in conjunction with the following drawings, where like
numerals represent like elements, in which:
[0008] FIG. 1 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0009] FIG. 2 illustrates a conductively doped resin-based material
wherein the conductive materials comprise a micron conductive
powder(s).
[0010] FIG. 3 illustrates a conductively doped resin-based material
wherein the conductive materials comprise micron conductive
fiber(s).
[0011] FIG. 4 illustrates a conductively doped resin-based material
wherein the conductive materials comprise both micron conductive
powder(s) and micron conductive fiber(s).
[0012] FIGS. 5a and 5b illustrate conductive fabric-like materials
formed from the conductively doped resin-based material using woven
and webbed construction, respectively.
[0013] FIGS. 6a and 6b illustrate, in simplified schematic form, an
injection molding apparatus and an extrusion molding apparatus that
may be used to mold circuit conductors of a conductively doped
resin-based material.
[0014] FIG. 7 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0015] FIG. 8 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0016] FIG. 9 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0017] FIG. 10 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0018] FIG. 11 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0019] FIG. 12 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0020] FIG. 13 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0021] FIG. 14 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0022] FIG. 15 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0023] FIG. 16 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0024] FIG. 17 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0025] FIG. 18 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0026] FIG. 19 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0027] FIG. 20 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0028] FIG. 21 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0029] FIGS. 22-24 illustrate one example of a part of a sporting
equipment device and method of manufacture depicting one embodiment
of the invention.
[0030] FIG. 25 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
[0031] FIG. 26 illustrates one example of a sporting equipment
device depicting one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Briefly, a sporting equipment device includes an operator
handle and a striking surface operatively coupled to the operator
handle wherein the striking surface includes a conductively doped,
resin-based material including micron conductive fiber in a base
resin host. In addition, in one example, the operator handle
includes a conductively doped, resin-based material. In addition,
in another example, a sporting equipment device includes a
structure adapted to covering at least a part of a human body
wherein the structure includes conductively doped resin-based
material. In addition, in another example, a sporting equipment
device includes a sheet of conductively doped resin-based material
having a top surface and a bottom surface wherein the top surface
is adapted to support an operator and wherein the bottom surface is
adapted for sliding. In addition, in another example, a sporting
equipment device includes an operator handle wherein the operator
handle comprises continuous strands of micron conductive fiber
molded into a resin-based material and a striking surface
operatively coupled to the operator handle.
[0033] As such, a sporting equipment device is disclosed with
excellent performance including tunable frequency response, low
cost of manufacture, durability, and low weight. In addition,
antenna devices or conductive sensing may be integrated into the
device due to the conductivity of the conductively doped
resin-based material. Other advantages will be recognized by one of
ordinary skill in the art.
[0034] The conductively doped resin-based materials can be molded,
extruded or the like to provide almost any desired shape or size.
The molded conductively doped 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,
electrical, and acoustical continuity and /or conductivity
characteristics of articles or parts fabricated using conductively
doped resin-based materials depend on the composition of the
conductively doped resin-based materials. The type of base resin,
the type of doping material, and the relative percentage of doping
material incorporated into the base resin can be adjusted to
achieve the desired structural, electrical, or other physical
characteristics of the molded material. The selected materials used
to fabricate the articles or devices are substantially homogenized
together using molding techniques and or methods such as injection
molding, over-molding, insert molding, compression 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 molecular polymer physics associated within
the conductive networks within the molded part(s) or formed
material(s).
[0035] In the conductively doped resin-based material, electrons
travel from point to point, 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 doping concentration and material
makeup, that is, the separation between the conductive doping
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.
[0036] 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 conductively
doped resin-based material are altered when molded into a
structure. A substantially homogenized conductive microstructure of
delocalized valance electrons is created within the valance and
conduction bands of the molecules. 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.
[0037] Conductively doped resin-based materials lower the cost of
materials and of the design and manufacturing processes needed for
fabrication of molded articles while maintaining close
manufacturing tolerances. The molded articles can be manufactured
into infinite shapes and sizes using conventional forming methods
such as injection molding, over-molding, compression molding,
thermoset molding, or extrusion, calendaring, or the like. The
conductively doped resin-based materials, when molded, typically
but not exclusively produce a desirable usable range of resistivity
of less than about 5 to more than about 25 ohms per square, but
other resistivity values can be achieved by varying the dopant(s),
the doping parameters and/or the base resin selection(s).
[0038] The conductively doped 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, electrical, thermal, and acoustical performing, close
tolerance manufactured part or circuit. The resulting molded
article comprises a three dimensional, continuous capillary network
of conductive doping particles contained and or bonding within the
polymer matrix. Exemplary micron conductive powders include
carbons, graphites, amines, eeonomers, 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 conductively doped
resin-based material. The addition of conductive powder to the
micron conductive fiber doping may improve the electrical
continuity on the surface of the molded part to offset any skinning
effect that occurs during molding.
[0039] 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, melamine, 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.
[0040] 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, conductive or non-conductive
powders are leached into the fibers prior to extrusion. In other
embodiments, 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: chemically inert coupling agents; gas plasma treatment;
anodizing; mercerization; peroxide treatment; benzoylation; or
other chemical or polymer treatments.
[0041] Chemically inert coupling agents are materials that are
molecularly bonded onto the surface of metal and or other fibers to
provide surface coupling, mechanical interlocking, inter-diffusion
and adsorption and surface reaction for later bonding and wetting
within the resin-based material. This chemically inert coupling
agent does not react with the resin-based material. An exemplary
chemically inert coupling agent is silane. In a silane treatment,
silicon-based molecules from the silane bond to the surface of
metal fibers to form a silicon layer. The silicon layer bonds well
with the subsequently extruded resin-based material yet does not
react with the resin-based material. As an additional feature
during a silane treatment, oxane bonds with any water molecules on
the fiber surface to thereby eliminate water from the fiber
strands. Silane, amino, and silane-amino are three exemplary
pre-extrusion treatments for forming chemically inert coupling
agents on the fiber.
