Composite Interconnect Accessory Rail System

Abstract

The present invention is an article of manufacture comprised of advanced composites having structural, electrical, and thermal characteristics. More specifically, it is an interconnection system that comprises at least one advanced composite material with controlled mechanical, electrical, and thermal properties. When employed in specific configurations and combinations, the subject invention is particularly suited for advanced armaments systems

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None

BACKGROUND

Armaments include rifles and other small weapons, i.e., weapons that are typically hand carried, e.g., those of the AR-15, M-16 and M-5 style; as well as handguns, e.g., Baretta® 92, Colt® 1911 and Glock® 17 styles; as well as other projectile propelling weapons, e.g., those which may be currently in use or development by US and Global armed forces, police agencies and sportsmen. Frequently these armaments are equipped with mounted accessories. Sometimes these armaments are equipped with numerous mounted accessories. In addition, these armaments may be equipped with numerous rail mounted accessories, e.g., combat optics, tactical optics, laser designators, laser sights, range finders, and flashlights.

Since these accessories are of conventional design and originate from numerous commercial sources, they frequently have a variety of power requirements, battery types, heat generation levels, and operating specifications. The result is an assortment of accessories and components which, upon integration with an armament, may create a heavy and/or bulky armament system.

Patent application Ser. No. 13/999,054 filed Jan. 8, 2014, the contents of which are incorporated by reference herein as if set forth in its' entirety, generically discloses apparatus having management of electrical power capacity regions and management of thermal capacity regions.

The publication; Military Standard: Dimensioning of Accessory Mounting Rail for Small Arms Weapons, AMSC, 3 Feb. 1995; establishes standard methods of dimensioning accessory mounting rails for small arms weapon systems. It also establishes uniform accessory mounting rails and requirements that are interchangeable among the different units of the U.S. Defense Department.

Thus, it is clear that armament system components and the materials with which they are made must be reconsidered in an effort to meet the still known unmet needs as well as those that will emerge well into the future.

SUMMARY

Disclosed in certain preferred embodiments herein is an advanced composite structure comprising: at least one region adapted for conducting an electric current, at least one region adapted for conducting a thermal energy, and, at least one region adapted for attaching a component to an integrated structural system.

In further embodiments the advanced composite structure has at least one region adapted for conducting an electric current to and/or from a power source.

In further embodiments the advanced composite structure has at least one region adapted for conducting an electric current, wherein, the at least one region adapted for conducting the current is the same as the at least one region adapted for conducting a thermal energy.

In further embodiments the advanced composite structure has at least two electrically insulating regions.

In further embodiments of the advanced composite structure the at least one region adapted for conducting an electric current is fully incorporated within the integrated structural system.

In further embodiments of the advanced composite structure the advanced composite structure further comprises at least one electrically insulating member.

In further embodiments of the advanced composite structure the advanced composite structure further comprises at least one region adapted for conducting an electric current which is partially incorporated within the integrated structural system.

In further embodiments of the advanced composite structure the advanced composite structure further comprises at least one electrically functional accessory.

In further embodiments of the advanced composite structure the at least one electrically functional accessory is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof.

In further embodiments of the advanced composite structure the advanced composite structure has at least one region adapted for attaching an accessory to the advanced composite structure, wherein the at least one region adapted for attaching an accessory is adapted for allowing the attached accessory to conduct an electric current to or from a power source.

In further embodiments of the advanced composite structure the advanced composite structure further has at least one of a first or second region adapted for conducting an electric current; this first or second region is fully and/or partially integrated within the integrated structural system.

In further embodiments of the advanced composite structure the advanced composite structure has at least one of a first or second region adapted to conduct thermal energy. This first or second region is fully and/or partially integrated within the integrated structural system.

In further embodiments of the advanced composite structure the advanced composite structure is an advanced composite having specific and predetermined structural, electrical, and thermal characteristics.

In further embodiments of the advanced composite structure the advanced composite structure has integrated electrical conduits and interconnections.

In further embodiments of the advanced composite structure the electrical current and thermal energy conducting regions are integrated to provide a multifunctional system having a high degree of mechanical strength and stability.

In further embodiments of the advanced composite structure the advanced composite structure has at least one region adapted for attaching an accessory onto or within the advanced composite structure.

In further embodiments of the advanced composite structure the advanced composite structure has at least one electrically functional accessory.

In further embodiments of the advanced composite structure the advanced composite structure has at least one electrically functional accessory which is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof.

In further embodiments of the advanced composite structure the advanced composite structure has embedded components selected from the group consisting of carbon fiber circuitry, carbon nanotube (CNT) circuitry, metal circuitry, imbedded synthetic metal circuitry, imbedded non-metal circuitry, composite conduits, composite chases, conductive stiffeners and combinations thereof.

