Aluminum extrusion comprising co-extruded insulating, coated and / or non-circular shaped reinforcing wires

Abstract

The co-extruded component includes an aluminum extrusion and a plurality of reinforcing wires. The plurality of filaments includes an outer coating, a non-circular cross-section, and / or an outer layer including woven glass fibers. A plurality of wires is disposed in the aluminum extrusion. A plurality of reinforcing wires are co-extruded with the aluminum extrusion.

Description

Technical Field

[0001] The present disclosure relates to aluminum extrusions, and more particularly to aluminum extrusions including co-extruded insulated, coated, and / or non-circular shaped reinforcing wires. Background Art

[0002] The information provided in this section is intended to generally introduce the background of the present disclosure. To the extent that the work currently attributed to the inventors is described in this section, and aspects of the specification that may not otherwise be determined to be prior art at the time of filing, are not expressly or impliedly admitted to be prior art against the present disclosure.

[0003] The present disclosure relates to aluminum extrusions, and more particularly to aluminum extrusions including co-extruded insulated, coated, and / or non-circular shaped reinforcing wires.

[0004] Extruded aluminum components can be used in a variety of applications as a substitute for steel components to reduce weight. Although aluminum is lighter than steel, its strength is lower than that of steel. For example, a vehicle may include extruded aluminum components that replace steel components. However, due to the lower strength of aluminum, it may be difficult to replace some steel structural components with aluminum. Summary of the Invention

[0005] The co-extruded component includes an aluminum extrusion and a plurality of reinforcing wires, the reinforcing wires including an outer coating and being disposed within the aluminum extrusion. The plurality of reinforcing wires are co-extruded with the aluminum extrusion.

[0006] In some examples, the aluminum extrusion is made of an aluminum alloy selected from 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075. The plurality of reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys. The plurality of reinforcing wires are made of a material selected from carbon steel, austenitic stainless steel spring steel, and martensitic stainless steel spring steel. The outer coating is made of a material selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc. The outer coating includes a zinc-based alloy that melts during the extrusion process to form a liquid diffusion bond. The outer coating includes a copper-based alloy that does not melt during the extrusion process to form a solid-state diffusion bond. The plurality of reinforcing wires have a diameter of 0.5 mm to 2 mm.

[0007] In other features, the thickness of the outer coating is 1 μm to 50 μm. The surface roughness (Ra) of the surface of the outer coating is 10% to 75% of the average thickness T of the outer coating.

[0008] Among other features, the outer coating includes an insulating layer selected from aluminum nitride (AlN), aluminum oxide (Al2O3), and boron nitride (BN). The plurality of reinforcing wires have a non-circular cross-section. The plurality of reinforcing wires includes helical reinforcing wires, and the helical reinforcing wires include longitudinal helical grooves.

[0009] The co-extruded component includes an aluminum extrusion and a plurality of reinforcing wires. The plurality of reinforcing wires are co-extruded with the aluminum extrusion. The cross-sectional shape of the plurality of reinforcing wires is a non-circular cross-sectional shape. The non-circular cross-sectional shape is selected from "D" shape, crescent shape, pie shape, oval shape, rounded rectangle, spiral shape, and rounded triangle. The plurality of reinforcing wires includes an outer coating.

[0010] Among other features, the aluminum extrusion is made of an aluminum alloy selected from 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075. The plurality of reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys. The outer coating is made of a material selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.

[0011] Among other features, the outer coating contains a zinc-based alloy that melts during the extrusion process to produce liquid diffusion bonding. The outer coating contains a copper-based alloy that does not melt during the extrusion process and produces solid-state diffusion bonding.

[0012] The co-extruded component includes an aluminum extrusion and a plurality of reinforcing wires, and the reinforcing wires include an outer layer containing woven glass fibers. The plurality of reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys. The aluminum extrusion and the plurality of reinforcing wires with the outer layer are co-extruded.

[0013] The present invention discloses the following solutions:

[0014] Solution 1. A co-extruded component, comprising:

[0015] an aluminum extrusion; and

[0016] a plurality of reinforcing wires, which include an outer coating and are arranged in the aluminum extrusion,

[0017] wherein the plurality of reinforcing wires are co-extruded with the aluminum extrusion.

[0018] Solution 2. The co-extruded component according to Solution 1, wherein the aluminum extrusion is made of an aluminum alloy selected from 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075.

[0019] Solution 3. The co-extrusion component according to Solution 1, wherein the multiple reinforcing wires are made of materials selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys.

[0020] Solution 4. The co-extrusion component according to Solution 1, wherein the multiple reinforcing wires are made of materials selected from carbon steel, austenitic stainless steel spring steel, and martensitic stainless steel spring steel.

