Extrusion conformal cooling apparatus, methods and systems

Abstract

A die assembly is provided that allows for cooling of the extruded profile. The die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending from the inlet end to the outlet end. The die assembly also includes an internal mandrel disposed within the internal cavity. The internal mandrel has an end proximate the outlet end of the die assembly. The die assembly also includes an internal cooling channel within the internal mandrel. The internal cooling channel has an exit at or near the end of the internal mandrel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional application entitled “Extrusion Conformal Cooling Devices, Methods, and Systems,” filed on February 28, 2022, and assigned Serial No. 63 / 314,762, the disclosure of which is expressly incorporated herein by reference in its entirety. [Technical field]

[0002] SUMMARY The present disclosure relates generally to apparatus, methods, and systems for cooling extrusion profiles. [Background technology]

[0003] Metal extrusion is a method of producing metal parts. During metal extrusion, a block or billet of extruded metal with a particular cross-section and length starts as a workpiece in an extrusion chamber and is forced to flow through a die of the same or smaller cross-sectional area, thus forming the billet into a new cross-section or profile. A large number of cross-sections are produced by this method. The cross-section or profile produced is uniform over the entire length of the metal extrusion. In one example, a cylindrical billet may be formed into a smaller diameter circular part, a hollow tube, or some other shape. Billets of other shapes are also possible.

[0004] Metal extrusion is possible at room temperature, but is often performed while the billet is at an elevated temperature. Extruding a metal billet while it is at an elevated temperature reduces the yield strength of the metal billet, which leads to a reduction in the force required to pass the metal billet through a die of smaller cross-sectional area. The temperature of the material may further increase due to plastic deformation of the billet as it flows through the extrusion die. The increased temperature during extrusion can be used to convert the heat treatable metal alloy into a single-phase solid solution ready for subsequent heat treatment. The heat treatable metal alloy can be quenched using a fluid as it exits the extrusion die to convert the metal from a single-phase solid solution to a supersaturated solid solution, ready for subsequent aging.

[0005] In recent years, metal extrusion has been increasingly used to produce complex extruded profiles containing multiple internal voids from quench-sensitive alloys. Summary of the Invention [Means for solving the problem]

[0006] According to one aspect of the disclosure, a die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending from the inlet end to the outlet end. The die assembly also includes an internal mandrel disposed within the internal cavity. The internal mandrel has an end proximate the outlet end of the die assembly. The die assembly also includes an internal cooling channel within the internal mandrel. The internal cooling channel has an exit at or near an end of the internal mandrel.

[0007] According to another aspect of the disclosure, there is a method of cooling an extrusion profile with a die assembly. The die assembly includes an inlet end, an outlet end opposite the inlet end, an internal cavity extending from the inlet end to the outlet end, an internal mandrel disposed within the internal cavity and having an end proximate the outlet end of the die assembly, and an internal cooling channel within the internal mandrel, the internal cooling channel extending from an inlet disposed on an exterior surface of the die assembly to an outlet disposed at or near an end of the internal mandrel. The method includes feeding a billet of material through the internal cavity of the die assembly such that the billet of material is extruded through the outlet end of the die assembly to form the extrusion profile. The extrusion profile has an internal hollow section formed by the internal mandrel. The method of cooling the extrusion profile also includes feeding a fluid to the internal cooling channel. The internal cooling channel is configured to convey a fluid from an inlet to an outlet of the internal cooling channel such that the fluid is dispersed within the internal hollow section of the extrusion profile at an outlet of the internal cooling channel within the internal mandrel to cool the extrusion profile.

[0008] According to yet another aspect of the disclosure, a system for cooling an extruded profile includes a die assembly. The die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending from the inlet end to the outlet end. The die assembly also includes an internal mandrel disposed within the internal cavity. The internal mandrel has an end proximate the outlet end of the die assembly. The internal mandrel is configured to form an internal hollow section in the extruded profile. The die assembly also includes an internal cooling channel within the internal mandrel. The internal cooling channel has an outlet disposed at or near an end of the internal mandrel. The system for cooling the extruded profile also includes a fluid source in communication with the internal cooling channel of the die assembly. The fluid source is configured to provide a flow of fluid through the internal cooling channel. The outlet of the internal cooling channel is configured to distribute a fluid within the internal hollow section of the extruded profile to cool the extruded profile.

[0009] According to yet another aspect of the disclosure, a die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending from the inlet end to the outlet end. The die assembly also includes an internal mandrel disposed within the internal cavity. The internal mandrel has an end proximate the outlet end of the die assembly. The die assembly also includes an internal cooling channel within the internal mandrel. The internal cooling channel has an outlet at or near the end of the internal mandrel. The die assembly also includes a conduit fluidly coupled to the outlet and extending from the end of the internal mandrel. The conduit includes an opening.