While the invention is described by way of non-limiting examples with reference to specific armament systems, it should be noted that the invention may be applied with equal success to other Electro Mechanical Structures (EMS) that may benefit from use of the inventive advanced composites to enable integration and management of mechanical, electrical, and thermal properties. It is thusly an object of the invention herein to provide these components in other Electro Mechanical Structures and systems comprising same.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of mounting of a prior art accessory attachment rail to an armament of the AR-15 style.

FIG. 2 is a perspective view of a prior art accessory rail (P).

FIG. 3 is a perspective view of a particular embodiment of the present invention.

FIG. 4 is an exploded view of the embodiment of the present invention shown in FIG. 3.

FIG. 5 is a transparent view of the embodiment of the present invention shown in FIG. 3.

DETAILED DESCRIPTION

Before explaining some embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of any particular embodiment shown or discussed herein since the invention comprises still further embodiments.

The terminology used herein is for the purpose of description and not of limitation. Further, although certain methods are described with reference to certain steps that are presented herein in a certain order, in many instances, these steps may be performed in any order as may be appreciated by one skilled in the art, and the methods are not limited to the particular arrangement of steps disclosed herein.

As utilized herein, the following terms and expressions will be understood as follows:

“accessibly embedded contact surface” refers to an area or region of an electrically and/or thermally conductive material encased within a second, typically insulative, encasement material where mechanical components of the insertion sites, recesses, indents, tapered regions, grooves, soft spots, blind holes, coated or covered thru-holes, coated or covered threaded holes, hatches, covered portals, designators, and the like are provided in the encasement material to enable physical contact to be made between at least a portion of the embedded conductor, i.e., the interconnect and an external contact member to complete a circuit. The external contact is inserted into and through the encasement material whereby the force required for insertion coupled with the shape of the contact member serves to displace the encasement material and enable direct contact between a portion of the embedded conductor and the inserted contact. One type of such contact is known as an insulation displacement contact. Alternately, the encasement or cover material may be removed prior to establishing the desired interconnection.

The term “advanced” means a material that due to its composition, design, or use is at, or performs at, a level that is above a generally accepted norm or base of comparison. In some instances it refers to a higher level of complexity when compared to common or contemporary materials, methods, or ideas.

The expression “advanced armaments systems” means any armament or projectile propelling apparatus comprising at least one advanced composite.

The expression “advanced composite” means a material capable of replacing metals and created by combining a reinforcing filler with a compatible host system. The advanced composite may be in any form, e.g., a rigid solid, a semi-rigid solid or a flexible solid, an elastomer, a prepreg, and the like.

The expression “advanced composite material” refers to a composition of matter comprised of a matrix material and at least one fibrous filler material. Typically, the fibrous filler works in concert with the matrix to provide or contribute to a critical property of the composite. Examples of such critical properties include high strength, high stiffness, high modulus of elasticity, electrical conductivity, thermal conductivity, and low specific density when compared to other common materials. Examples of matrix materials may include: polymers, ceramics, glasses, metals as well as blends and combinations thereof. Examples of fibrous filler materials include: carbon fiber(s), carbon nanotubes, fiberglass, metal fibers, fine metal filaments, mineral fibers, basalt fibers, metalized carbon fibers, metalized carbon nanotubes, metalized glass, metalized basalt, metalized mineral fibers, natural fibers, metalized natural fibers, and mixtures and combinations thereof.

The expression “advanced composite structure” means a physical member comprised of at least one advanced composite material.

The term “critical property” refers to at least one physical, mechanical, electrical, thermal, or optical property of a composite that enables the composite to provide the desired functionality when used in a specific application.

The expression “electrically and/or thermally functional accessory” refers to any adapted component or accessory that utilizes or produces an electrical current or thermal energy; for example, a sight, a scope, an aiming component, an enhancement to an existing aiming component, a flashlight, an infrared light, a black box IR source, an illumination component of any adapted wavelength(s) in the spectrum, a laser, a Taser, a night-vision apparatus, a communications component, and combinations thereof.

The expression “electrically conductive composite member” means any component partially or fully composed of a composite having an electrical current carrying or signal carrying capability.

The expression “electrical conduits and interconnects” refers to, in the case of electrical conduits any material capable of conveying current or transporting electrical or electrostatic charge; and in the case of electrical interconnects and electrical interconnections refers to physical contact or near contact between two or more electrical conduits enabling passage of current or transport of charge(s). In certain instances, it refers to the interface region between two, or more electrical conduits.

The expression “electrically functional” means an outcome of an electrical component, such as a resistor, capacitor, inductor, transformer, diode, integrated circuit, and the like, that when combined with at least one other electrical member creates an electric circuit wherein at least one characteristic of the circuit is influenced or affected by the operation of the subject component in the energized circuit.

The expression “electrically insulating” means an electrically resistive material having a high effective electrical resistance, for example having a d.c. volume resistivity in the range greater than about 10̂14 ohm-cm and having a capability to prevent the flow of current in the circuit.