[0021] Solution 5. The co-extrusion component according to Solution 1, wherein the outer coating is made of materials selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.

[0022] Solution 6. The co-extrusion component according to Solution 1, wherein the outer coating contains a zinc-based alloy, and the zinc-based alloy melts during the extrusion process to form a liquid diffusion bond.

[0023] Solution 7. The co-extrusion component according to Solution 1, wherein the outer coating contains a copper-based alloy, and the copper-based alloy does not melt during the extrusion process to produce a solid-state diffusion bond.

[0024] Solution 8. The co-extrusion component according to Solution 1, wherein the multiple reinforcing wires have a diameter of 0.5 mm to 2 mm.

[0025] Solution 9. The co-extrusion component according to Solution 1, wherein the thickness of the outer coating is 1 μm to 50 μm.

[0026] Solution 10. The co-extrusion component according to Solution 1, wherein the surface roughness (Ra) of the surface of the outer coating is 10% to 75% of the average thickness T of the outer coating.

[0027] Solution 11. The co-extrusion component according to Solution 1, wherein the outer coating includes an insulating layer selected from aluminum nitride (AlN), aluminum oxide (Al2O3), and boron nitride (BN).

[0028] Solution 12. The co-extrusion component according to Solution 1, wherein the multiple reinforcing wires have a non-circular cross-section.

[0029] Solution 13. The co-extrusion component according to Solution 1, wherein the multiple reinforcing wires include helical reinforcing wires, and the helical reinforcing wires include longitudinal helical grooves.

[0030] Solution 14. A co-extrusion component, comprising:

[0031] An aluminum extrusion; and

[0032] Multiple reinforcing wires,

[0033] wherein the multiple reinforcing wires are co-extruded together with the aluminum extrusion,

[0034] Wherein the cross-sectional shapes of the multiple reinforcing wires are non-circular cross-sectional shapes.

[0035] Aspect 15. The co-extruded component according to Aspect 14, wherein the non-circular cross-sectional shape is selected from a "D" shape, a crescent shape, a pie shape, an oval shape, a rounded rectangle shape, a spiral shape, and a rounded triangle shape.

[0036] Aspect 16. The co-extruded component according to Aspect 14, wherein the multiple reinforcing wires include an outer coating.

[0037] Aspect 17. The co-extruded component according to Aspect 16, wherein:

[0038] the aluminum extrusion is made of an aluminum alloy selected from 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075,

[0039] the multiple reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys, and

[0040] the outer coating is made of a material selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.

[0041] Aspect 18. The co-extruded component according to Aspect 16, wherein the outer coating comprises a zinc-based alloy that melts during the extrusion process to form a liquid diffusion bond.

[0042] Aspect 19. The co-extruded component according to Aspect 16, wherein the outer coating comprises a copper-based alloy that does not melt during the extrusion process and produces a solid-state diffusion bond.

[0043] Aspect 20. A co-extruded component, comprising:

[0044] an aluminum extrusion; and

[0045] multiple reinforcing wires, which include an outer layer containing woven fiberglass,

[0046] wherein the multiple reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys, and

[0047] wherein the aluminum extrusion is co-extruded with the multiple reinforcing wires having an outer layer.

[0048] From the detailed description, the claims, and the drawings, further applicable fields of the present disclosure will become apparent. The detailed description and specific examples are only intended to illustrate and are not intended to limit the scope of the present disclosure. Description of the Drawings

[0049] The present disclosure will be more fully understood through specific embodiments and the accompanying drawings, wherein:

[0050] Figure 1A is a side cross-sectional view of an example of a compound extrusion die head according to the present disclosure, which is configured to co-extrude aluminum and an insulated, coated, and / or reinforced wire having a non-circular cross-section;

[0051] Figure 1B is a perspective view of an example of an aluminum extrusion according to the present disclosure, which includes a co-extruded reinforced wire that is insulated, coated, and / or has a non-circular cross-section;

[0052] Figure 2 is a partial side cross-sectional view of an example of a co-extruded component according to the present disclosure, which includes an aluminum extrusion and a co-extruded reinforced wire having an outer coating or insulating layer;

[0053] Figures 3A to 3F is a side cross-sectional view of an example of a reinforced wire having a non-circular profile according to the present disclosure;

[0054] Figure 4A and Figure 4B are a plan view and a perspective view, respectively, of an example of a helical wire according to the present disclosure;

[0055] Figure 5 is a side cross-sectional view of an example of a component having co-extruded aluminum and a reinforced wire according to the present disclosure;