[0010] According to yet another aspect of the disclosure, a system for cooling an extruded profile includes a die assembly. The die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending from the inlet end to the outlet end. The die assembly also includes an internal mandrel disposed within the internal cavity. The internal mandrel has an end proximate the outlet end of the die assembly. The internal mandrel is configured to form an internal hollow section in the extruded profile. The die assembly also includes an internal cooling channel within the internal mandrel. The internal cooling channel has an outlet disposed at or near an end of the internal mandrel. The die assembly also includes a conduit fluidly coupled to the outlet and extending from the end of the internal mandrel. The conduit includes an opening. The system for cooling the extruded profile also includes an auxiliary conduit connected to an exterior surface of the die assembly. The auxiliary conduit extends in an extrusion direction of the system. The auxiliary conduit is fluidly coupled to the internal cooling channel and includes an opening. The system for cooling the extrusion profile also includes a fluid source in communication with the internal cooling channel and the auxiliary conduit of the die assembly. The fluid source is configured to provide a flow of fluid through the internal cooling channel and the auxiliary conduit. The openings in the conduit are configured to distribute fluid within the internal hollow section of the extrusion profile to cool the extrusion profile. The openings in the auxiliary conduit are configured to distribute fluid to an exterior of the extrusion profile to cool the extrusion profile.

[0011] In relation to any of the aforementioned aspects, the devices, methods, and systems described herein may alternatively or additionally include any combination of one or more of the following features.

[0012] The internal cooling channel includes another outlet disposed at the outflow end of the die assembly. The die assembly further includes a bridge connecting the internal mandrel to an inner surface of the die assembly, the inner surface of the die assembly being formed by the internal cavity. The internal cooling channel extends from an inlet disposed at an outer surface of the die assembly to an outlet such that the internal cooling channel extends through the die assembly, the bridge, and the internal mandrel. The inlet of the internal cooling channel is configured to receive a fluid into the internal cooling channel, the internal cooling channel is configured to allow the fluid to flow through the internal cooling channel in the die assembly, the bridge, and the internal mandrel to the outlet, and the outlet is configured to distribute the fluid from the internal cooling channel to cool the internal channel of the extrusion profile.

[0013] The die assembly further includes an insulator lining the interior or interior cooling channel. The die assembly includes two or more interior mandrels disposed within the interior cavity, the two or more interior mandrels being connected to an interior surface of the die assembly by one or more bridges, the interior surface of the die assembly being formed by the interior cavity. The die assembly further includes a temperature sensor channel extending into the die assembly from an opening on an exterior surface of the die assembly, the temperature sensor channel being configured to accommodate a temperature sensor.

[0014] The method further includes supplying a fluid through interior cooling channels extending through the die assembly and through a bridge connecting the interior mandrel to an interior surface of the die assembly, the interior surface of the die assembly being formed by the interior cavity and the interior mandrel. The fluid is uniformly distributed within the interior hollow section of the extrusion profile.

[0015] The method further includes insulating the fluid within the interior cooling channel via insulation lining the interior of the interior cooling channel. The fluid is conveyed by a plurality of interior cooling channels, each interior cooling channel of the plurality of interior cooling channels having an outlet located near or at an end of the interior mandrel such that the fluid is conveyed to a respective outlet of the respective interior cooling channel. The fluid is dispersed within the interior hollow section of the extruded profile at the respective outlet of the respective interior cooling channel.

[0016] The method further includes controlling a flow rate of the fluid in the internal cooling channel. The die assembly further includes a bridge connecting the internal mandrel to an inner surface of the die assembly, the inner surface of the die assembly being formed by the internal cavity. The die assembly further includes an internal cooling channel inlet located at an outer surface of the die assembly such that the internal cooling channel extends through the die assembly, the bridge, and the internal mandrel.

[0017] The system further includes a thermocouple disposed within the die assembly. The system further includes a controller configured to control a flow rate of the fluid from the fluid source. The system further includes a controller configured to control a dummy block in the extrusion chamber to pass a billet of material through the die assembly. The controller is configured to control a rate at which the billet of material is extruded through the die assembly. The opening is disposed at or near a distal end of the conduit. The opening is disposed along a length of the conduit. The opening includes a nozzle. The interior space of the conduit is converging or diverging. The opening is configured to control a flow rate and an angle at which the fluid impinges on a particular surface of the interior hollow section of the extruded profile. The conduit has a non-circular cross section. The interior cooling channel is configured to allow the fluid to flow through the interior cooling channel, bridge, and interior mandrel in the die assembly to the outlet and the conduit. The conduit is configured to allow the fluid to flow from the outlet through an interior space of the conduit to disperse the fluid from the interior space to cool the interior hollow section of the extruded profile.

[0018] The system further includes a quench box configured to cool an outer surface of the extruded profile. The quench box is disposed downstream in the extrusion direction from the die assembly. The system further includes a straightening device configured to contact and straighten the extruded profile. The straightening device is disposed downstream in the extrusion direction from the quench box. The straightening device comprises a dummy die. The dummy die includes an internal component configured to contact a surface of an internal hollow section of the extruded profile. The dummy die includes an external component configured to contact an outer surface of the extruded profile. The straightening device comprises a clamp configured to grip the extruded profile and pull the extruded profile in the extrusion direction such that tension is applied to the extruded profile.