The expression “electro mechanical structure (EMS)” means a combination or assembly of two or more members into a unit having a capability to support a load in the form of a mechanical stress or strain without deleterious effect to the member and the capability to convey a current or transport charge.

A “fluid-tight” contact refers to an interconnection between two contacts wherein provision is made in a contact assembly region to exclude fluids, e.g., water, sea water, air, and other gases from entering or exiting the contact region. Provision means; e.g., the rubber seals, sealants, greases, over-coatings, tight fitting joints, secondary enclosures, and the like; are capable of providing fluid tight seals.

The term “integrated” refers to a structural system which is organized so that constituent units function cooperatively.

The expression “integrated structural system” means two or more structural members combined into a unit. In preferred embodiments, the combination of members creates an enhancement to, or synergy between one, or more critical properties, such as mechanical strength, impact resistance, vibration tolerance, and the like.

The term “interconnected” refers to establishment of a connection between two or more members forming a circuit wherein electric or thermal energy may flow between the members.

The expression “manage a thermal energy” means the movement, removal or storage of thermal energy.

The term “reinforcing” refers to the effect of one material when combined with at least one second material that results in strengthening, fortification, and/or improvement of at least one characteristic of the material or the combination of materials.

The term “self-repairing” seal which may also be referred to as “smart seal” and “smart sealing” refers to the class of interfacial sealant materials used to form fluid-tight contact regions where the sealant comprises a cross-linkable fluid encapsulated within microspheres mixed into a host polymer, e.g., silicone or urethane and upon disturbance of the fluid-filled microspheres the fluid is released and cures in place thereby self-sealing deformed/damaged regions.

The term “self-sealing” refers to eliminating fluid-permeable gaps which may have occurred during the pairing or usage of the contacts. Typically, the self-sealing event requires no intervention or supplemental actions. Examples of self-sealing contact materials include conductive greases, rubber gasket sealing members, and liquid-to-solid phase coating materials.

The expression “structural member” means a physical member having a capability to support a load in the form of a mechanical stress or strain without deleterious effect to the member.

The expression “thermally conductive composite member” means any component partially or fully composed of an advanced composite having a capability to move or transport thermal energy.

The expression “thermal conduits” refers to any material that conveys or conducts heat, therefore thermal interconnects and thermal interconnections refers to the physical contact or near contact between two, or more thermal conduits that enables passage of heat. In certain instances, it refers to the interface region between two, or more thermal conduits.

The present invention may be an integrated, multi-component, multifunctional structural system for a firearm or other trajectory propelling apparatus wherein at least one first member comprising an electrically conductive composite having controlled thermal properties is combined, for example, by adapted fabrication process with a second structural member having controlled thermal and electrical properties to form a functional assembly for an armament of any size. Examples of adapted fabrication processes include, but are not limited to, pultrusion, extrusion, lay-up, insert molding, cast molding, injection molding, blow molding, resin transfer molding, lamination, press- or friction-fit assembly, and/or combinations thereof. The first member is preferably electrically conductive throughout or upon or within selected regions and may consist of an intrinsically conductive polymer or a host polymer containing electrically conductive fibers, powders, flakes, shards, or other electrically conducting fillers or a conductive composite or filler having an adapted metal layer applied thereto. In the case where continuous, conductive fibers or discontinuous length fibers of any size are preferred, they may be assembled into convenient to handle and process intermediate forms, for example, in the form of tows, yarns, films, ribbons, foils, sheets, cloths, 2-dimensional and 3-dimensional fabrics, or felts by any adapted method to produce a woven or non-woven or knitted intermediate which may be pre-impregnated with an adapted binder to form an intermediate referred to as a prepreg. Combinations of the foregoing are also options for forming a first member. Metallic fibers or fine wires may be integrated into an intermediate film, foil, sheet, fabric, or felt along with other non-metallic polymers or fibers. Further, metals may be applied in any adapted thickness or location upon or within a filler or other polymeric substrate to enhance the electrical or thermal conductivity by various methods such as electroless plating, electro plating, electro spraying, vapor deposition, vacuum deposition, ion intercalation; dip-, spray-, or other-coating method of a base metal or metal containing fluid, emulsion, ink, paint, or paste; or combinations thereof. In some applications, a Nobel or corrosion resistant metal overplating of a base metal intermediate layer on a substrate may be preferred. The first member may be adapted for conducting power and/or a signal between one location and a second. Within or upon the first member may be regions that provide electric interconnection sites for an accessory, a power source, a system or component specific controller, a user-interface apparatus, or other element.

In addition, the first member may have controlled thermal properties and would therefore be thermally conductive, semiconductive or insulating; depending upon the requirements of the specific local application. In preferred embodiments the first member serves to provide the ability to move, remove, and/or store heat which may be generated by operation of an advanced armament system or by operation of the electric circuit generated by a first member and thereby serves to manage local temperatures within the integrated structure to optimize operational functions and component life.