[0042] In a gas plasma treatment, the surfaces of the metal fibers
are etched at atomic depths to re-engineer the surface. Cold
temperature gas plasma sources, such as oxygen and ammonia, are
useful for performing a surface etch prior to extrusion. In one
embodiment of the present invention, gas plasma treatment is first
performed to etch the surfaces of the fiber strands. A silane bath
coating is then performed to form a chemically inert silicon-based
film onto the fiber strands. In another embodiment, metal fiber is
anodized to form a metal oxide over the fiber. The fiber
modification processes described herein are useful for improving
interfacial adhesion, improving wetting during homogenization,
and/or reducing oxide growth (when compared to non-treated fiber).
Pretreatment fiber modification also reduces levels of particle
dust, fines, and fiber release during subsequent capsule
sectioning, cutting or vacuum line feeding.
[0043] The resin-based structural material may be any polymer resin
or combination of compatible polymer resins. Non-conductive resins
or inherently conductive resins may be used as the structural
material. Conjugated polymer resins, one example being
polythiophene, may be used as the structural material. Complex
polymer resins, examples being polyimide and polyamide, may be used
as the structural material. 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 conductively doped 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, ionomer, 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.
[0044] The resin-based structural material doped 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 to create desired
shapes and sizes. The molded conductively doped resin-based
materials can also be stamped, cut or milled as desired to form
create the desired shapes and form factor(s). The doping
composition and directionality associated with the micron
conductors within the doped base resins can affect the electrical
and structural characteristics of the articles 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.
[0045] 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 articles that could be embedded in a person's
clothing as well as 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.
[0046] The conductively doped resin-based material may also be
formed into a prepreg laminate, cloth, or webbing. A laminate,
cloth, or webbing of the conductively doped resin-based material is
first homogenized with a resin-based material. In various
embodiments, the conductively doped 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-Lip is performed by
laminating the conductively doped resin-based prepreg over a
honeycomb structure. In another embodiment, the honeycomb structure
is made from conductively doped, resin-based material. In yet
another embodiment, a wet prepreg is formed by spraying, dipping,
or coating the conductively doped resin-based material laminate,
cloth, or webbing in high temperature capable paint.
[0047] Prior art carbon fiber and resin-based composites are found
to display unpredictable points of failure. In carbon fiber systems
there is little if any elongation of the structure. By comparison,
in the present invention, the conductively doped resin-based
material, even if formed with carbon fiber or metal plated carbon
fiber, displays greater strength of the mechanical structure due to
the substantial homogenization of the fiber created by the moldable
capsules. As a result a structure formed of the conductively doped
resin-based material of the present invention will maintain
structurally even if crushed while a comparable carbon fiber
composite will break into pieces.
[0048] The conductively doped 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 dopants and base resins that are resistant to
corrosion and/or metal electrolysis. For example, if a
corrosion/electrolysis resistant base resin is combined with
fibers/powders or in combination of such as stainless steel fiber,
inert chemical treated coupling agent warding against corrosive
fibers such as copper, silver and gold and or carbon
fibers/powders, then corrosion and/or metal electrolysis resistant
conductively doped resin-based material is achieved. Another
additional and important feature of the present invention is that
the conductively doped 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 applications as described herein.
[0049] 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 transforms a 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 within a base resin.
[0050] As an additional and important feature of the present
invention, the molded conductor doped resin-based material exhibits
excellent thermal dissipation characteristics. Therefore, articles
manufactured from the molded conductor doped 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 an article of
the present invention.
[0051] As a significant advantage of the present invention,
articles constructed of the conductively doped resin-based material
can be easily interfaced to an electrical circuit or grounded. In
one embodiment, a wire can be attached to conductively doped
resin-based articles via a screw that is fastened to the article.
For example, a simple sheet-metal type, self tapping screw can,
when fastened to the material, can achieve excellent electrical
connectivity via the conductive matrix of the conductively doped
resin-based material. To facilitate this approach a boss may be
molded as part of the conductively doped 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 is embedded into the conductively doped resin-based
material. In another embodiment, the conductively doped 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
article and a grounding wire.
[0052] Where a metal layer is formed over the surface of the
conductively doped 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 conductively doped resin-based
material article or to otherwise alter performance properties.
Well-known techniques, such as electroless metal plating, electro
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 conductively doped,
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.
[0053] A typical metal deposition process for forming a metal layer
onto the conductively doped resin-based material is vacuum
metallization. Vacuum metallization is the process where a metal
layer, such as aluminum, is deposited on the conductively doped
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
conductively doped resin-based material of the present invention
facilitates the use of extremely efficient, electrostatic painting
techniques.
[0054] The conductively doped resin-based materials can be
contacted in any of several ways. In one embodiment, a pin is
embedded into the conductively doped 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 conductively doped resin-based material
conductive matrix. In another embodiment, a hole is formed in to
the conductively doped 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 conductively doped resin-based material. In this
case, a hole is formed in the conductively doped 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 soldered.
[0055] Another method to provide connectivity to the conductively
doped 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
conductively doped 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 conductively doped
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.
[0056] A ferromagnetic conductively doped 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 substantially
homogenized with the base resin. Ferrite materials and/or rare
earth magnetic materials are added as a conductive doping to the
base resin. With the substantially homogeneous mixing of the
ferromagnetic micron conductive fibers and/or micron conductive
powders, the ferromagnetic conductively doped resin-based material
is able to produce an excellent low cost, low weight, high aspect
ratio magnetize-able item. The magnets and magnetic devices of the
present invention can be magnetized during or after the molding
process. Adjusting the doping levels and or dopants of
ferromagnetic micron conductive fibers and/or ferromagnetic micron
conductive powders that are homogenized within the base resin can
control the magnetic strength of the magnets and magnetic devices.