[0056] Figure 6 is a perspective view of an example of an insulating layer including woven fiberglass according to the present disclosure;

[0057] Figures 7A to 7C is a partial side view illustrating an example of an interface between extruded aluminum, an outer coating, and a reinforced wire during an extrusion process according to the present disclosure;

[0058] Figure 8 is a graph showing the variation of the mass percentage of zinc with the distance from the interface between the extruded aluminum, the outer coating, and the reinforced wire according to the present disclosure;

[0059] Figure 9A and Figure 9B is a partial side view illustrating an example of an interface between extruded aluminum, an outer coating, and a reinforced wire during an extrusion process according to the present disclosure; and

[0060] Figure 10 is a graph showing the variation of the mass percentage of copper with the distance from the interface between the extruded aluminum and the outer coating according to the present disclosure.

[0061] In the drawings, reference numerals may be reused to identify similar and / or identical elements. Detailed implementation manners

[0062] Although the following describes an extruded component including aluminum co-extruded with an insulated, coated, and / or non-circular shaped reinforcing wire in the context of a motor vehicle, the extruded component can be used in other types of vehicles and / or stationary applications.

[0063] Extruded aluminum components can be used in a variety of applications as a substitute for steel components to reduce weight. Although aluminum is lighter in weight, its strength is also lower. For example, a vehicle may include extruded aluminum components that replace steel structural members in applications such as rockers, rails, or other components. However, certain applications of aluminum require higher strength. The thickness of the aluminum can be increased, which increases the cost of the component. Alternatively, high-strength steel can be used at the expense of increased weight.

[0064] Recently, aluminum has been co-extruded with steel reinforcing wires to increase the strength of the components. Due to the combined advantages of light weight and higher stiffness, wire-reinforced aluminum extrusions are desirable in vehicle applications. Previous attempts to co-extrude aluminum and steel wires typically used uncoated spring steel with a uniform circular cross-section. However, the reinforcing wire may not form a strong bond with the extruded aluminum. If the reinforcing wire is not bonded to the aluminum, or delamination occurs due to a weak bond after extrusion, the strength of the component will be reduced because the reinforcing wire will have significantly reduced pullout resistance.

[0065] The co-extruded component according to the present disclosure includes co-extruded aluminum and a reinforcing wire. In some examples, the reinforcing wire is insulated and / or coated, and / or a reinforcing wire with a non-circular cross-section is used. The coated reinforcing wire forms a stronger bond with the aluminum (e.g., a liquid or solid-state diffusion bond). The reinforcing wire with a non-circular cross-section or increased roughness increases the pullout resistance because the aluminum flows into the grooves in the reinforcing wire.

[0066] The outer coating provides a medium for bonding the extruded aluminum to the steel reinforcing wire. For example, the outer coating can include materials such as zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.

[0067] In some examples, the reinforcing wire includes an insulating layer to allow the reinforcing wire to be insulated from the extruded aluminum and other reinforcing wires. As a result, the reinforcing wire can be used to transmit electrical signals from one location to another.

[0068] Now refer to Figure 1A, an example of a co - extrusion system 10 is shown. The co - extrusion system 10 includes a container 14 that includes an inner cavity for receiving heated aluminum 16 (or billet). A piston 18 or other device reciprocates to change / reduce the volume of the inner cavity and force the softened aluminum through a compound extrusion die 20 under pressure. The compound extrusion die 20 produces a co - extruded component 30 having co - extrusion reinforcing wires 24 embedded therein.

[0069] In some examples, the compound extrusion die 20 includes a cover plate that includes a first opening and a second opening for receiving heated aluminum. A feed plate is disposed adjacent to the cover plate and includes a first opening and a second opening that are aligned on an inlet side for receiving softened aluminum flowing under pressure. The first and second openings of the feed plate combine into a single outlet. The feed plate also includes a wire supply opening for supplying reinforcing wires between the first and second openings. The reinforcing wires are guided by the feed plate into the softened aluminum that exits the feed plate at the single outlet. A die is disposed adjacent to the feed plate to shape the co - extruded component. In other examples, the die is a one - piece die that guides the reinforcing wires into the extruded aluminum.

[0070] Now refer to Figure 1B , an example of a co - extruded component 100 (e.g., a plate) includes extruded aluminum and multiple reinforcing wires 110 - 1, 110 - 2, …, and 110 - W, where W is an integer greater than 1. The multiple reinforcing wires 110 - 1, 110 - 2, …, and 110 - W extend parallel to each other and longitudinally through the co - extruded component 100 (in the extrusion direction indicated by the arrow).