When in combination with a second structural member that is electrically insulative and having controlled thermal properties, the integrated member serves in general as a major portion of an advanced armament system. For many advanced armament systems, a second member is larger in area or volume in comparison to the first and serves as a primary component of a stock, a housing, a grip, shroud, a frame, or body member. More than one first and second member may be combined to form a large structure and may contain one or more accessibly embedded contact surface regions. Moreover, the second structural member may be electrically insulative but thermally conductive which permits enhanced external cooling of portions of the armament or of the entire armament. Optionally, portions of the external surface of the advanced armament system may have macroscopic surface components, such as fins, louvers, gratings, ports, holes, slots, struts, threaded, clamp-type fastening sites and the like, or microscopic surface components, e.g., a micro-roughness, mixed surface composition, colorants, or modified surface energy which may assist in heat dissipation, aesthetics, as well as handling ability and maintenance of the armament system. Also, optionally, the structure may comprise one or more regions having accessibly embedded contact surface regions that provide for electric or thermal interconnection that are self-sealing, self-repairing, self-healing, fluid tight, environmentally stable or in combination. Also, optionally, the structure may comprise one or more regions having embedded or partially embedded optically transparent or transmissive members, i.e., fiber optic elements made from glass, polymer, quartz, or any other material having suitable optical properties.

The first member may be integrated within or upon the second member to form an advanced composite member and serves to conduct signal or power adapted to activate, monitor, control, or energize an accessory that is appropriately mounted onto the advanced composite member which is configured to provide points or regions of electric interconnectivity amongst the conducting inner member and one or more circuit elements such as a battery, a switch, a user-interface, electronic controller, or other accessory. Any region at the ends of, or along any surface of, or upon the conductive first member, may be configured in the form of an accessibly embedded contact surface which serves to make electrical contact between the conductor and circuit element.

Any appropriate approach may be used to produce the desired surface contact wherein the contact may be embedded and thereby not be initially fully exposed or operational. These approaches include, but not limited to, waterjet cutting, waterjet sculpturing, laser cutting, laser forming, thermoforming, solvent cleaning, chemical etching, mechanical-milling, mechanical-piercing, mechanical-abrading, mechanical-turning, mechanical-polishing, and combinations thereof. In general, establishment of an effective electrical contact involves physical contact between two conductive domains, pads, regions, or surfaces at an interface wherein sufficient mechanical force is exerted, for example compressively and/or in shear, to create and maintain sufficient contact pressure between the mating contacts.

The pressure across the contact interface creates an electromechanical connection that serves to achieve a low contact resistance. This provides a path for current flow from one contact member to another. The contact pressure across the contact region also serves to assist in sealing out, eliminating, minimizing dirt, dust, snow, and moisture from contaminating the contact.

Advanced conductive composites are comprised of a conductive filled polymer system which typically have a polymer rich exterior surface layer that is microscopically different in composition that the rest of the composite materials may be used. However, the surface layer is generally too resistive to provide for low contact resistances at specific contact pressures. In this case, as in the case of accessibly embedded contact surfaces in general, the surface may require alteration, displacement, or removal of at least some of the surface layer in the regions where electric contact will be made in order to alter the surface composition in favor of a higher conductive filler concentration and a resulting lower contact resistance region.

In addition to the earlier mentioned surface preparation methods, other methods may be used to alter the surface resistance at the desired points of contact. These include, but are not limited to, chemical washing, etching, or erosion of the polymer phase at the surface, mechanical sanding or polishing, interpenetrating the surface with an adapted conductive penetrant, overcoating with a suitably conducting layer, e.g., a conductive paint or lubricant, a metal overplating layer, or combinations thereof. In addition, an adaptive sealant or seal may be applied to the contact regions to provide for a fluid tight and environmentally robust contact zone. The seal may be of the smart, self-repairing, or self-sealing type. Contacts made in accordance with the present invention provide a high degree of corrosion resistance, low contact resistance at minimal contact pressure, excellent vibration and temperature tolerance, and as a consequence are generally highly reliable.

Likewise, contact(s) made between two or more thermally conducting members where heat movement across the interconnect is desirable may be configured in a similar fashion such that guidelines for establishing reliable electrical interconnects also apply to establishing thermal interconnects.

The electrical interconnect, when formed by two contacts, may be permanent or temporary. In the case where a permanent interconnect is desired conductive adhesives, chemical bonding, thermal welding, mechanical impact coining, soldering, insert molding, or combinations thereof may be used to join the contact surfaces. In the case where a circuit element is affixed at a contact interconnect in a temporary or removable condition, the contact pressure may be established by employing flexure in the composite member by configuring some, or the entire element similar to a leaf or coil spring. The contact regions may be configured into blade or pin and socket pairings where displacement, for example, in a semi-rigid socket member by a slightly oversize blade creates the desired contact properties. Alternatively, a non-permanent conducting adhesive, conductive grease or similar material may be used to temporarily or removeably secure the contacting elements. In addition to the contact members themselves, other means may be used to provide for permanent or temporary contact interconnects. These include but are not limited to mechanical fasteners, e.g., screws, bolts, nuts, rivets, clamps, and the like.