By increasing the aspect ratio of the ferromagnetic doping, the
strength of the magnet or magnetic devices can be substantially
increased. The substantially homogenous mixing of the conductive
fibers/powders or in combinations there of allows for a substantial
amount of dopants to be added to the base resin without causing the
structural integrity of the item to decline mechanically. The
ferromagnetic conductively doped resin-based magnets display
outstanding physical properties of the base resin, including
flexibility, moldability, strength, and resistance to environmental
corrosion, along with superior magnetic ability. In addition, the
unique ferromagnetic conductively doped resin-based material
facilitates formation of items that exhibit superior thermal and
electrical conductivity as well as magnetism.
[0057] 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 fibers/powders or
combinations there of in a 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 conductively doped 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 conductively doped
resin-based material during the molding process.
[0058] The ferromagnetic conductively doped 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 or
powders. 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 doping may be combined with a
non-ferromagnetic conductive doping to form a conductively doped
resin-based material that combines excellent conductive qualities
with magnetic capabilities.
[0059] FIG. 1 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A golf club
driver 5 is shown. The golf club driver 5 includes an operator
handle 15 and a striking surface 10 attached to the operator handle
15. The striking surface 10, or club head, may include several
parts including a face 12, a hosel 14, a sole 18, and a back 16. In
one example, the back 16 and sole 18 support the face 12 while the
hosel 14 connects to the operator handle 15, or shaft. In various
embodiments, any, any combination, or all of the face 12, hosel 14,
sole 18, and the back 16 of the golf club driver head 10 may be
formed of the conductively doped resin-based material. For example,
the entire golf club head 10 may be formed of the conductively
doped resin-based material by, for example, injection molding.
[0060] Typical golf club driver head construction utilizes a face
formed of titanium or other specialty metal attached to a two-piece
body comprising the sole and back. The hosel is typically formed
along with the sole and back sections and allows the head to attach
to a shaft. When the face of the club comes in contact with the
golf ball it flexes inward and springs back in what is known as
"the trampoline effect". This effect helps to propel the ball
greater distances than traditional wooden clubs. The grooves on the
face of the club help to give the ball the desired backspin for
aerodynamic stability in flight. In the past few years there has
been a trend of increasing the size of the club heads. The larger
sized heads give the average golfer a bigger striking face that
tends to be more forgiving with misaligned or improperly struck
golf balls.
[0061] In one embodiment of the present invention, the face 12 is
molded of the conductively doped resin-based material and inserted
into interior grooves, not shown, formed in the back 16 and sole 18
that are formed of metal. The face 12 is attached to the grooves by
gluing, ultrasonic welding, chemical solvent, or the like. In
another embodiment, the face 12 may be metal plated and/or metal
coated for appearance. The conductively doped resin-based face 12
is preferably formed with a percent conductive loading, by weight,
such that the "trampoline effect" of the face 12 matches the
compression and subsequent expansion of the ball upon impact. By
matching the compression and expansion of the face 12 with the
compression and expansion of the ball, a greater energy potential
is realized and more distance is achieved. In another embodiment,
the face 12 is not metal plated and/or metal coated.
[0062] The use of the conductively doped, resin-based material of
the present invention allows the creation of a striking face 12
having an exceptionally large "sweet spot". The resonant frequency
response of the conductively doped, resin-based material can be
easily tuned by adjusting the percentage doping of conductive
material and/or type of base resin. For example, while the Rockwell
hardness of a sheet grade type 316 stainless steel is in the range
of about 95 HRB, micron conductive fiber grade stainless steel
should exhibit a hardness of about 70 HRB or less. When combined
with the resin-based host, the conductively doped, resin-based
material is tuned to provide a resonant frequency "trampoline"
response optimized to deliver maximum energy to the ball impact,
excellent surface durability, and to minimize energy vibration in
club shaft.
[0063] In another embodiment, the entire golf club driver head 10
is formed of the conductively doped resin-based material of the
present invention. In this embodiment, the back 16 and the sole 18
are molded to allow weighted inserts into the hollow perimeter of
the club head 10. The weighted inserts are insertion molded or
over-molded into the interior of the club head 10. The conductively
doped resin-based face 12 is inserted into place and the sections
are joined by gluing, ultrasonic welding, chemical solvent, or the
like. The conductively doped resin-based club head 10 is then metal
plated and/or metal coated. The inserts give the conductively doped
resin-based club head 10 enough mass to effectively transfer the
needed energy to the golf ball. In another embodiment, the
conductively doped resin-based club head 10 is painted. The
conductive characteristic of the conductively doped resin-based
material is particularly useful for electrostatic painting. In yet
another embodiment, the conductively doped resin-based club head 10
is formed with coloring agents or dyes in the resin matrix to allow
for the desired appearance after manufacturing.
[0064] In another embodiment, the golf club shaft 15 comprises the
conductively doped resin-based material of the present invention.
Typical golf club shaft construction utilizes various metals or
graphite. A mechanical advantage is gained by having a larger
amount of flex in the shaft for a weaker player or a player with a
slow swing due to the whipping action of the stick. When a player
has a stronger faster swing however, the whipping action of the
club is not as desirable due to the amount of precision and control
that is lost.
[0065] In one embodiment of the present invention, the shaft 15 may
be molded entirely of the conductively doped resin-based material
of the present invention. In another embodiment, the shaft 15 may
be molded with a hollow center core to allow a rod of metal or some
other material to be inserted for added weight and/or added
rigidity. The shaft 15 may be formed to the desired shape with a
percent conductive loading, by weight, such that the amount of flex
in the handle corresponds to the intended players' strength and
speed of swing. In one embodiment, the golf club shaft 15 may be
formed of the conductively doped resin-based material of the
present invention and then metal plated and/or metal coated. In
another embodiment, the golf club shaft 15 may be formed of the
conductively doped resin-based material of the present invention
with a coloring or dye added to the resin matrix to achieve the
desired appearance after the manufacturing process.