[0019] For a more complete understanding of the present disclosure, reference should be made to the following detailed description and the accompanying drawings, in which like reference numerals identify like elements throughout. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 illustrates a perspective view of a die assembly according to an example. [Diagram 2] 2 is a partial cutaway view of the die assembly of FIG. 1 according to an example. [Diagram 3] FIG. 1 illustrates a perspective view of a die assembly according to an example. [Figure 4] FIG. 1 is an exploded perspective view of a die assembly according to an example. [Diagram 5] FIG. 5 is an exploded cross-sectional view of the die assembly of FIG. 4 according to an example. [Figure 6] FIG. 1 is an exploded perspective view of a die assembly according to an example. [Figure 7] FIG. 6 is a cross-sectional view of the die cap of FIG. 5 according to an example. [Figure 8] 1 is a flow diagram of a method for cooling an extrusion profile using a die assembly, according to an example. [Figure 9] 1 is a schematic diagram of a system for cooling an extrusion profile according to an example. [Figure 10] 1 is a schematic diagram of a system for cooling an extrusion profile according to an example. [Figure 11] FIG. 2 is a partial perspective view of an extrusion profile according to an example. [Figure 12] FIG. 2 is a plan view of a cross section of an extrusion profile according to an example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] While the disclosed die assemblies, methods, and systems are susceptible of embodiment in various forms, specific embodiments of the invention are shown in the drawings (and described below), it will be understood that the disclosure is intended to be illustrative and is not intended to limit the invention to the specific embodiments described and illustrated herein.

[0022] As mentioned above, the metal billet may be heated to various elevated temperatures before being extruded through the die. After passing through the die, the heat treatable profile is often cooled. Traditional cooling methods only directly cool the exterior of the extrusion. For example, the exterior of the extrusion may be cooled by spraying (i.e., quenching) a fluid such as water onto the extrusion. One example of this is a quench curtain. However, this can cause the exterior of the extrusion to cool more quickly than the interior of the extrusion. This is called differential cooling, where different parts of the profile cool at different rates. If the extrusion cools unevenly, it will create geometric distortions (i.e., warping) and residual stresses (stresses that try to hold the geometric shape) in the extrusion, which can result in high (e.g., up to 50%) rejection rates of the extrusion. The problems of distortion and residual stresses are exacerbated by complex profiles with multiple internal voids, especially asymmetric profiles. Extrusion Profiles When conventional cooling methods are used, such as spraying a quench curtain on the exterior surface of the billet, there may be a gap between the exit (i.e., outflow end) of the extrusion die and the entrance of the quench curtain. During a billet push, there may be a length of the extrusion profile (shape) that passes through the extrusion die but does not reach the quench curtain and thus is not sprayed with fluid. This length of extrusion profile may not be cooled quickly enough to retain certain material properties, and as a result, this length of extrusion profile may have to be discarded.

[0023] A die assembly for cooling an extrusion profile is described. Methods and systems for cooling an extrusion profile using the die assembly are also described. The die assembly, methods, and systems described herein can provide a fluid flow to an internal hollow section formed in the extrusion profile. The die assembly, methods, and systems described herein can directly cool the internal hollow section(s) of the extrusion profile and / or the exterior of the extrusion profile.

[0024] The die assembly includes an inlet end, an outlet end opposite the inlet end, and an internal cavity extending between the inlet end and the outlet end. The die assembly includes an internal mandrel disposed within the internal cavity of the die assembly. The internal mandrel can be configured to form an internal hollow section within the extrusion profile. The internal mandrel has an end near the outlet end of the die assembly and includes an internal cooling channel having an outlet located at or near the end of the internal mandrel, or an outlet located further away from the end of the internal mandrel when an extension or conduit is connected to the internal mandrel, as described below. The internal cooling channel can be configured to receive, convey, and distribute a fluid flow through the outlet to cool the internal hollow section of the extrusion profile. The fluid flow distributed within the internal hollow section of the extrusion profile at the outlet of the internal cooling channel can be used to cool the extrusion profile.

[0025] The die assembly may be configured to receive a billet of material at an inlet end, the die assembly may be configured to convey the billet material through an internal cavity, and extrude the billet material as an extruded profile out of an outlet end of the die assembly.

[0026] In some examples, the die assembly can include multiple internal mandrels. The extrusion profile can include an internal hollow section for each internal mandrel in the die assembly. Thus, the die assemblies described herein can be used to manufacture complex extrusion profiles having multiple internal hollow channels. In these examples, each of the internal mandrels can have a respective internal cooling channel configured to receive, convey, and distribute fluid through a respective outlet to cool the internal hollow channels formed in the extrusion profile by the multiple internal mandrels.