Although this description pertains largely to the components, performance, and preparation of the electric contact region, any desired thermal interconnect may be designed and constructed in similar fashion wherein effective heat flow is managed within the member and across its interconnect with another element.

Thus, the integration of the first and second members into a single multi-component member having the above-described contact interconnects provides a means to activate, interrogate (sense), or energize a suitably mounted accessory, e.g., a flashlight or other light source, an electronic sight, a range determining laser component, a signaling component, a switching component, a secondary non-lethal propulsion component, e.g., a Taser, or a secondary lethal propulsion component, e.g., a grenade or tear gas launcher.

A non-limiting example of an application of the invention herein is use of the invention described herein as a composite firearm stock, grip member, housing, mounting, shroud, rail, frame, accessory base, and/or barrel for modern armament. Since the appropriately configured thermal and electrical pathways may be imbedded within the composite member, many individual components may be integrated into a single unit thereby reducing the parts count and avoiding certain failure modes. Also, the first member may serve, either in part or fully, as a mounting or housing for a portion of the component or accessory enabling the user to interface with the firearm or accessory in ways that are safe and reliable.

There are commercially available butt stocks, rails, grips, and similar armament related products. The invention herein allows for designs which take advantage of available space within and around the commercially available member. In such an embodiment of the invention herein the same principles as described above are equally applicable to other portions of an advanced armament system and any such variation would be within modifications that do not part from the scope and spirit of the present invention as claimed herein.

The invention may be better understood by reference to the drawings wherein like figure numbers are used to illustrate like components contained in the drawings. FIG. 1 illustrates an AR 15 type rifle that is typical of a small armament (1) in contemporary use. A prior art accessory mounting rail (P) is shown affixed at a topmost center position upon the receiver portion (10) of the armament (1). One or more accessory rails (P) may be affixed at various other locations on the armament (1) to enable mechanical attachment of one or more user selected accessories (not shown). FIG. 2 provides additional details of a prior art accessory mounting rail (P) comprised of ribs (R) and spaces (S). The ribs (R) are generally uniformly distributed along the topmost surface (30) of the accessory mounting rail (P) thereby providing a relatively standardized configuration for mechanical attachment of functional accessories (not shown).

FIG. 3 shows a particular embodiment of the present invention comprising an accessory mounting power rail apparatus (300) which includes a pair of electro conductive power buss inserts (310) (see also FIGS. 4 and 5) that span the length of the accessory mounting power rail apparatus (300). In this embodiment of the invention herein, the accessory mounting power rail apparatus (300) comprises various regions that can be represented by an upper surface (320) having an interdigited array of grooves (380) and ridges (390) below which the earlier mentioned pair of electro conductive power buss inserts (310) are located. The electro conductive power buss inserts (310) are preferably made from a suitable electro conductive composite. This embodiment of the accessory mounting power rail apparatus (300) reflects the mechanical features that are typical of a military standard accessory mounting rail apparatus (P) as shown in FIG. 2, as well as a provision to conduct electrical current to various locations within and along the accessory mounting power rail apparatus (300), i.e., the electro conductive power buss inserts (310). The electro conductive power buss inserts (310) serve to conduct electric current along the length of the accessory mounting power rail apparatus (300) and are contained within the composite second member (330) comprised of a thermally conductive, electrically insulating polymer formed to provide the illustrated features.

Other features, such as side grooves (370) may be molded, machined, or otherwise formed into the accessory power rail apparatus (300) to provide additional locating and mounting options for a variety of accessories (not shown).

The accessory mounting power rail apparatus (300) of FIG. 3 may be fabricated by any adapted process, processes, and process steps; including, for example, insert molding of pultruded rod-shaped preforms via the following process steps: 1) pultrusion of a rod shaped pre-form first member(s) comprising electro conductive fibers secured in a host polymer where the first member(s) are rigid and are circular (310) or angular electrically conductive rods, i.e., electro conductive power buss inserts (310) 2) insertion of the electro conductive power buss inserts (310) into ports within a suitably designed and prepared injection molding die, 3) injection molding of an adapted thermally conductive polymer under heat and pressure to fill the mold and, at least partially, encapsulate the pre-form first member(s) (310), 4) cooling the composite filled die comprising the electro conductive power buss inserts (310) secured within a thermally and electrically insulative second member (330) to sufficiently low temperature(s) to solidify the assembly (300), and then, 5) ejecting the accessory mounting power rail apparatus (300) from the die resulting in the accessory power rail apparatus (300) of FIG. 3.