[0071] As described above, co - extruded components using uncoated spring steel with a uniform circular cross - section tend to delaminate. Uncoated spring steel generally does not have sufficient bonding strength with the extruded aluminum and may separate from it, which reduces the strength of the component. In addition, the spring steel and aluminum are in direct contact and may experience galvanic corrosion.

[0072] Now refer to Figure 2 , in some examples, the co - extruded component includes extruded aluminum 134 and multiple reinforcing wires 130 having an outer coating 132. The outer coating 132 enhances the bond between the material of the multiple reinforcing wires 130 and the extruded aluminum 134.

[0073] In some instances, the extruded aluminum 134 is made of aluminum alloys such as 3xxx, 5xxx, 6xxx, and 7xxx alloys (e.g., 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075), but other types of aluminum can also be used. In some instances, the plurality of reinforcing wires 130 are made of materials selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and alloys of the foregoing metals. For example, nitinol or nickel-titanium alloy can be used. In some instances, the plurality of reinforcing wires 130 are made of materials selected from carbon steel (e.g., grades 1009, 1095), austenitic stainless steel spring steel (e.g., grades 301, 302, 304, 316), and martensitic stainless steel spring steel (e.g., grades 414, 420, 431, 441, 455), but other types of materials can also be used.

[0074] In some instances, the outer coating is made of materials selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc. In some instances, the outer coating includes a zinc-based alloy that melts during the aluminum extrusion process to produce a liquid diffusion bond. In other instances, the outer coating includes a copper-based alloy that melts at a temperature higher than the temperature used during the extrusion process. Although the copper alloy does not melt during the extrusion process, a solid-state diffusion bond is produced.

[0075] In some instances, the reinforcing wires have a diameter of 0.5 mm to 2 mm. In some instances, the reinforcing wires have a diameter of 0.5 mm to 1 mm. In some instances, the thickness of the outer coating is 1 μm to 50 μm. In some instances, the thickness of the outer coating is 1 μm to 20 μm. In some instances, the surface roughness (Ra) of the surface of the outer coating is 10% to 75% of the average thickness T of the outer coating. In other instances, the outer surface of the reinforcing wire has a comparable roughness and the outer coating has a more uniform thickness.

[0076] In applications that include an insulating layer to allow the reinforcing wires to transmit signals, the outer coating includes an insulating coating with a melting temperature higher than the extrusion temperature. In some instances, the outer coating is selected from aluminum nitride (AlN), aluminum oxide (Al2O3), and boron nitride (BN) or other dielectric coatings. In some instances, a woven fiberglass layer surrounds the reinforcing wires. The use of the outer coating and / or the woven fiberglass layer allows the reinforcing wires to transmit separate signals.

[0077] Now referring to Figures 3A to 3F , the reinforcing wire 130 according to the present disclosure can have a uniform circular cross-section (as shown in Figure 2 ) with or without an outer coating or a non-circular cross-section. Examples of non-circular shapes are shown in Figures 3A to 3F . In Figure 3AIn , the wire is "D"-shaped and includes a flat side 164, an arcuate side 162, and rounded transitions. In Figure 3B In , the wire has a crescent shape having a convex side 166, a concave side 168, and rounded transitions. In Figure 3C In , the wire has a pie shape having a "V"-shaped side 170, an arcuate side 172, and rounded transitions. In Figure 3D In , the wire has an oval shape. In Figure 3E In , the wire has a rounded rectangular shape. In Figure 3F In , the wire has a rounded triangular shape.

[0078] In Figure 4A and Figure 4B In , the helical wire 230 includes a helical groove 234 that spirally winds around the outer surface of the helical wire 230, as shown in Figure 4B shown. Aluminum fills the helical groove 234 of the helical wire 230 during extrusion to provide a stronger bond and enhance the pull-out resistance during component loading.

[0079] Now referring to Figure 5 , the extruded structure can have a more complex shape. In the example of Figure 5 , the extruded structure 310 has a "B" shape having legs extending therefrom. It will be appreciated that the sides of the extruded component 310 have different thicknesses represented by dimensions d1, d2, d3, d4, and d5. In some examples, when using the reinforcing wire 314, the thickness of one or more of the dimensions d1, d2, d3, d4, and d5 can be reduced relative to a solid aluminum component without loss of strength.

[0080] Now referring to Figure 6 , in some examples, the reinforcing wire includes an insulating layer made of fiberglass or other insulating material capable of withstanding the extrusion temperature without melting. For example, an insulating layer including woven fiberglass can be used.

