Foamed aluminum filled profile and preparation method thereof

Abstract

The invention provides a foamed aluminum filled profile and a preparation method thereof, and the preparation method comprises the following steps: S1, preparing a metal profile with a cavity, and making foamed aluminum into a shape matched with the cavity of the metal profile; s2, the outer side of the foamed aluminum is wrapped with a layer of fabric soaked with an adhesive, and the friction coefficient of the fabric and the metal profile is smaller than that of the foamed aluminum and the metal profile; s3, thrust is applied to the foamed aluminum, and the cavity of the metal profile is filled with the foamed aluminum; and S4, the metal profile filled with the foamed aluminum is subjected to standing till the adhesive is cured, and the foamed aluminum filled profile is obtained. According to the novel method for mechanically filling the foamed aluminum into the metal profile, the filling pressure needed for pushing the foamed aluminum can be reduced, and it is guaranteed that the position of the filled foamed aluminum is fixed.

Description

Technical Field

[0001] The present invention relates to the technical field of profiles, and in particular to a foam aluminum filled profile and a preparation method thereof. Background Art

[0002] Metal profiles offer advantages such as corrosion resistance, excellent electrical conductivity, non-ferromagnetic properties, and machinability, making them widely used in a variety of fields, including construction, machinery manufacturing, aerospace, and the automotive industry. However, due to their hollow structure, metal profiles also have some performance limitations, such as poor impact resistance, flame retardancy, thermal insulation, and sound insulation, which limit their further application.

[0003] Filling the cavities of metal profiles with aluminum foam is a promising solution for improving their performance. Aluminum foam offers advantages such as lightweight, high damping and shock absorption, excellent sound insulation, electromagnetic shielding, and heat resistance. Filling with aluminum foam can imbue metal profiles with these same properties.

[0004] There are two existing methods for filling aluminum foam. One is through foaming or metallurgical processes, such as the method disclosed in patent document CN110867545A. A metal profile is placed in a foaming mold, and a foamed aluminum preform is filled into the metal profile's cavity. The foaming process then proceeds, causing the aluminum foam to completely fill the metal profile's cavity. This method allows the aluminum foam to tightly bond to the metal profile's inner wall, but the preparation process is complex, requiring specialized molds, resulting in high equipment costs and poor versatility. The other method is mechanical filling, where the formed aluminum foam is cut into a shape that matches the metal profile's cavity and then mechanically inserted into the cavity. This method is simple to operate and highly versatile, allowing it to fill finished metal profiles of various structures. However, this filling method can easily leave gaps between the aluminum foam and the profile's inner wall, adversely affecting material properties. Furthermore, the high surface friction of the aluminum foam requires significant pressure during the filling process, making it difficult to operate. After filling, the aluminum foam and the metal profile are held together solely by friction, making it susceptible to slipping when subjected to significant impact. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a new method for mechanically filling foam aluminum with metal profiles, which reduces the filling pressure required to push the foam aluminum and ensures that the position of the foam aluminum is fixed after filling.

[0006] To achieve the above object, the present invention provides a method for preparing a foam aluminum filled profile, comprising the following steps:

[0007] S1. Prepare a metal profile with a cavity, and make the foamed aluminum into a shape matching the cavity of the metal profile;

[0008] S2. Wrapping the outer side of the aluminum foam with a layer of fabric impregnated with adhesive, wherein the friction coefficient between the fabric and the metal profile is smaller than the friction coefficient between the aluminum foam and the metal profile;

[0009] S3, applying a thrust to the foamed aluminum to fill the cavity of the metal profile;

[0010] S4. The metal profile filled with the foamed aluminum is allowed to stand until the adhesive is cured, thereby obtaining a foamed aluminum filled profile.

[0011] The method of the present invention wraps a fabric with a low friction coefficient on the surface of the foam aluminum, reduces the friction resistance encountered during the mechanical filling process of the foam aluminum, reduces the pressure required to push the foam aluminum, and facilitates production operation; the fabric is impregnated with an adhesive, and after the foam aluminum is filled in place, the adhesive is allowed to stand and solidify, so that the fabric can be bonded to the foam aluminum surfaces on both sides and the inner wall of the metal profile cavity, so that the relative position of the foam aluminum and the metal profile is fixed, and the foam aluminum is prevented from slipping under force; the fabric bonding structure can eliminate the gap between the foam aluminum and the inner wall of the cavity, and ensure that the filled profile achieves the designed performance.