[0066] FIG. 7 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A golf club iron
head 100 is shown. In golf, "irons" are used for short to middle
distance shots and are called irons because of the traditional
material used in their manufacture. The iron head 20 comprises the
conductively doped resin-based material of the present invention.
In the embodiment, any component or several components, of the iron
head 100 comprises the conductively doped resin-based material of
the present invention. In various embodiments, the face, not shown,
hosel 102, sole 104, and/or the back 103 of the golf club iron head
100 may be formed of the conductively doped resin-based
material.
[0067] Typical golf club iron head construction utilizes a forged
or molded metal design that allows most of the weight of the club
to be dispersed around the edge. The weight along the perimeter
helps to keep the club from twisting or turning when striking the
ball slightly off center. The grooves on the face of the club help
to give the ball the desired backspin for aerodynamic stability in
flight.
[0068] In one embodiment of the present invention, the golf club
iron head 100 may be formed by over-molding the conductively doped
resin-based material onto a metal weight, not shown, that is
encased within the perimeter of the club head 100. The golf club
iron head 20 may then be metal plated and/or metal coated. In
another embodiment, the golf club iron head 100 may be formed in
two sections where the back 103 and sole 104 are one piece and the
face is the other. A metal weight may then be inserted before
joining the sections together by gluing, ultrasonic welding,
chemical solvent, or the like. The golf club iron head I 00 may
then be metal plated and/or metal coated.
[0069] The use of the conductively doped, resin-based material of
the present invention allows the creation of an iron 100 having an
exceptionally large "sweet spot". The resonant frequency response
of the conductively doped, resin-based material can be easily tuned
by adjusting the percentage doping of conductive material and/or
type of base resin. When combined with the resin-based host, the
conductively doped, resin-based material is tuned to provide a
resonant frequency "trampoline" response optimized to deliver
maximum energy to the ball impact, excellent surface durability,
and to minimize energy vibration in the club shaft.
[0070] In another embodiment of the present invention, a putter
head is formed of the conductively doped resin-based material of
the present invention. In one embodiment, the putter head is molded
and then metal plated and/or metal coated for appearance. In
another embodiment, the putter head is molded with a coloring or
dye in the resin matrix to allow for the desired appearance after
the manufacturing process.
[0071] FIG. 8 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A baseball bat
105 is shown. The baseball bat 105 includes an operator handle 106
attached a striking surface 108, or barrel. Typically a baseball
bat is formed of hardwood such as hickory or a metal such as
aluminum. The typical aluminum baseball bat utilizes the
"trampoline effect" much like the golf club drivers mentioned
earlier. In one embodiment, a hollow bat structure 105, including
both operator handle 106 and striking surface 108, is molded of the
conductively doped resin-based material of the present invention in
the desired length and diameter. The conductively doped resin-based
baseball bat 105 is preferably formed to the desired thickness with
a percent conductive loading, by weight, such that the "trampoline
effect" of the baseball bat 105 matches the compression and
subsequent expansion of the baseball upon impact. The use of the
conductively doped, resin-based material of the present invention
allows the creation of a bat 105 having an exceptionally large
"sweet spot". The resonant frequency response of the conductively
doped, resin-based material can be easily tuned by adjusting the
percentage doping of conductive material and/or type of base resin.
When combined with the resin-based host, the conductively doped,
resin-based material is tuned to provide a resonant frequency
"trampoline" response optimized to deliver maximum energy to the
ball impact, excellent surface durability, and to minimize energy
vibration in bat handle.
[0072] The interior of a hollow bat 105 may be filled with filler
such as metal in order to simulate the approximate weight and feel
of a wooden baseball bat and plugged at the end. In one embodiment,
the conductively doped resin-based baseball bat 105 may be metal
plated and/or metal coated. In another embodiment, the conductively
doped resin-based baseball bat 105 may be formed with a coloring or
dye in the resin matrix in order to achieve the desired appearance
after manufacturing.
[0073] FIG. 9 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A hockey stick
110 is shown. The hockey stick 110 includes an operator handle 18
attached to a striking surface 114, or blade. Typical hockey stick
construction utilizes a wood, such as aspen, graphite, or a layered
composite of wood and fiberglass. The size and construction of the
hockey stick determines the amount of flex that it is capable of. A
mechanical advantage is gained by having a large amount of flex in
the handle for a younger weaker player due to the whipping action
of the stick. When a player matures and is able to swing the hockey
stick at greater speeds the whipping action is desired less due to
the amount of precision and control that is lost.
[0074] In one embodiment of the present invention, the hockey stick
110, including operator handle 118 and striking surface 114, is
molded of the conductively doped resin-based material as a
one-piece unit. In another embodiment, the operator handle 118 and
striking surface 114 are molded separately of the conductively
doped resin-based material to allow the striking surface 114 to be
changed when it starts to show signs of wear. The conductively
doped resin-based hockey stick 110 is preferably formed to the
desired thickness with a percent conductive loading, by weight,
such that the amount of flex in the operator handle 118 corresponds
to the intended players' strength and speed of swing. In another
embodiment, the operator handle 118 for the conductively doped
resin-based hockey stick is designed with a hollow center channel
to allow for different weights and/or materials to be inserted and
control the feel and flex of the hockey stick 110. The use of the
conductively doped, resin-based material of the present invention
allows the creation of a hockey stick 110 having exceptional
performance. The resonant frequency response of the conductively
doped, resin-based material can be easily tuned by adjusting the
percentage doping of conductive material and/or type of base resin.
When combined with the resin-based host, the conductively doped,
resin-based material is tuned to provide a resonant frequency
"trampoline" response optimized to deliver maximum energy to the
puck impact, excellent surface durability, and to minimize energy
vibration in operator handle 118.