[0027] Complex extrusion profiles with multiple internal hollow channels may be useful in several different applications. For example, the die assemblies, methods, and systems disclosed herein may be used to manufacture complex extrusion profiles in automotive applications. For example, geometrically complex aluminum extrusion profiles can be used to create battery trays for electric vehicles. For example, stronger alloys and thinner wall sections are needed to reduce the weight of metal parts for electric vehicles. More complex shaped profiles with internal cavities, thinner walls, and stronger alloys lead to greater distortion issues as the profile is quenched as it exits the die. Cooling the extrusion profile more uniformly can help avoid these issues. In addition, internal cooling of the extrusion profile can ensure that peak age hardening is achieved. For example, internal cooling of the extrusion profile can ensure that the extrusion profile is cooled quickly and uniformly to maximize the benefits of the subsequent heat treatment process. Thus, internal cooling of the extrusion profile allows the highest potential alloy strength to be achieved. Obtaining higher alloy strength may allow for further weight reduction (e.g., reduced extrusion profile size) and / or higher performance of the extrusion profile.

[0028] The die assemblies, methods, and systems described herein may be used independently or in combination with other known or later developed devices, methods, and systems for cooling extruded profiles. For example, the die assemblies, methods, and systems described herein may be used in combination with a quench curtain that applies fluid to an exterior surface of the extruded profile to cool the exterior surface of the extruded profile.

[0029] The die assemblies, methods, and systems described herein are configured to provide a fluid flow to the internal hollow section of the extrusion profile to cool the extrusion profile, more specifically to cool the interior of the extrusion profile. A fluid flow can be provided to the internal hollow section of the extrusion profile to more uniformly cool the extrusion profile. More uniform cooling of the extrusion profile can reduce or eliminate residual stresses and / or geometric distortions in the extrusion profile. Specifically, internal cooling can eliminate insufficient mechanical properties (e.g., material strength) of the interior of complex multi-hollow aluminum profiles (profiles) made from quench-sensitive alloys. In addition, more uniform cooling of the extrusion profile can improve the material strength of the extrusion profile. Thus, the rejection rate of the extruded profile can be reduced, less material, energy, time, and labor is wasted, and the extrusion process and system become more efficient.

[0030] Although described below in connection with metal extrusion, the disclosed die assembly apparatus, methods, and systems are also useful in a variety of other applications. For example, the disclosed die assembly apparatus, methods, and systems may be used in connection with other materials, such as plastic extrusion and food processing extrusion (e.g., cooling and / or filling the interior of an extruded food product).

[0031] 1 and 2 show a die assembly 100 according to an example of the present disclosure. FIG. 1 shows a perspective view of the die assembly 100. As shown in FIG. 1, the die assembly 100 includes an inlet end 101 and an internal cavity 102. The inlet end 101 of the die assembly 100 may be configured to receive a billet of material. The internal cavity 102 may be configured to convey the billet of material received at the inlet end 101 through one or more portholes 103 through the die assembly 100. The internal cavity 102 forms an inner surface 104 of the die assembly 100. As shown in FIG. 1, the die assembly 100 also includes an inner mandrel 105 centrally disposed within the internal cavity 102 and connected or coupled to the inner surface 104 of the die assembly 100 via one or more bridges 106. In the example shown in FIG. 1, four bridges 106 connect the single inner mandrel 105 to the inner surface 104 of the die assembly 100. However, any number of bridges 106 and internal mandrels 105 may be used. The portholes 103 are openings or entrances to the internal cavities 102 separated by the bridges 106. The location of the internal mandrels 105 within the internal cavities 102 may vary as well. For example, rather than being centered within the internal cavities 102, the internal mandrels 105 may be offset from the center and positioned closer to the inner surface 104. FIG. 1 also shows internal cooling channel inlets 107 on the exterior surface 108 of the die assembly 100. As described below, the internal cooling channel inlets 107 may be located on other surfaces of the die assembly 100. FIG. 1 shows an external view of the die assembly 100 according to one example, although internal details of the various components of the die assembly 100 are described below with respect to the die assembly 100 shown in FIG. 2.

[0032] Figure 2 illustrates a partial cutaway view of a die assembly 100, such as the die assembly 100 of Figure 1 described above. As shown in Figure 2, the die assembly 100 includes an inlet end 101, an outlet end 110, an internal cavity 102 extending from the inlet end 101 to the outlet end 110, an internal mandrel 105, and internal cooling channels 111. In some examples, the die assembly 100 may further include a bridge 106 connecting the internal mandrel 105 to the die assembly 100.

[0033] The inlet end 101 of the die assembly 100 may be configured to receive a block or billet of material ("billet material"). The billet material may be the material from which the extrusion profile is produced. In some examples, the billet material may be a metal. In some examples, the billet material may be aluminum or an aluminum alloy. For example, the billet material may be aluminum alloy AA6082. In other examples, the billet material may be a higher strength aluminum alloy such as a 7000 series aluminum alloy (e.g., AA7005, AA7055, etc.). The billet material is not limited to the alloys or alloy ranges mentioned above. It should be understood that alloys from any range of alloys may be used. In other examples, the billet material may be copper, steel, magnesium, lead, or any alloy thereof. In yet another example, the billet material may be a plastic or a food product.