[0012] Furthermore, the fabric is selected from one of non-woven fabric, nylon fiber fabric and spandex fiber fabric.

[0013] Furthermore, the material of the metal profile is selected from one of aluminum alloy, copper alloy, carbon steel and stainless steel.

[0014] Furthermore, the friction coefficient between the fabric and the metal profile is less than or equal to 0.2.

[0015] For metal profiles made of different materials, the friction coefficient between the fabric and the metal profile can be adjusted by selecting the fabric material and the production process to ensure that the thrust required during the foam aluminum filling process is small, facilitate production operations, and avoid damage to the foam aluminum during the filling process.

[0016] Furthermore, the fabric has a thickness of 0.1 to 1 mm.

[0017] Furthermore, the gap a between the foam aluminum and the inner wall of the cavity of the metal profile and the thickness b of the fabric satisfy the relationship: 0 mm ≤ ab ≤ 0.2 mm.

[0018] When foam aluminum is made according to the shape of the cavity, the gap size is designed to match the thickness of the fabric. It should be convenient for filling operation without interference, and the gap should not be too large to ensure that the fabric is in contact with the inner wall of the cavity for bonding.

[0019] Furthermore, in step S1, the method for preparing the filling foam aluminum can be to cut a piece of foam aluminum into the desired shape, or to cut and splice multiple pieces of foam aluminum into the desired shape. Some metal profiles have irregular cavities, which can be filled by splicing multiple pieces of foam aluminum. This reduces the difficulty of preparing the foam aluminum, eliminates the need for making special-shaped molds, and reduces production costs. Since the outer surface of the foam aluminum is wrapped with fabric, it can also limit the spliced ​​foam aluminum.

[0020] Furthermore, the adhesive has a curing time of greater than or equal to 1 hour at room temperature and is selected from one of epoxy resin adhesives, polyurethane adhesives, polyolefin resin adhesives, polyester polyol adhesives, polyisocyanate adhesives, and silicone adhesives. Selecting an adhesive with a longer curing time avoids generating additional resistance during the aluminum foam filling process.

[0021] The present invention also provides a foamed aluminum filling profile, produced by the aforementioned preparation method. The foamed aluminum filling profile comprises a metal profile having a cavity filled with fabric-wrapped aluminum foam, the fabric being bonded to the inner wall of the cavity and the aluminum foam. The fabric bonding structure creates a tight connection between the aluminum foam and the metal profile, preventing the aluminum foam from slipping when the profile is impacted and eliminating gaps in the metal profile cavity, thereby ensuring that the filling profile achieves its designed performance.

[0022] In summary, compared with the prior art, the present invention has the following beneficial effects:

[0023] (1) The present invention wraps fabric on the surface of the foam aluminum to reduce the friction force encountered when the foam aluminum is filled into the metal profile cavity, thereby reducing the pressure required for filling and assembly, facilitating production operations, and reducing the probability of stress damage to the foam aluminum during filling.

[0024] (2) The fabric of the present invention is impregnated with an adhesive. After curing, the fabric can be bonded to the foam aluminum and the metal profile on both sides, that is, an adhesive layer is added between the foam aluminum and the metal profile, so that the relative positions of the foam aluminum and the metal profile are fixed, avoiding relative slippage when impacted, and maintaining stable material properties.

[0025] (3) The present invention ensures that the foam aluminum filling operation is convenient and that there are no gaps in the metal profile cavity after filling through size design and heating and bonding methods, thereby ensuring that the filled profile achieves the designed performance.

[0026] (4) The foam aluminum filled profile prepared by the present invention has excellent machinability, impact resistance, flame retardancy, heat insulation and sound insulation properties, and has good application prospects in the fields of construction, machinery manufacturing, aerospace, automobile industry and so on. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 The figure is a flow chart of a method for preparing a foam aluminum filled profile in a specific embodiment of the present invention.

[0028] Figure 2 This is a schematic diagram of the preparation process structure of the foam aluminum filled profile in a specific embodiment of the present invention. Description of the drawings:

[0030] 1-Metal profile, 2-Foamed aluminum, 3-Fabric. DETAILED DESCRIPTION

[0031] To make the above-mentioned objects, features, and advantages of the present invention more clearly understood, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. It should be noted that the following embodiments are only intended to illustrate the implementation methods and typical parameters of the present invention, and are not intended to limit the parameter ranges described in the present invention. Reasonable variations derived therefrom are still within the scope of protection of the claims of the present invention.