[0075] FIG. 10 illustrates one example of a sport equipment device
depicting one embodiment of the invention. A tennis racquet 120 is
shown. The tennis racquet 120 includes an operator handle 128
attached to a striking surface 124 and 126. The striking surface
124 and 126 may further include a head frame 124 attached to the
operator handle 128 and a string grid 126 attached to the head
frame 124. Traditional tennis racquets were formed of wood and have
been gradually replaced with steel, fiberglass, titanium, aluminum,
or graphite. The evolution of the tennis racquet has been driven by
the desire to keep the head frame and handle as light weight and
stiff as possible.
[0076] In one embodiment of the present invention, the operator
handle 128 and head frame 124 of the tennis racquet 120 are molded
of the conductively doped resin-based material of the present
invention. The molded racquet may then be metal plated and/or metal
coated. In another embodiment, the tennis racquet 120 is molded of
the conductively doped resin-based material with a coloring or dye
in the resin matrix to allow the desired appearance after the
manufacturing process. The conductively doped resin-based tennis
racquet 120 is preferably formed to the desired shape with a
percent conductive loading, by weight, such that the flex of the
frame and handle is kept to a minimal amount. The choice of the
base resin is selected from any number of resins capable of
providing the tensile strength needed for the tennis racquet 120.
In one embodiment, the string grid 126 may be formed of the
conductively doped resin-based material by, for example, extrusion
of a continuous string that is strung into the head frame 124.
[0077] FIG. 11 illustrates one example of a sports equipment device
depicting one embodiment of the invention. A racquetball racquet
130 is shown. The racquetball racquet 130 includes an operator
handle 1 38 attached to a striking surface 134 and 136. The
striking surface 134 and 136 may further include a head frame 134
attached to the operator handle 138 and a string grid 136 attached
to the head frame 134. Traditional racquetball racquets were formed
of wood and have been gradually replaced with steel, fiberglass,
titanium, aluminum, or graphite. The evolution of the racquetball
racquet has been driven by the desire to keep the head frame and
handle as light weight and stiff as possible.
[0078] In one embodiment of the present invention, the operator
handle 138 and head frame 134 of the racquetball racquet 130 are
molded of the conductively doped resin-based material of the
present invention. The molded racquet may then be metal plated
and/or metal coated. In another embodiment, the racquetball racquet
120 is molded of the conductively doped resin-based material with a
coloring or dye in the resin matrix to allow the desired appearance
after the manufacturing process. The conductively doped resin-based
tennis racquet 130 is preferably formed to the desired shape with a
percent conductive loading, by weight, such that the flex of the
frame and handle is kept to a minimal amount. The choice of the
base resin is selected from any number of resins capable of
providing the tensile strength needed for the tennis racquet 130.
In one embodiment, the string grid 136 may be formed of the
conductively doped resin-based material by, for example, extrusion
of a continuous string that is strung into the head frame 134.
[0079] FIG. 12 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. An electronic
fencing foil 140 includes an operator handle 147 attached to a
striking surface 142 and 144. The electric fencing foil 140 may
include a striking surface including a tip 142 and a blade 144 and
an operator handle including a handle 147, a bell guard 148, and an
electrical connector 146. In various embodiments, any, any
combination, or all of these components may be formed of the
conductively doped resin-based material of the present
invention.
[0080] In fencing competitions an electronic scoring system is
utilized. For the electronic scoring system to work each fencer
wears a metallic vest or (lame) that covers the target area and a
mask made of a metal wire mesh. The foil has a tip with an
integrated electronic button at the end. A set of wires runs down
the center of the blade and terminates at the connectors on the
underside of the bell guard. A wire electronically connects the
foil and the lame to a reel that retracts and expands with each
fencer as they move. The reel is connected electronically to a
scoring machine with a set of lights for scoring.
[0081] In one embodiment of the present invention, the tip 142 for
the electric fencing foil 140 is formed with electrical contact
points molded of the conductively doped resin-based material of the
present invention. Typical tips used in electric foils are
manufactured with electrical contact points made of metal. However,
in one embodiment of the present invention, the tip 142 is formed
of the conductively doped resin-based material. The tip 142 may
then be metal plated and/or metal coated.
[0082] In one embodiment, the blade 144 may be formed of the
conductively doped resin-based material of the present invention.
Typical electric fencing foil construction utilizes a blade that is
forged from special alloy steel that incorporates iron, nickel, and
titanium. However, in the embodiment of the present invention, the
blade 144 formed of the conductively doped resin-based material may
be formed to the desired shape with a percent conductive loading,
by weight, such that the amount of flex is similar to the flex of a
metal forged blade. In one embodiment, the blade 144 may be molded
of the conductively doped resin-based material of the present
invention. The molded blade 144 may then be metal plated and/or
metal coated. In another embodiment, the blade 144 may be molded of
the conductively doped resin-based material with a coloring or dye
in the resin matrix to give the desired appearance after the
manufacturing process.
[0083] In one embodiment, the electrical connector 146 may be
molded from the conductively doped resin-based material of the
present invention. Typical electrical contact points for connectors
are formed of metal. However, in one embodiment of the present
invention, the connector 146 may be molded from the conductively
doped resin-based material. The molded connector 146 may then be
metal plated and/or metal coated. In another embodiment, the
connector 146 may be molded of the conductively doped resin-based
material and not metal plated and/or metal coated. The bell guard
148 and the handle 147 may be formed of a non-conductive
resin-based material.
[0084] FIG. 13 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A football helmet
140 is shown. The football helmet 150 includes a structure 152
adapted to covering at least a part of a human body wherein the
structure 152 comprises conductively doped resin-based material
comprising micron conductive fiber in a base resin host. The
football helmet 150 may include the structure 152, or body, and a
face mask 154. In various embodiments, the helmet body 152 or the
face guard 154 or both may be formed of the conductively doped
resin-based material of the present invention.