[0034] The billet material may be at an elevated temperature when it is received by the inlet end 101 of the die assembly 100. Receiving the billet material at an elevated temperature reduces the yield strength of the billet material and subsequently reduces the force required to feed the billet material through the die assembly 100. The temperature of the billet material when it is received by the inlet end 101 of the die assembly 100 may depend on the billet material used. For example, if the billet material is aluminum or an aluminum alloy, the billet material may be between 700°F and 930°F when it is received by the inlet end 101 of the die assembly 100. The billet material may be received by the inlet end 101 of the die assembly 100 at other temperatures as well. During the extrusion process, plastic deformation of the material as it flows through the die may cause a further increase in the material temperature, transforming the material into a single-phase solid solution.

[0035] The outflow end 110 of the die assembly 100 is located opposite the inflow end 101. The outflow end 110 of the die assembly 100 may be configured to extrude the billet material into an extrusion profile. The outflow end 110 of the die assembly 100 may include an opening (e.g., an orifice) having a shape corresponding to a desired outer periphery of the extrusion profile. When the billet material reaches the outflow end 110 of the die assembly 100, the billet material may be extruded (e.g., thrust, forced) through the opening of the outflow end 110 of the die assembly 100. Thus, while passing through the outflow end 110, the billet material may be forced into the shape of the opening of the outflow end 110 (e.g., a shape corresponding to a desired outer periphery of the extrusion profile). After passing through the outflow end 110, the billet material may become an extrusion profile having an outer periphery corresponding to the shape of the opening of the outflow end 110 of the die assembly 100. The shape of the opening of the outflow end 110 may be variously modified to create extrusion profiles having various shapes and sizes.

[0036] The internal cavity 102 of the die assembly 100 extends from the inlet end 101 of the die assembly 100 to the outlet end 110 of the die assembly 100. The internal cavity 102 may be configured to transport billet material from the inlet end 101 of the die assembly 100 to the outlet end 110 of the die assembly 100. The die assembly 100 further includes an inner surface 104 formed by the internal cavity 102 of the die assembly 100. The inner surface 104 may extend around the internal cavity 102 from the inlet end 101 to the outlet end 110 of the die assembly 100. The internal cavity 102 may vary in size and shape and may or may not be uniform from the inlet end 101 to the outlet end 110.

[0037] 2, the internal mandrel 105 is disposed within the internal cavity 102 and has an end 113 proximate the outflow end 110 of the die assembly 100. The distance from the end 113 of the internal mandrel 105 to the outflow end 110 of the die assembly 100 may vary such that the faces of the end 113 of the internal mandrel 105 and the outflow end 110 of the die assembly 100 may be adjacent (i.e., the faces share the same plane or are substantially close to sharing the same plane) or may be offset by a distance. In some examples, the face of the end 113 of the internal mandrel 105 may be disposed beyond the plane of the outflow end 110 of the die assembly 100 (i.e., the internal mandrel 105 may extend beyond the internal cavity 102 formed in the die assembly 100). As shown in FIG. 2, the end 113 of the internal mandrel 105 is offset (inwardly within the internal cavity 102) from the outflow end 110 of the die assembly 100. The internal mandrel 105 can be configured to form an internal hollow section within the extrusion profile. Specifically, as the billet material moves through the internal cavity 102 of the die assembly 100, the billet material can be forced to move around the internal mandrel 105. In other words, the internal mandrel 105 is held in place by the bridge 106, over which the billet material flows to form the internal shape of the profile. As the billet material is extruded through the outflow end 110 of the die assembly 100, the billet material can be forced to flow both through the openings in the outflow end 110 of the die assembly 100 and around the internal mandrel 105. In some examples, the internal mandrel 105 can extend into an opening formed in the outflow end 110. As the billet material passes through an opening at the outflow end 110 of the die assembly 100, it may move (e.g., be extruded) past an end 113 of the internal mandrel 105 proximate the outflow end 110 of the die assembly 100. As the billet material moves past the end 113 of the internal mandrel 105, an internal hollow section may be formed into the extrusion profile.The internal mandrel 105 can form an internal hollow section within the extrusion profile that corresponds to the size and position of the internal mandrel 105. The size and position of the internal mandrel 105 can be varied to form internal hollow sections of various shapes and sizes within the extrusion profile.

[0038] In some examples, the die assembly 100 can include two or more internal mandrels 105 disposed within the internal cavity 102. Each of the two or more internal mandrels 105 can generate a respective internal hollow section in the extrusion profile as the billet material is extruded through the outflow end 110 of the die assembly 100 and around each of the two or more internal mandrels 105. Multiple internal mandrels 105 can be used to create complex extrusion profiles having multiple internal hollow sections.