Referring now to FIG. 4, illustrated is one embodiment of internal features of the accessory mounting power rail apparatus (300). The pair of electro conductive power buss inserts (310) shown in FIG. 4 are embedded in a second advanced composite material (470) and serve as interconnections at specific regions (412) in and on the accessory mounting power rail apparatus (300). In specific, it illustrates one (415) of a pair of two first members (310) that run inside of the upper (450) and lower (460) member of the accessory mounting power rail apparatus (300). The second (not shown) of first member (415) can be seen in FIG. 5. The first members (310, 415) are comprised of electrically conductive composite materials having predetermined and controlled thermal properties. The first members (310, 415) are preferably molded as pre-forms and then located in an electrically insulated second member (450) and combined with a third base member formed of the second advanced composite material (470) to form the accessory mounting power rail apparatus (300). The first members (310, 415) serve to conduct current from and to various locations at the ends (417) and (416) and to specific regions (412) along the length of the accessory mounting power rail apparatus (300) where connection to an accessory (not shown) may be made. After assembly resulting in the accessory mounting power rail apparatus (300), the two first members (310, 415) are nearly fully embedded in the advanced composite of the second member (450, 470) and encased at the bottom by the third base member (470). Within the base member (460) and within the top member (450) are shown one type of additional feature such as a series of thru holes (480) that permit mechanical mounting of the rail assembly (300) to the armament (1) of FIG. 1. Thus, FIG. 4 shows additional details of the accessory mounting power rail apparatus's (300) internal structure. One of a pair of electro conductive advanced composite members (310) are embedded in a second advanced composite material (450, 470) that serve as interconnections at various locations (412) in and on the power rail mounting apparatus (300) and are visible in FIG. 3 as two dots (310) at the leftmost region (417) of the accessory mounting power rail apparatus (300). While in practice and as above mentioned, the first member (414) and second member (450) may be formed into a single assembly, i.e., the upper portion of the accessory mounting power rail apparatus (300) by, for example, insert injection or transfer molding. Thus, the upper member (450) containing the conductive first members (415, 412) and lower member (470) containing the conductive first members (310) may be formed individually and then joined together by any adapted means, e.g., adhesive bonding, thermal welding, sonic welding, mechanical fastening, and combinations thereof.

Provision is made for the first members (310, 415) to span the length of the accessory mounting power rail apparatus (300) from one end (417) to the other (416). Along the span of the accessory mounting power rail apparatus (300) further provisions (412) are incorporated in the upper member (450) for linking appendages (412) to electro-mechanically interconnect between the electro conductive power buss inserts (310, 415) and a plurality of locations (412) forming a network where a power requiring accessory (not shown) is capable of being mounted and connected to the electro conductive power buss network (310, 412, 415). Electrical current is provided to the accessory (not shown) by interconnecting contact regions (not shown) on the accessory to appropriate mating contact points or regions (412) on the accessory mounting power rail (300). The lower member (470) serves to complete the assembly and enables mounting of the rail apparatus onto other apparati, such as to the receiver member of a small arm (1) as illustrated in FIG. 1.

FIG. 5 is a transparent view of the embodiment of the present invention shown in FIGS. 3 and 4 providing additional details of the accessory mounting power rail apparatus (300) illustrating the inset assembly of first members (310, 412, 415) integrated into the upper (450) and lower (470) members of FIG. 4 thus illustrating the electro conductive power buss inserts (310) with interconnecting conductive appendages (512) to comprise the electro conductive power buss network (310, 412, 415) as an element of the integrated assembly of first mechanically strong and rigid electro conductive power buss members (310, 415) with interconnecting linkages (412) configured within the second, mechanically strong, rigid, predetermined thermally conductive members (330, 450, 470) as shown in FIGS. 3 and 4. Examples of adapted fabrication processes which may be used to form the accessory mounting power rail apparatus include, but are not limited to, pultrusion, extrusion, lay-up, insert molding, cast molding, injection molding, blow molding, resin transfer molding, lamination, press- or friction-fit assembly, and/or combinations thereof. Examples of suitably adapted materials include, for example, conductive composite plastics, preformed metals, foils, intrinsically conductive polymers or a host polymers containing electrically conductive fibers, powders, flakes, shards, or other electrically conducting fillers or conductive composites or fillers having an adapted metal layer applied thereto. In the case where continuous conductive fibers or discontinuous length fibers of any size are preferred, they may be assembled into convenient to handle and process intermediate forms, for example, in the form of tows, yarns, films, ribbons, foils, sheets, cloths, 2-dimensional and 3-dimensional fabrics, or felts by any adapted method to produce a woven or non-woven or knitted intermediate which may be pre-impregnated with an adapted binder to form an intermediate referred to as a prepreg. Combinations of the foregoing are also options.

Metallic fibers or fine wires may be integrated into an intermediate film, foil, sheet, fabric, or felt along with other non-metallic polymers or fibers. Further, metals may be applied in any adapted thickness or location upon or within a filler or other polymeric substrate to enhance the electrical or thermal conductivity by various methods such as electroless plating, electro plating, electro-spraying, vapor deposition, vacuum deposition, ion intercalation, dip-, spray-, or other-coating method of a base metal or metal containing fluid, emulsion, ink, paint, or paste, or combinations thereof. In some applications, a Nobel or corrosion resistant metal overplating of a base metal intermediate layer on a substrate may be preferred. The first member is adapted for conducting power and/or a signal between one location and a second. Within or upon the first member are regions that provide electric interconnection sites for an accessory, a power source, a system or component specific controller, a user-interface apparatus, or other element.

