Internal combustion engine header/tubing fiber composite exhaust system or carbon fiber composite exhaust (CMX)

Abstract

This invention is a light weight, high heat resistant composite exhaust, header/tubing system for an internal combustion system constructed out of fiber and resin. The carbon fiber composite exhaust, CMX invention employs fibers and resin, but is not limited to carbon fiber and alumina-silicate resin. To accomplish the objectives of the present invention, the fiber system is first molded into the desired component by using a collapsible apparatus. Secondly, a single layer of fiber material such as, but not limited to, carbon is applied to uniformly cover the component. Third, the resin is evenly coated by brushing, injection, or squeezing method, and is pushed through the uniform weave. Thus, when the resin has been converted to a ceramic by means of the firing process, the mold can be removed to reveal the first layer of the composite. In order to achieve the desired stiffness and rigidity the following steps must be performed a number of times, depending on the application that will use the exhaust component.

1 . An internal combustion engine header/tubing exhaust system made of a high temperature fiber reinforced resin matrix. 
 The combustion engine header/tubing exhaust system, as cite, is a composite matrix.    The combustion engine header/tubing exhaust system, as cited, is comprised of a matrix of organic materials.    The combustion engine header/tubing exhaust system, as cited, incorporates the use of a uniform weaved fiber, but not limited to carbon, sleeve.    The combustion engine header/tubing exhaust system, as cited, incorporates the use of a water based resin.    
   
   
       2 . An internal combustion engine header/tubing exhaust system, as recited in  claim 1 , is an ultra-light exhaust system, or component, consisting of composite material. 
 The combustion engine header/tubing exhaust system, as cited, incorporates the use of light weight material to create an ultra-light weight exhaust system or component.    The combustion engine header/tubing exhaust system, as cited, incorporates the use of fibers and resin, as stated in  claim 1 , to manufacture from a mold, a composite exhaust system or component.    The combustion engine header/tubing exhaust system, as cited, incorporates layers of fibers and resin as needed for the desired application.    The combustion engine header/tubing exhaust system, as cited, incorporates layers of fibers and resin, reducing the weight of the full exhaust system or component, as compared to its metallic counterpart.    
   
   
       3 . CMX can be formed in to a flangeless exhaust system. 
 The combustion engine header/tubing exhaust system, as recited in  claim 1 , is a composite matrix that can be formed as one piece flangeless exhaust system.    The combustion engine header/tubing exhaust system, as cited, is a composite matrix formed out of a collapsible apparatus that can hold the shape any combustion engine.    The combustion engine header/tubing exhaust system, as cited, is a composite matrix that is formed from to adapt to the length and shape of the client's specification.    The combustion engine header/tubing exhaust system, as cited, is a composite matrix exhaust formed with no flanges, creating a direct path for gases to pass, unlike its metallic counter parts that are connected with welds and flanges that disrupt the gas flow and negatively impact the performance of the internal combustion engine.    
   
   
       4 . An internal combustion engine header/tubing exhaust system, as recited in  claim 1 , has the property of low heat retention. 
 The combustion engine header/tubing exhaust system as recited in  claim 1  is a composite matrix, resulting in a significantly less thermal retention, unlike its metallic counter parts.    The combustion engine header/tubing exhaust system, as cited, is a composite matrix exhaust that has the capability to rapidly cool to a safe handling temperature (cooling to or around ambient temperature) within one minute of engine shut down.    The combustion engine header/tubing exhaust system, as cited, is a composite matrix formed from materials stated in previous  claim 1 .    The combustion engine header/tubing exhaust system as cited, is a composite matrix exhaust capable of withstanding extreme temperatures and fluctuating with no thermal fatigue.    
   
   
       5 . An internal combustion engine header/tubing exhaust system, as cited in  claim 1 , can manifest in numerous forms to meet the needs of any application. 
 The combustion engine header/tubing exhaust system, as cited in  claim 1 , can be formed into numerous custom shapes.    The combustion engine header/tubing exhaust system, as cited, is formed using an inflatable apparatus, able to be manipulated into any form or shape    The combustion engine header/tubing exhaust system, as cited, can be shaped into various forms, such as individual tubes or one-piece monocoque, from fiber stated in previous  claim 1 .    The combustion engine header/tubing exhaust system, as recited in  claim 1 , enables the mold to have a complex shape allowing the fiber to conform tightly to the custom form.    
   
   
       6 . An internal combustion engine header/tubing exhaust system, as cited in  claim 1 , can be decorated to match client's application. 
 The combustion engine header/tubing exhausts system as recited in  claim 1 , is coated with paint, but not limited to, silicone to protect the fiber composite form UV light.    The combustion engine header/tubing exhaust system, as cited, may be coated with numerous colors to match the client's application.    
   
   
       7 . An internal combustion engine header/tubing exhaust system, as cited in  claim 1 , is a performance enhancing product. 
 The combustion engine header/tubing exhaust system, as recited in  claim 2 , will enable the combustion engine to produce more horsepower, because of the weight differential between a CMX system and its metallic counterparts.    The combustion engine header/tubing exhaust system, as recited in  claim 3 , can be custom formed to maximize engine efficiency which will enable more horsepower and torque to be achieved.    
   
   
       8 . An internal combustion engine header/tubing exhaust system, as recited in  claim 1 , can be recycled, limited to instances of low to moderate we ar and tear on the system.