[0085] In one embodiment, the helmet body 152 may be molded from
the conductively doped resin-based material of the present
invention. The helmet body 152 may be formed to the desired shape
with a percent conductive loading, by weight, to allow high
strength rigid protection to the players head. In another
embodiment, the conductively doped resin-based helmet body 152
further includes an antenna 156 for an integrated wireless
transmitter/receiver unit, not shown. A wide variety of antenna
structures are easily formed of the conductively doped resin-based
material of the present invention. Monopole, dipole, geometric
shapes, 2D, 3D, 4D, 5D, isotropic structures, planar, inverted F,
PIFA, and the like, are all within the scope of the present
invention. The antenna 156 design can be molded by, for example,
injection molding. The molded antenna shape determines the resonant
frequency response of the antenna.
[0086] FIG. 14 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A baseball
batting helmet 160 is shown. The baseball helmet 150 includes a
structure 160 adapted to covering at least a part of a human body
wherein the structure 160 comprises conductively doped resin-based
material comprising micron conductive fiber in a base resin host.
The helmet 160 formed of the conductively doped resin-based
material is preferably formed to the desired shape with a percent
conductive loading, by weight, to allow high strength rigid
protection to the players head.
[0087] FIG. 15 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. Shoulder pads 170
are shown. The shoulder pads 170 include a structure 160 adapted to
covering at least a part of a human body wherein the structure 160
comprises conductively doped resin-based material comprising micron
conductive fiber in a base resin host. The shoulder pads 170 are of
a type useful for playing American football or hockey. In the
embodiment, any component or several components of the shoulder
pads 170 comprise the conductively doped resin-based material of
the present invention. The shoulder pads 170 may further include a
chest pad 172, a cloth pad 178, a lower pad 176, and/or a top pad
174. In various embodiments, the chest pad 172, cloth pad 178,
lower pad 176, and/or the top pad 174 for the shoulder pads 170 may
be formed of the conductively doped resin-based material.
[0088] FIG. 16 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. An electronic
fencing mask 180 is shown. The fencing mask 180 includes a
structure 160 adapted to covering at least a part of a human body
wherein the structure 160, or shroud, comprises conductively doped
resin-based material comprising micron conductive fiber in a base
resin host. The electronic fencing mask 180 may further include a
mesh 182.
[0089] Typical electronic fencing mask construction utilizes
stainless steel mesh capable of withstanding a 12 Kg punch test.
The conductivity of the mesh is necessary as is the conductivity of
the shroud that covers the front of the neck for electronic sabre
fencing. When fencing with electronic foils, the shroud for the
neck does not require it to be conductive since the only score-able
hit is to the body area that is covered by the conductive lame.
[0090] In one embodiment of the present invention, the mesh 182 is
molded of the conductively doped resin-based material of the
present invention. The mesh 182 for the electronic fencing mask 230
formed of the conductively doped resin-based material is preferably
formed to the desired shape with a percent conductive loading, by
weight, such that the mesh 182 is rigid enough to withstand the 12
Kg punch test. In another embodiment, the mesh 182 is formed of the
conductively doped resin-based material and then metal plated
and/or metal coated. In another embodiment, the mesh 182 is formed
of the conductively doped resin-based material with a coloring or
dye in the resin matrix to allow for the desired appearance after
the manufacturing process.
[0091] In one embodiment, the fencing mask 180 further includes an
electrical connector 183 that may be formed of the conductively
doped resin-based material and then may be metal plated and/or
metal coated. In another embodiment, the electrical connector 183
is formed of the conductively doped resin-based material and not
metal plated and/or metal coated.
[0092] FIG. 17 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. An electronic
fencing lame 190 is shown. The electronic fencing lame 190 includes
a structure 190 adapted to covering at least a part of a human body
wherein the structure 190 comprises conductively doped resin-based
material comprising micron conductive fiber in a base resin
host.
[0093] Typical electronic fencing lame construction utilizes an
outer conductive fabric layer that is woven from stainless steel
fibers. The fencing lame of this requires regular hand washing in
order to clean the fabric of salt crystals left behind from dried
sweat that can cause the break down of the metal fibers. However,
in one embodiment of the present invention, the outer layer for the
electronic fencing lame 190 is formed from a fabric comprising the
conductively doped resin-based material. In this embodiment the
conductively doped resin-based material is extruded into a fine
thread and then woven into a cloth like fabric. In one embodiment,
the outer layer for the lame 190 is formed of the conductively
doped resin-based material and then may be metal plated and/or
metal coated. In another embodiment, the outer layer for the lame
190 is formed of the conductively doped resin-based material with a
coloring or dye in the resin to allow for the desired appearance
after the manufacturing process.
[0094] In one embodiment, the lame further includes an electrical
connector 192 that may be formed of the conductively doped
resin-based material and then may be metal plated and/or metal
coated. In another embodiment, the electrical connector 192 is
formed of the conductively doped resin-based material and not metal
plated and/or metal coated.
[0095] FIG. 18 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A snowboard 200
is shown. The snowboard 200 includes a sheet 202 of conductively
doped resin-based material comprising micron conductive fiber in a
base resin host and having a top surface 205 and a bottom surface
207. The top surface 205 is adapted to support an operator. The
bottom surface 207 is adapted for sliding. The top surface 205 may
include bindings 204 adapted to couple to operator boots, not
shown. In various embodiments, the sheet 202, or board platform, or
the bindings 204, or both, for the snowboard 200 are formed of the
conductively doped resin-based material. The snowboard 200 formed
of the conductively doped resin-based material is preferably formed
to the desired shape with a percent conductive loading, by weight,
to allow the flexibility desired to maneuver down the hill. The
choice of the base resin is selected from any number of resins
capable of providing the tensile strength needed for the snowboard
200.