The interconnective conducting appendages (512) may be co-formed with the main electro conductive buss members (310, 415) by any suitable adapted process including, for example, machine forming, compression forming of pin or rod shaped members into holes, adhesive bonding of appendages to the base member, and the like. Provisions may be made to enable the ends of the electro conductive power buss members (310, 415) and/or the interconnective conductive appendages (512) to be exposed at the end locations (416, 417) and along the rail surfaces (320) either during formation process of the accessory mounting power rail (300) or subsequent to assembly fabrication of the accessory mounting power rail (300). Any suitable adapted means may be used to prepare the exposed contact surfaces at all, or optionally, at only designated locations. In the case where an accessory (not shown) is to be mounted permanently, for example, onto the accessory mounting power rail (300) apparatus, it may be desired to only expose contact regions where the accessory will be interconnected thus preventing unwanted electrical shorting between unused contact points.

Embodiments

Embodiment 1 is an advanced composite structure comprising at least one region adapted for conducting an electric current, at least one region adapted for conducting a thermal energy, and; at least one region adapted for attaching an electrically and/or thermally functional accessory to the advanced composite structure.

Embodiment 2 is an advanced composite structure of embodiment 1 wherein the at least one region adapted for conducting an electric current is capable of conducting the electric current to and/or from a power source.

Embodiment 3 is the advanced composite structure of embodiments 1 or 2 wherein the region for conducting the current is the same as the at least one region adapted for conducting a thermal energy.

Embodiment 4 is an advanced composite structure of embodiment 3 wherein the advanced composite structure further comprises at least one electrically insulating member.

Embodiment 5 is an advanced composite structure of embodiment 4 wherein the advanced composite structure further comprises at least two electrically insulating members.

Embodiment 6 is an advanced composite structure of embodiments 1 or 2 wherein the at least one region adapted for conducting an electric current is fully incorporated within the integrated structural system.

Embodiment 7 is an advanced composite structure of embodiment 6 wherein the advanced composite structure further comprises at least one electrically insulating member.

Embodiment 8 is an advanced composite structure of embodiments 1 or 2 wherein the at least one region adapted for conducting an electric current is partially incorporated within the integrated structural system.

Embodiment 9 is an advanced composite structure of embodiment 8 wherein the advanced composite structure further comprises at least one electrically insulating member.

Embodiment 10 is an advanced composite structure of embodiment 3 wherein the advanced composite structure further comprises at least one electrically functional accessory.

Embodiment 11 is an advanced composite structure of embodiment 3 wherein the at least one electrically functional accessory is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof.

Embodiment 12 is an advanced composite structure of embodiment 3 wherein the at least one region adapted for attaching an accessory component to the advanced composite structure is configured for the attached accessory component to be capable of conducting the electric current from or to a power source.

Embodiment 13 is an advanced composite structure of embodiment 3 wherein at least one of the first or second region adapted for conducting an electric current is fully and/or partially integrated within the integrated structural system.

Embodiment 14 is an advanced composite structure of embodiment 3 wherein at least one of the first or second region adapted for conducting a thermal energy is fully and/or partially integrated within the advanced composite structure.

Embodiment 15 is an advanced composite system comprising at least one region adapted for conducting an electric current, at least one region adapted for conducting a thermal energy, at least one region adapted for attaching an electrically and/or thermally functional accessory to the advanced composite structure, and; at least one power source.

Embodiment 16 is an advanced composite system of embodiment 15 wherein the at least one region adapted for conducting an electric current is capable of conducting the electric current to and/or from a power source.

Embodiment 17 is an advanced composite system of embodiment 16 wherein the advanced composite system comprises an advanced composite having predetermined and intentionally selected structural, electrical, and thermal characteristics.

Embodiment 18 is an advanced composite system of embodiment 15 wherein the advanced composite system further comprises integrated electrical conduits and interconnections.

Embodiment 19 is an advanced composite system wherein integration of reinforcing electrically and thermally active constituents provides for a multifunctional system having a high degree of mechanical strength and stability.

Embodiment 20 is an advanced composite system of embodiment 17 wherein the advanced composite system further comprises at least one region adapted for attaching an accessory onto or within the advanced composite structure.

Embodiment 21 is an advanced composite system of embodiment 18 wherein the advanced composite system further comprises at least one electrically functional accessory.

Embodiment 22 is an advanced composite system of embodiment 19 wherein the at least one electrically functional accessory is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof.