[0032] An embodiment of the present invention provides a method for preparing a foam aluminum filled profile, which is used to fill foam aluminum into the cavity of a metal profile to improve the material's impact resistance, heat insulation, flame retardancy, sound absorption and other properties.

[0033] Combine Figure 1 and Figure 2 As shown, the preparation method of the foam aluminum filled profile includes the following steps:

[0034] S1. Prepare a metal profile 1 with a cavity. The material of the metal profile 1 can be aluminum alloy, copper alloy, carbon steel, stainless steel, etc. Make foam aluminum 2 into a shape matching the cavity of the metal profile 1 as a filling material.

[0035] In a specific embodiment, a single piece of foam aluminum 2 can be cut into the desired shape based on the cavity's shape; alternatively, multiple pieces of foam aluminum 2 can be cut and spliced ​​together to form the desired shape, with the spliced ​​parts secured with pressure-sensitive adhesive. This filling method is highly versatile and can accommodate metal profiles 1 of various structures, eliminating the need to design multiple filling molds and reducing production costs.

[0036] S2. Wrap a layer of fabric 3 impregnated with adhesive on the outside of the cut foam aluminum 2 or the spliced ​​foam aluminum 2. The fabric 3 can limit the spliced ​​foam aluminum 2.

[0037] In a specific embodiment, the fabric 3 can be selected from non-woven fabrics, nylon fiber cloth, spandex fiber cloth, etc., and a material with a smaller friction coefficient with the metal profile 1 is selected. It is necessary to ensure that the friction coefficient between the fabric 3 and the metal profile 1 is smaller than the friction coefficient between the foam aluminum 2 and the metal profile 1.

[0038] Generally, the friction coefficient between the foam aluminum 2 and the metal profile 1 is between 0.3 and 1.0. In a preferred embodiment, by selecting materials and adjusting the manufacturing process, the friction coefficient between the fabric 3 and the metal profile 1 can be made less than or equal to 0.2, which makes subsequent mechanical filling more convenient.

[0039] S3. Apply a thrust to the aluminum foam 2 to fill the cavity of the metal profile 1. Due to the presence of the low-friction fabric 3, the friction force experienced by the aluminum foam 2 when filling the cavity of the metal profile 1 is reduced, thereby reducing the pressure required for filling and assembly, facilitating production operations. In addition, the aluminum foam 2 is subjected to less pressure, which can reduce the probability of material damage due to stress.

[0040] In a preferred embodiment, the thickness of the fabric 3 and the dimensions of the aluminum foam 2 are specified, with the thickness b of the fabric 3 being 0.1 to 1 mm. The aluminum foam 2 is manufactured to the same dimensions as the cavity of the metal profile 1, but with a clearance for assembly. The gap a between the aluminum foam 2 and the inner wall of the cavity of the metal profile 1 after filling and the thickness b of the fabric 3 satisfy the following relationship: 0 mm ≤ ab ≤ 0.2 mm. This dimensioning ensures that the filling process does not cause interference, facilitating the filling operation, while ensuring that the aluminum foam 2 completely fills the cavity and maintains material properties.

[0041] S4. The metal profile 1 filled with aluminum foam 2 is allowed to stand for a period of time. After the adhesive solidifies, the fabric 3 is bonded to the aluminum foam 2 and metal profile 1 on both sides, fixing the relative positions of the aluminum foam 2 and metal profile 1. This results in a profile filled with aluminum foam 2. The fabric 3 bonding structure also eliminates gaps between the aluminum foam 2 and the inner wall of the cavity, ensuring that the filled profile meets the designed performance.

[0042] In a specific embodiment, the adhesive used may be epoxy resin adhesive, polyurethane adhesive, polyolefin resin adhesive, polyester polyol adhesive, polyisocyanate adhesive, silicone adhesive, etc. After the adhesive is cured, the fabric 3 can play a bonding role to ensure that the relative positions of the foam aluminum 2 and the metal profile 1 are fixed.

[0043] Preferably, an adhesive with a curing time of 1 hour or more is selected to ensure that the adhesive does not cure during the filling process, thereby avoiding generating additional filling resistance.

[0044] Preferably, after filling in place, the adhesive curing time can be shortened by heating to improve production efficiency.