[0081] Now referring to Figures 7A to 8 , an interface between a wire 430 having an outer coating 432 and extruded aluminum 434 is shown. When the melting temperature of the outer coating 432 is less than or equal to the extrusion temperature (about 450 °C to 550 °C), the outer coating 432 can melt during co-extrusion. For example, the melting temperature of some zinc-based coatings is below or equal to the extrusion temperature. When the outer coating 432 melts, a liquid bond between the coating and the aluminum 434 occurs.

[0082] In Figure 7A , a zinc-coated wire is co-extruded with aluminum. In 7B, the high-temperature heating of the outer coating 432 by the aluminum 434 causes melting. In Figure 7Cin which the liquid zinc from the outer coating 432 reacts with the molten aluminum to form a bond therebetween, as can be seen in the simulations in Figure 8 as shown.

[0083] Now referring to Figures 9A to 10 , an interface between a wire 530 having an outer coating 532 and aluminum 534 is shown. The temperature during the co-extrusion process may not be high enough to cause the outer coating 532 to melt. For example, the outer coating 532 may include a copper or copper-zinc coating. Although melting does not occur, the temperature can be high enough to cause solid-state diffusion bonding of the outer coating 532 to the extruded aluminum. In other words, the outer coating 532 serves as a medium for solid-state diffusion bonding of the extruded aluminum 534 to copper. For example, copper diffuses into the aluminum. In Figure 9A , a reinforcing wire 530 having an outer coating 532 and aluminum 534 are co-extruded. In Figure 9B and Figure 10 , the high-temperature heating of the outer coating 532 by the aluminum 534 causes copper to diffuse into the aluminum (e.g., solid-state diffusion bonding).

[0084] The foregoing description is exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure may be implemented in a variety of forms. Thus, although the disclosure includes specific examples, the true scope of the disclosure should not be so limited since other modifications will become apparent after study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be implemented in a different order (or concurrently) without altering the principles of the disclosure. Additionally, although each embodiment is described above as having certain features, any one or more of the features described with respect to any one embodiment of the disclosure may be implemented in and / or combined with the features of any other embodiment, even if not explicitly described in combination. In other words, the described embodiments are not mutually exclusive, and the interchanging of one or more embodiments is still within the scope of the disclosure.

[0085] Spatial and functional relationships between components (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "joined," "coupled," "adjacent," "next to," "on top of," "on," "under," and "disposed." Unless explicitly described as "direct," when a relationship between a first element and a second element is described in the foregoing disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, or an indirect relationship in which one or more intervening elements exist between the first element and the second element (spatially or functionally). The phrase "at least one of A, B, and C" as used herein should be construed to mean a logical (A OR B OR C) using a non-exclusive logical OR, and should not be construed to mean "at least one A, at least one B, and at least one C."

[0086] In the drawings, the direction of an arrowhead as shown by an arrow generally demonstrates the flow of information (such as data or description) related to the illustration. For example, when component A and component B exchange various information and the information transmitted from component A to component B is related to the illustration, the arrow can point from component A to component B. Such a unidirectional arrow does not mean that no other information is transmitted from component B to component A. In addition, for the information transmitted from component A to component B, component B can send a request for the information or receive an acknowledgment from component A.

Claims

1. A co-extruded component, comprising: an aluminum extrusion; and a plurality of reinforcing wires, which include an outer coating and are disposed in the aluminum extrusion, wherein the plurality of reinforcing wires are co-extruded with the aluminum extrusion.

2. The co-extruded component according to claim 1, wherein the aluminum extrusion is made of an aluminum alloy selected from 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and / or 7075.

3. The co-extruded component according to claim 1, wherein the plurality of reinforcing wires are made of a material selected from iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and their alloys.

4. The co-extruded component according to claim 1, wherein the plurality of reinforcing wires are made of a material selected from carbon steel, austenitic stainless steel spring steel, and martensitic stainless steel spring steel.

5. The co-extruded component according to claim 1, wherein the outer coating is made of a material selected from zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.

6. The co-extruded component according to claim 1, wherein the outer coating comprises a zinc-based alloy, and the zinc-based alloy melts during the extrusion process to form a liquid diffusion bond.

7. The co-extruded component according to claim 1, wherein the outer coating comprises a copper-based alloy, and the copper-based alloy does not melt during the extrusion process to produce a solid-state diffusion bond.

8. The co-extruded component according to claim 1, wherein the plurality of reinforcing wires have a diameter of 0.5 mm to 2 mm.

9. The co-extruded component according to claim 1, wherein the thickness of the outer coating is 1 μm to 50 μm.

10. The co-extruded component according to claim 1, wherein the surface roughness (Ra) of the surface of the outer coating is 10% to 75% of the average thickness T of the outer coating.

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