[0039] An internal cooling channel 111 is formed within the inner mandrel 105. The internal cooling channel 111 can be configured to convey a flow of fluid to an outlet 112 located at or near an end 113 of the inner mandrel 105. In one example, an outlet 112 located at an end 113 of the inner mandrel 105 can mean that the outlet 112 can be located at an end face of the inner mandrel 105. In another example, an outlet 112 located near an end 113 of the inner mandrel 105 can mean that the outlet 112 can be located on a side of the inner mandrel 105 adjacent an end face of the inner mandrel 105. In one example, an outlet 112 located at or near an end of the mandrel can mean that the outlet 112 can be located on a surface of the inner mandrel 105 downstream (relative to the flow of billet material) of the welding chamber 114. In some examples, multiple internal cooling channels 111 can be formed within the inner mandrel 105. In these examples, each internal cooling channel 111 can have an outlet 112 disposed at an end 113 of the internal mandrel 105 (i.e., the end 113 of the internal mandrel 105 can include multiple outlets 112). The partially cut away cross section shown in FIG. 2 illustrates two internal cooling channels 111. In some examples, the or each outlet 112 can include a nozzle. Various types of nozzles can be used. For example, flat fan nozzles, hollow cone nozzles, full cone nozzles, etc. can be used. In some examples, the outlets 112 can be configured to direct the fluid flow such that the fluid flow impinges on a surface of the internal hollow section of the extruded profile formed by the internal mandrel 105 (i.e., the internal channel of the extruded profile). In one example, the outlets 112 can be configured to uniformly disperse, distribute, or release the fluid within the internal hollow section of the extruded profile. In another example, the outlets 112 can be configured to non-uniformly disperse the fluid within the internal hollow section of the extruded profile. In this case, the fluid may be ejected directionally, directing the flow of fluid to specific regions or locations within the internal hollow section of the extruded profile.For example, the outlets 112 may be shaped to direct the flow of fluid toward a particular side of the internal hollow section, such as a side that requires more cooling than other sides (e.g., due to different wall thicknesses or different wall temperatures as the extrusion profile exits the die assembly 100). A particular type of nozzle or fitting may also be used for this purpose. In some examples, the outlets may control the flow rate of fluid dispersed, distributed, or ejected by the outlets 112. In examples including multiple internal cooling channels 111 and therefore multiple outlets 112 formed in the internal mandrel 105, each of the outlets 112 may direct the flow of fluid toward a different surface of the internal hollow section of the extruded profile.

[0040] The location of the outlet(s) 112 at the end 113 of the inner mandrel 105 may vary. For example, the outlets 112 of the interior cooling channels 111 may be located anywhere on the face of the end 113 of the inner mandrel 105 such that the outlets 112 may be located along the edge of the face, in the central portion of the face, or anywhere in between. The location of the outlet(s) 112 may depend on the desired directional flow of the cooling fluid and / or whether the outlet(s) 112 are configured to emit the fluid directionally or uniformly. In an example where the inner mandrel 105 extends beyond the internal cavity 102 of the die assembly 100, the outlet(s) 112 may be located on the exterior surface 108 of the inner mandrel 105 other than the end 113 of the inner mandrel 105. In an example including multiple cooling channels, two or more of the multiple cooling channels may meet within the inner mandrel 105 to form a combined interior cooling channel 111. In this case, the number of outlets 112 of the internal cooling channels 111 may be less than the number of inlets 107 of the internal cooling channels 111. For example, a die assembly 100 having four bridges 106 connected to a single internal mandrel 105 may have four separate internal cooling channels 111 in each bridge 106, but the four internal cooling channels 111 may meet within the internal mandrel 105 to form a single combined internal cooling channel 111 within the internal mandrel 105. In this case, even though there are four inlets 107 to the internal cooling channels 111 located on the exterior surface 108 of the die assembly 100, there is only a single outlet 112 located at the end 113 of the internal mandrel 105. The reverse may also be true. For example, a single internal cooling channel 111 located within a single bridge 106 may split into multiple internal cooling channels 111 within the internal mandrel 105 such that there is a single inlet 107 to the internal cooling channel 111, but multiple outlets 112.The number of inlets 107, outlets 112, and internal cooling channels 111 may depend on various factors, such as, for example, the size of the die assembly 100, the size and / or shape of the internal cavity 102 of the die assembly 100, the number and / or geometry of the bridges 106, the number and / or geometry of the internal mandrels 105, the desired size of the inlets 107 and / or outlets 112, the billet material being extruded, the cooling fluid, the desired extrusion profile, etc.