[0045] The above preparation method has the advantages of strong versatility, low preparation cost, and convenient process operation. After filling, the position of the foam aluminum 2 is fixed and not easy to slide, and the filling material can completely fill the cavity of the metal profile 1, thereby improving the impact resistance, flame retardancy, heat insulation, sound absorption and other properties of the metal profile 1, and has great industrial promotion and application value.

[0046] The following examples illustrate the technical solutions and effects of the present invention. The metal profile used in the following examples is a rectangular aluminum alloy profile with a rectangular cavity cross-section. The aluminum alloy profile has cross-sectional dimensions of 100 × 60 mm, a length of 100 mm, and a wall thickness of 3 mm. The aluminum foam used is a closed-cell aluminum foam sheet with a porosity of 60% and a friction coefficient of 0.5 with the aluminum alloy profile. The adhesive used is a two-component epoxy resin adhesive.

[0047] Example 1

[0048] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0049] (1) Cut the foam aluminum plate into 98×58×100mm foam aluminum filling materials.

[0050] (2) Prepare a non-woven fabric impregnated with adhesive, the friction coefficient of which with aluminum alloy is 0.3 and the thickness is 0.8 mm, and wrap the cut foam aluminum with the non-woven fabric.

[0051] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 500N to the foam aluminum at a pushing speed of 5mm / s to make the foam aluminum enter the cavity of the aluminum alloy profile.

[0052] (4) The aluminum alloy profile is left to stand at room temperature for 24 hours to allow the adhesive to solidify, thereby obtaining a foam aluminum filled profile.

[0053] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, and the foam aluminum will not slide.

[0054] Example 2

[0055] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0056] (1) Cut the foam aluminum plate into 99×59×100mm foam aluminum filling materials.

[0057] (2) Prepare a nylon fiber cloth impregnated with adhesive, the friction coefficient of which with aluminum alloy is 0.15 and the thickness is 0.5 mm, and wrap the cut foam aluminum with the nylon fiber cloth.

[0058] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 500N to the foam aluminum at a pushing speed of 5mm / s to make the foam aluminum enter the cavity of the aluminum alloy profile.

[0059] (4) The aluminum alloy profile is left to stand at room temperature for 24 hours to allow the adhesive to solidify, thereby obtaining a foam aluminum filled profile.

[0060] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, and the foam aluminum will not slide.

[0061] Example 3

[0062] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0063] (1) Cut the foam aluminum plate into 99×59×100mm foam aluminum filling materials.

[0064] (2) Prepare a spandex fiber cloth impregnated with adhesive, the friction coefficient of which with aluminum alloy is 0.2 and the thickness is 0.3 mm, and wrap the cut foam aluminum with the nylon fiber cloth.

[0065] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 400N to the foam aluminum at a pushing speed of 5mm / s to make the foam aluminum enter the cavity of the aluminum alloy profile.

[0066] (4) The aluminum alloy profile is left to stand at room temperature for 24 hours to allow the adhesive to solidify, thereby obtaining a foam aluminum filled profile.

[0067] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, and the foam aluminum will not slide.

[0068] Example 4

[0069] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0070] (1) Cut the foam aluminum plate into 99×59×100mm foam aluminum filling materials.

[0071] (2) Prepare a non-woven fabric impregnated with adhesive, the friction coefficient of which with aluminum alloy is 0.2 and the thickness is 0.4 mm, and wrap the cut foam aluminum with the non-woven fabric.

[0072] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 400N to the foam aluminum at a pushing speed of 5mm / s to make the foam aluminum enter the cavity of the aluminum alloy profile.

[0073] (4) The aluminum alloy profile is left to stand at room temperature for 24 hours to allow the adhesive to solidify, thereby obtaining a foam aluminum filled profile.

[0074] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, and the foam aluminum will not slide.

[0075] Example 5

[0076] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0077] (1) Cut the foam aluminum plate into 98×58×100mm foam aluminum filling materials.

[0078] (2) Prepare a non-woven fabric impregnated with adhesive, the friction coefficient of which with aluminum alloy is 0.2 and the thickness is 1 mm, and wrap the cut foam aluminum with the non-woven fabric.

[0079] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 500N to the foam aluminum at a pushing speed of 5mm / s to make the foam aluminum enter the cavity of the aluminum alloy profile.

[0080] (4) The aluminum alloy profile is left to stand at room temperature for 24 hours to allow the adhesive to solidify, thereby obtaining a foam aluminum filled profile.