Embodiment 23 is an advanced composite system of embodiment 15 wherein the advanced composite system further comprises embedded components selected from the group consisting of carbon fiber circuitry, carbon nanotube (CNT) circuitry; imbedded metal, synthetic metal, non-metal circuitry; composite conduits and chases; conductive stiffeners and combinations thereof.

Embodiment 24 is an advanced composite system of embodiment 17 wherein the advanced composite system further comprises embedded components selected from the group consisting of carbon fiber circuitry, carbon nanotube (CNT) circuitry; imbedded metal, synthetic metal, non-metal circuitry; composite conduits and chases; conductive stiffeners and combinations thereof.

Embodiment 25 is any combination of embodiments 1-24, in whole or in part, and combined in any order.

Having thus described illustrative embodiments of the concepts and technologies disclosed herein, it should be noted by those ordinarily skilled in the art that the within disclosures are illustrative only, and that various other alternatives, adaptations, and modifications may be made without departing from the scope of the various embodiments of the concepts and technologies disclosed herein. Accordingly, the various embodiments of the concepts and technologies disclosed herein are not limited to the specific embodiments illustrated herein, but rather are limited only by the scope of the following claims.

Claims

1. An advanced composite structure comprising:

a physical member comprised of at least one advanced composite material, and wherein the advanced composite structure further comprises:

at least one region adapted for conducting an electric current,

at least one region adapted for conducting a thermal energy, and

at least one region adapted for attaching an electrically and/or thermally functional accessory to the advanced composite structure.

2. The advanced composite structure of claim 1 wherein the at least one region adapted for conducting an electric current is capable of conducting the electric current to and/or from a power source.

3. The advanced composite structure of claim 1 or 2 wherein the region for conducting the current is the same as the at least one region adapted for conducting a thermal energy.

4. The advanced composite structure of claim 3 wherein the advanced composite structure further comprises at least one electrically insulating member.

5. The advanced composite structure of claim 4 wherein the advanced composite structure further comprises at least two electrically insulating members.

6. The advanced composite structure of claim 1 or 2 wherein the at least one region adapted for conducting an electric current is fully incorporated within an integrated structural system.

7. The advanced composite structure of claim 6 wherein the advanced composite structure further comprises at least one electrically insulating member.

8. The advanced composite structure of claim 1 or 2 wherein the at least one region adapted for conducting an electric current is partially incorporated within an integrated structural system.

9. The advanced composite structure of claim 8 wherein the advanced composite structure further comprises at least one electrically insulating member.

10. The advanced composite structure of claim 3 wherein the advanced composite structure further comprises at least one electrically functional accessory.

11. The advanced composite structure of claim 3 wherein the at least one electrically functional accessory is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof

12. The advanced composite structure of claim 3 wherein the at least one region adapted for attaching an accessory component to the advanced composite structure is configured for the attached accessory component to be capable of conducting the electric current from or to a power source.

13. The advanced composite structure of claim 3 wherein at least one of the first or second region adapted for conducting an electric current is fully and/or partially integrated within an integrated structural system.

14. The advanced composite structure of claim 3 wherein at least one of the first or second region adapted for conducting a thermal energy is fully and/or partially integrated within an advanced composite structure.

15. An advanced composite system comprising:

at least one region adapted for conducting an electric current,

at least one region adapted for conducting a thermal energy,

at least one region adapted for attaching an electrically and/or thermally functional accessory to the advanced composite structure, and;

at least one power source.

16. The advanced composite system of claim 15 wherein the at least one region adapted for conducting an electric current is capable of conducting the electric current to and/or from a power source.

17. The advanced composite system of claim 16 wherein the advanced composite system comprises an advanced composite having predetermined and intentionally selected structural, electrical, and thermal characteristics.

18. The advanced composite system of claim 15 wherein the advanced composite system further comprises integrated electrical conduits and interconnections.

19. An advanced composite system wherein integration of reinforcing electrically and thermally active constituents provides for a multifunctional system having a high degree of mechanical strength and stability.

20. The advanced composite system of claim 17 wherein the advanced composite system further comprises at least one region adapted for attaching an accessory onto or within the advanced composite structure.

21. The advanced composite system of claim 18 wherein the advanced composite system further comprises at least one electrically functional accessory.

22. The advanced composite system of claim 19 wherein the at least one electrically functional accessory is selected from the group consisting of a high intensity light, a light emitting diode (LED), an array of LEDs, a laser light, a laser designator, and combinations thereof

23. The advanced composite system of claim 15 wherein the advanced composite system further comprises embedded components selected from the group consisting of carbon fiber circuitry, carbon nanotube (CNT) circuitry; imbedded metal, synthetic metal, non-metal circuitry; composite conduits and chases; conductive stiffeners and combinations thereof.

24. The advanced composite system of claim 17 wherein the advanced composite system further comprises embedded components selected from the group consisting of carbon fiber circuitry, carbon nanotube (CNT) circuitry; imbedded metal, synthetic metal, non-metal circuitry; composite conduits and chases; conductive stiffeners and combinations thereof.