[0041] In some examples, the die assembly may further include one or more extensions or conduits fluidly coupled to the outlet(s) 112. FIG. 3 shows a die assembly 120 including two internal mandrels 105 and a conduit 121 extending from an end 113 of each internal mandrel 105. Some of the die assembly 120 and its respective components may be the same as those described above with respect to the die assembly 100 of FIGS. 1 and 2. For example, the inlet end 101, the outlet end 110, the internal cavity 102, the inner surface 104, the bridge 106, the internal mandrels 105, the outer surface 108, and the outlet 112 may be the same as those described above with respect to the die assembly 100 of FIGS. 1 and 2. However, the die assembly 120 includes two internal mandrels 105, each of which creates an internal hollow section in the extruded profile as the billet material is extruded through the outlet end 110 of the die assembly 120. The die assembly 120 of FIG. 3 also includes two conduits 121 , each of which is fluidly connected to an outlet 112 disposed at an end 113 of a respective inner mandrel 105 .

[0042] Each conduit 121 may be fluidly coupled to an outlet 112 disposed at an end 113 of the inner mandrel 105 and may extend or protrude away from the end 113 of the inner mandrel 105. Each conduit 121 may extend away from the end 113 of the inner mandrel 105 in a direction in which the billet material is extruded through the die assembly 120. The distance from the inner mandrel that the conduits 121 extend may vary. For example, the distal end 123 of the conduit 121 may be more than 0.5 meters from the end 113 of the inner mandrel 105, more than 1 meter from the end 113 of the inner mandrel 105, or more than 1.5 meters from the end 113 of the inner mandrel 105. In some examples, the distal end 123 of the conduit 121 may be located between 0.5 meters and 2 meters away from the end 113 of the inner mandrel 105. In some examples, the distal end 123 of the conduit 121 may be less than 5 meters from the end 113 of the inner mandrel 105. In some examples, the distal end 123 of the conduit 121 may be less than 0.5 meters from the end 113 of the inner mandrel 105.

[0043] Each conduit 121 may be attached or coupled to an outlet 112. In some examples, a threaded connection may be used to connect or couple the outlets 112 and the conduits 121. In other examples, the conduits 121 may be welded to the outlets 112. In some examples, the conduits 121 may be attached or coupled (e.g., welded) to the end 113 of the inner mandrel 105. In other embodiments, the conduits 121 may be bolted to the end 113 of the inner mandrel 105 using a flange. In some examples, two or more conduits 121 may extend away from the end 113 of a single inner mandrel 105. For example, two outlets 112 may be disposed at the end 113 of a single inner mandrel 105, and a conduit 121 may be attached or coupled to each outlet 112.

[0044] The conduit 121 includes an interior space, channel, or pathway through which a fluid can flow through the conduit 121. The conduit 121 may be configured to convey or allow the flow of a fluid from the outlet 112 of the internal cooling channel 111 to the opening 122 of the conduit 121. The opening 122 of the conduit 121 may be configured to disperse, distribute, or release a fluid into the internal hollow section of the extrusion profile. In some examples, the opening 122 may be located at a distal end 123 of the conduit 121 opposite the internal mandrel 105. In other examples, the opening 122 may be located along the length of the conduit 121 (i.e., either a separate opening 122 at a single location along the length of the conduit 121 or a long opening 122 that is continuously open along a particular length of the conduit 121). In some examples, the conduit 121 may include two or more openings 122. For example, the conduit 121 may include an opening 122 disposed at a distal end 123 of the conduit 121 and one or more openings 122 disposed along the length of the conduit 121, as shown in Figure 3. In some examples, the conduit 121 may include multiple openings 122 disposed radially around the conduit 121. In some examples, the openings 122 may be disposed downstream of the outflow end 110 of the die assembly 120.

[0045] In some examples, the or each opening 122 can include a nozzle 125. In some examples, one or more of the openings 122 disposed along the length of the conduit 121 can include a nozzle 125. Various types of nozzles can be used. For example, flat fan nozzles, hollow cone nozzles, full cone nozzles, etc. can be used. In some examples, the openings can control the flow rate of the fluid dispersed, dispensed, or emitted from the openings 122. In some examples, the openings 122 can be configured to direct the fluid flow such that the fluid flow impinges on a surface of the interior hollow section of the extruded profile formed by the interior mandrel 105 (i.e., the interior channel of the extruded profile). In one example, the openings 122 can be configured to uniformly disperse, distribute, or emit the fluid within the interior hollow section of the extruded profile. In another example, the openings 122 can be configured to non-uniformly disperse the fluid within the interior hollow section of the extruded profile. In this case, the fluid can be directionally discharged to direct the fluid flow to a specific area or location of the interior hollow section of the extruded profile. For example, the openings 122 may be shaped to direct the fluid flow to a particular side of the interior hollow section. A particular type of nozzle or fitting may also be used for this purpose. In examples including multiple openings 122, each of the openings 122 may direct the fluid flow toward a different surface of the interior hollow section of the extrusion profile.

[0046] The conduit 121 may allow the fluid to be dispersed downstream of the outflow end 110 of the die assembly 120, i.e., in the extrusion direction. In some examples, the internal spaces, channels, or paths within the conduit 121 may converge or diverge to manage fluid pressure as desired. In other examples, the internal spaces, channels, or paths within the conduit may be the same size along the length of the conduit 121. Thus, the location where the fluid is dispersed into the internal hollow section of the extrusion profile may be controlled to be downstream of the outflow end 110 of the die assembly 120. In some examples, the location where the fluid is dispersed into the internal hollow section of the profile may be advantageously selected to be the same location where the fluid is dispersed to the exterior of the extruded profile to provide more uniform cooling of the extruded profile, thereby minimizing deformation of the extruded profile and improving material strength.