[0096] In one embodiment of the present invention, the board
platform 202 is molded with an outer layer of a non-conductive
resin-based material by for example co-extrusion. The outer layer
resin-based material is chosen from any number of resins that will
provide the bottom 207 of the snowboard 200 with an extremely
non-porous slippery surface. In another embodiment, the board
platform 202 is formed entirely of the conductively doped
resin-based material without an additional outer layer.
[0097] FIG. 19 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A skateboard 210
is shown. The skateboard 210 includes a sheet 212, or board
platform, of conductively doped resin-based material comprising
micron conductive fiber in a base resin host and having a top
surface 215 and a bottom surface 217. The top surface 215 is
adapted to support an operator. The bottom surface 217 includes
wheels 218. In various embodiments, the board platform 212 or the
wheels 218, or both, for the skateboard 210 are formed of the
conductively doped resin-based material. The skateboard 210 formed
of the conductively doped resin-based material is preferably formed
to the desired shape with a percent conductive loading, by weight,
to allow the flexibility desired to maneuver. The choice of the
base resin is selected from any number of resins capable of
providing the tensile strength needed for the skateboard 210.
[0098] FIG. 20 illustrates one example of sporting equipment
devices depicting one embodiment of the invention. Snow skis 220
and ski poles 230 are shown. The snow skis 220 includes a sheet 222
of conductively doped resin-based material comprising micron
conductive fiber in a base resin host and having a top surface 225
and a bottom surface 227. The top surface 22 is adapted to support
an operator. The bottom surface 2207 is adapted for sliding. The
top surface 225 may include bindings 224 adapted to couple to
operator boots, not shown. In various embodiments, the sheet 222,
or board platform, or the bindings 224, or both, for the snow skis
220 are formed of the conductively doped resin-based material. The
snowboard 220 formed of the conductively doped resin-based material
is preferably formed to the desired shape with a percent conductive
loading, by weight, to allow the flexibility desired to maneuver
down the hill. The choice of the base resin is selected from any
number of resins capable of providing the tensile strength needed
for the snow skis 220.
[0099] In one embodiment of the present invention, the board
platform 222 is molded with an outer layer of a non-conductive
resin-based material by for example co-extrusion. The outer layer
resin-based material is chosen from any number of resins that will
provide the bottom 207 of the snow skis 220 with an extremely
non-porous slippery surface. In another embodiment, the board
platform 222 is formed entirely of the conductively doped
resin-based material without an additional outer layer.
[0100] The ski poles 230 includes an operator handle 233 attached
to a striking surface 235. Typical ski pole construction utilizes
light weight carbon fiber or aluminum shafts. However, in one
embodiment of the present invention, the ski poles 230 are molded
from the conductively doped resin-based material of the present
invention and then may be metal coated and/or metal plated. In
another embodiment, the ski poles 230 are molded from the
conductively doped resin-based material and are not metal plated
and/or metal coated. The ski poles 230 formed of the conductively
doped resin-based material are preferably formed to the desired
shape with a percent conductive loading, by weight, to give it the
desired rigidity needed by the skier.
[0101] FIG. 21 illustrates one example of a sporting equipment
device depicting one embodiment of the invention. A hockey puck 250
is shown. The hockey puck 250 includes a body 252 formed of the
conductively doped resin-based material. In addition, the hockey
puck may include an antenna 254 formed of the conductively doped
resin-based material and coupled to a wireless
transmitter/receiver, not shown, to be placed in the core of the
puck 250. A wide variety of antenna structures are easily formed of
the conductively doped resin-based material of the present
invention. Monopole, dipole, geometric shapes, 2D, 3D, 4D, 5D,
isotropic structures, planar, inverted F, PIFA, and the like, are
all within the scope of the present invention. The antenna 254
design can be molded by, for example, injection molding. The molded
antenna 254 shape determines the resonant frequency response of the
antenna. The internal transmitting/receiving device in the puck 250
sends a signal to a positioning receiving sensor inside a
television camera and focuses the camera on the puck 250 during
play.
[0102] FIGS. 22-24 illustrate one example of a part of a sporting
equipment device and method of manufacture depicting one embodiment
of the invention. An operator handle for a sporting equipment
device, and a method of manufacture, are illustrated. In
particular, in FIG. 22 shows an operator handle 300 at a
preliminary step in manufacture. A bundled 310 of continuous
strands of micron conductive fiber is shown. The micron conductive
fiber is further illustrated in FIG. 23 which shown a cross section
of the bundle 310 of FIG. 22 taken along lines 23-23. The bundle
310 may have a relatively circular cross-sectional shape 320, for
example. Alternatively, the bundle 310 cross-sectional shape 320
may be any shape, may have a hollow interior to the shape, or may
be amorphous. Alternatively, the continuous strands of micron
conductive fiber 310 may be woven or webbed together. The micron
conductive fiber 310 may be metal, such as stainless steel micron
fiber, copper micron fiber, silver micron fiber or combinations
thereof. The micron conductive fiber 310 may be a non-metal fiber
that is metal plated, such as metal plated carbon fiber. Referring
now to FIG. 24, the continuous strands of micron conductive fiber
is molded with a resin-based material 330 to complete the operator
handle 300. Preferably, the resin-based material is molded under
pressure 340 to force the resin-based material to thoroughly wet
the strands of micron conductive fiber 310. Molding may be, for
example, by injection molding resin-based material 330 on the
bundle 310 of continuous micron conductive fiber 310 inserted into
a mold. Alternatively, the resin-based material 330 may be extruded
onto the continuous strands of micron conductive fiber 310. The
resulting operator handle 300 may be used in any sporting equipment
application including, but not limited to, golf clubs, racquets,
hockey sticks, ski poles, and fishing poles.