[0081] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, and the foam aluminum will not slide.

[0082] Comparative Example 1

[0083] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0084] (1) Cut the aluminum foam plate into 100×60×100 mm aluminum foam filling materials.

[0085] (2) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 1500N to the foam aluminum at a pushing speed of 5mm / s, so that the foam aluminum enters the cavity of the aluminum alloy profile to obtain a foam aluminum filled profile.

[0086] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 2000N to the filled foam aluminum, causing the foam aluminum to slide.

[0087] Comparative Example 2

[0088] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0089] (1) Cut the foam aluminum plate into 99×59×100mm foam aluminum filling materials.

[0090] (2) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 1000N to the foam aluminum at a pushing speed of 5mm / s, so that the foam aluminum enters the cavity of the aluminum alloy profile to obtain a foam aluminum filled profile.

[0091] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 1500N to the filled foam aluminum, causing the foam aluminum to slide.

[0092] Comparative Example 3

[0093] The specific process steps for preparing foam aluminum filled profiles are as follows:

[0094] (1) Cut the foam aluminum plate into 98×58×100mm foam aluminum filling materials.

[0095] (2) Prepare a non-woven fabric having a friction coefficient of 0.3 with aluminum alloy and a thickness of 0.8 mm, and wrap the cut foam aluminum with the non-woven fabric.

[0096] (3) Fix the aluminum alloy profile and use an electric push rod to apply a thrust of 500N to the foam aluminum at a pushing speed of 5mm / s, so that the foam aluminum enters the cavity of the aluminum alloy profile to obtain a foam aluminum filled profile.

[0097] Fix the foam aluminum filled profile and use an electric push rod to apply a thrust of 1000N to the filled foam aluminum, causing the foam aluminum to slide.

[0098] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some or all of the technical features therein. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a foam aluminum filled profile, characterized in that: The following steps are involved: S1. Prepare a metal profile with a cavity, and make the foamed aluminum into a shape matching the cavity of the metal profile; S2, wrapping a layer of fabric impregnated with adhesive on the outside of the foamed aluminum, wherein the friction coefficient between the fabric and the metal profile is smaller than the friction coefficient between the foamed aluminum and the metal profile; S3, applying a thrust to the foam aluminum to fill the cavity of the metal profile; S4, leaving the metal profile filled with the foam aluminum to stand until the adhesive is cured to obtain a foam aluminum filled profile.

2. The method for preparing the foam aluminum filled profile according to claim 1, characterized in that: The fabric is selected from non-woven fabric, nylon fiber fabric and spandex fiber fabric.

3. The method for preparing the foam aluminum filled profile according to claim 1, characterized in that: The material of the metal profile is selected from one of aluminum alloy, copper alloy, carbon steel and stainless steel.

4. The method for preparing the foamed aluminum filled profile according to any one of claims 1 to 3, characterized in that: The friction coefficient between the fabric and the metal profile is less than or equal to 0.

2.

5. The method for preparing the foam aluminum filled profile according to claim 1, characterized in that: The thickness of the fabric is 0.1-1 mm.

6. The method for preparing the foam aluminum filled profile according to claim 5, characterized in that: The gap a between the foam aluminum and the inner wall of the cavity of the metal profile and the thickness b of the fabric satisfy the relationship: 0mm≤ab≤0.2mm.

7. The method for preparing the foam aluminum filled profile according to claim 1, characterized in that: In the step S1, the method for preparing the filled foam aluminum is to cut a piece of foam aluminum into a desired shape, or to cut multiple pieces of foam aluminum and then splice them into the desired shape.

8. The method for preparing the foam aluminum filled profile according to claim 1, characterized in that: The curing time of the adhesive at room temperature is greater than or equal to 1 hour, and the adhesive is selected from one of epoxy resin adhesive, polyurethane adhesive, polyolefin resin adhesive, polyester polyol adhesive, polyisocyanate adhesive, and silicone adhesive.

9. A foam aluminum filled profile, characterized in that: The foamed aluminum filled profile is prepared by the preparation method of any one of claims 1 to 8.

10. The foam aluminum filled profile according to claim 9, characterized in that: The invention comprises a metal profile having a cavity, the cavity is filled with foamed aluminum wrapped with fabric, and the fabric is bonded to the inner wall of the cavity and the foamed aluminum.

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