[0103] FIG. 25 illustrates one example one example of a part of a
sporting equipment device depicting one embodiment of the
invention. Another operator handle 350 for a sporting equipment
device is shown. The operator handle 350 may included, for example,
a core portion 352, a bundle 354 of continuous strands of micron
conductive fiber surrounding the core portion 352, and a
resin-based material 356 molded onto the bundle 354. The core
portion 352 may have a relatively circular cross-sectional shape,
for example. Alternatively, the core portion 352 cross-sectional
shape may be any shape. The core portion 352 may be a resin-based
material. The bundle 354 of continuous strands of micron conductive
fiber may be woven or webbed together. The micron conductive fiber
may be metal, such as stainless steel micron fiber, copper micron
fiber, silver micron fiber or combinations thereof. The micron
conductive fiber may be a non-metal fiber that is metal plated,
such as metal plated carbon fiber. The bundle 354 of continuous
strands of micron conductive fiber may be wrapped onto the core 352
and further be twisted or radially turned about the core 352. The
resin-based material 356 may be molded under pressure to force the
resin-based material 356 to thoroughly wet the strands of the
bundle 354 of continuous micron conductive fiber. Molding may be,
for example, by injection molding resin-based material 356 on a
sub-assembly of the core portion 352 and bundle 354 inserted into a
mold. Alternatively, the resin-based material 356 may be extruded
onto the sub-assembly of the core portion 352 and bundle 354. The
resulting operator handle 350 may be used in any sporting equipment
application including, but not limited to, golf clubs, racquets,
hockey sticks, ski poles, and fishing poles.
[0104] FIG. 26 illustrates one example one example of a part of a
sporting equipment device depicting one embodiment of the
invention. Another operator handle 360 for a sporting equipment
device is shown. The operator handle 360 may included, for example,
a core portion including a first bundle 366 of continuous strands
of micron conductive fiber molded with a resin-based material 362.
The core portion 362 and 366 may have a relatively circular
cross-sectional shape, for example. Alternatively, the core portion
362 and 366 cross-sectional shape may be any shape. The bundle 366
of continuous strands of micron conductive fiber may be woven or
webbed together. The micron conductive fiber may be metal, such as
stainless steel micron fiber, copper micron fiber, silver micron
fiber or combinations thereof. The micron conductive fiber may be a
non-metal fiber that is metal plated, such as metal plated carbon
fiber. A second bundle 364 of continuous strands of micron
conductive fiber may be wrapped onto the core portion 362 and 366
and further be twisted or radially turned about the core portion
362 and 366. The second bundle 364 of continuous strands of micron
conductive fiber may be woven or webbed together. The micron
conductive fiber may be metal, such as stainless steel micron
fiber, copper micron fiber, silver micron fiber or combinations
thereof The micron conductive fiber may be a non-metal fiber that
is metal plated, such as metal plated carbon fiber. A second
resin-based material 368 may be molded under pressure to force the
resin-based material 368 to thoroughly wet the strands of the
second bundle 364 of continuous micron conductive fiber. Molding
may be, for example, by injection molding resin-based material 368
onto the second bundle 364 inserted into a mold. Alternatively, the
resin-based material 368 may be extruded onto the second bundle
364. The resulting operator handle 360 may be used in any sporting
equipment application including, but not limited to, golf clubs,
racquets, hockey sticks, ski poles, and fishing poles.
[0105] The conductively doped resin-based material 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 a cross section view of an example of
conductively doped 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.
[0106] FIG. 3 shows a cross section view of an example of
conductively doped 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.
[0107] These conductor particles and/or fibers are substantially
homogenized within a base resin. As previously mentioned, the
conductively doped resin-based materials have a sheet resistance of
less than about 5 to more than about 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 conductively doped resin-based material.
More preferably, the weight of the conductive material comprises
between about 20% and about 40% of the total weight of the
conductively doped 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 conductively doped resin-based
material. Still more preferably yet, the weight of the conductive
material comprises about 30% of the total weight of the
conductively doped 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 conductively doped
resin-based material will produce a very highly conductive
parameter, efficient within any EMF, thermal, acoustic, or
electronic spectrum.
[0108] In yet another preferred embodiment of the present
invention, the conductive doping is determined using a volume
percentage. In a most preferred embodiment, the conductive doping
comprises a volume of between about 4% and about 10% of the total
volume of the conductively doped resin-based material. In a less
preferred embodiment, the conductive doping comprises a volume of
between about 1% and about 50% of the total volume of the
conductively doped resin-based material though the properties of
the base resin may be impacted by high percent volume doping.
[0109] 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.
[0110] Referring now to FIGS. 5a and 5b , a preferred composition
of the conductively doped, resin-based material is illustrated. The
conductively doped resin-based material can be formed into fibers
or textiles that are then woven or webbed into a conductive fabric.
The conductively doped 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).
[0111] 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.
[0112] Articles formed from conductively doped resin-based
materials can be formed or molded in a number of different ways
including injection molding, extrusion, calendaring, compression
molding, thermoset molding, 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. Conductively doped 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 articles are removed.
[0113] FIG. 6b shows a simplified schematic diagram of an extruder
70 for forming articles using extrusion. Conductively doped
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 thermally molten, chemically-induced compression, or
thermoset curing conductively doped resin-based material through an
extrusion opening 82 which shapes the thermally molten curing or
chemically induced cured conductively doped resin-based material to
the desired shape. The conductively doped 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 conductively doped resin-based articles of the
present invention.
[0114] Accordingly, many advantages of the above illustrated
described structure will be recognized by those ordinary skilled in
the art. As such, a sporting equipment device is disclosed with
excellent performance including tunable frequency, trampoline
response, low cost of manufacture, durability, and low weight. In
addition, antenna devices or conductive sensing may be integrated
into the device due to the conductivity of the conductively doped
resin-based material.
[0115] The above detailed description of the invention, and the
examples described therein, has been presented for the purposes of
illustration and description. While the principles of the invention
have been described above in connection with a specific device, it
is to be clearly understood that this description is made only by
way of example and not as a limitation on the scope of the
invention.
* * * * *