[0047] In some examples, as shown in FIG. 3, the conduit 121 may have a hollow cylindrical shape. However, the shape of the conduit 121 is not limited thereto. For example, the conduit 121 may have a hollow rectangular shape, or any other shape suitable for conveying a fluid flow. The conduit 121 may be constructed from a metal or a metal alloy. In some examples, the conduit 121 may be constructed from a steel alloy. For example, the conduit 121 may be constructed from stainless steel. In some examples, the conduit 121 may be constructed from an H-13 steel alloy. In some examples, the conduit 121 may be heat treated. In other examples, the conduit 121 may be constructed from another material, such as a ceramic, a plastic, or another suitable material.

[0048] The fluid can be configured to cool the extrusion profile. The fluid may be one of water (i.e., H2O), nitrogen (i.e., N2), oxygen (O2), carbon dioxide (CO2), and the like, and any mixtures thereof. Other fluids are possible. In some examples, the internal cooling channel 111 can further include an insulator 116 (i.e., an insulating coating applied directly to the inside of the walls of the internal cooling channel 111) lining the interior of the internal cooling channel 111. The insulator 116 can insulate the fluid flowing through the internal cooling channel 111 from various components of the die assembly 100 in which the internal cooling channel 111 is located. The insulator lining 116 can prevent excessive heating of the fluid as it travels through or traverses the die assembly 100. Additionally, the insulator 116 can prevent excessive cooling of the die assembly 100. As described below, insulating tubes or hoses can also be used to achieve these purposes.

[0049] In addition to conveying fluid to the outlet 112 for cooling the internal channels of the extrusion profile, the internal cooling channels 111 and the fluid conveyed therein can be used to cool the die assembly 100 and its components. The internal cooling channels 111 can be configured to cool any portion of the die assembly 100 in which the internal cooling channels 111 are formed. For example, the internal cooling channels 111 can be configured to cool the internal mandrel 105 as fluid flows through a portion of the internal cooling channels 111 located within the internal mandrel 105. The internal cooling channels 111 can also be enabled to cool the bridge 106, as described below. The internal cooling channels 111 in the die assembly 100 can also help prevent overheating of the workpiece material (billet) inside the die assembly 100, which would increase the productivity of an extrusion process, such as aluminum extrusion.

[0050] In some examples, the die assembly 100 can include a bridge 106. The bridge 106 can connect the internal mandrel 105 to the inner surface 104 of the die assembly 100. As described above, the inner surface 104 of the die assembly 100 can be formed by the internal cavity 102. The bridge 106 can be disposed within the internal cavity 102 of the die assembly 100. In some examples, only a single bridge 106 can connect the internal mandrel 105 to the inner surface 104 of the die assembly 100. In other examples, two or more bridges 106 may connect the internal mandrel 105 to the inner surface 104 of the die assembly 100. As shown in FIG. 1, there are four bridges 106 connecting the internal mandrel 105 to the inner surface 104 of the die assembly 100. The partially cut away cross section shown in FIG. 2 shows two bridges 106. In some examples, a portion of the internal cooling channel 111 can be formed within the bridge 106. In some examples, a single cooling channel may be formed within the bridge 106. In other examples, multiple cooling channels may be formed within the bridges 106. In the example shown in FIG.

[0051] In examples including bridges 106, as the billet material moves through the internal cavity 102 of the die assembly 100, the billet material may move around and over one or more bridges 106. In some examples, the billet material may move through one or more port holes 103. A port hole 103 may be an opening or entrance to an internal cavity 102 of the die assembly 100 formed by two or more bridges 106 disposed within the internal cavity 102. In other words, a port hole 103 is an opening or entrance to an internal cavity 102 separated by a bridge 106. FIG. 1 shows four port holes 103. In some examples, as shown in FIG. 2, the internal cavity 102 includes a weld chamber 114 that is joined after the billet material flows through different port holes 103 and around bridges 106 in the die assembly 100. The welding chamber 114 can provide sufficient volume for the portions of the billet material flowing through the different portholes 103 and around the bridge 106 before flowing around the inner mandrel 105 and through the outflow end 110 of the die assembly 100 to be welded.

[0052] The internal cooling channels 111 can have inlets 107 located on the exterior surface 108 of the die assembly 100. Thus, in these examples, the internal cooling channels 111 can extend from the inlets 107 located on the exterior surface 108 of the die assembly 100, through the die assembly 100, through the bridge 106, through the internal mandrel 105, to an outlet 112 located at an end 113 of the internal mandrel 105. The inlets 107 of the internal cooling channels 111 can be configured to receive a fluid into the internal cooling channels 111. The internal cooling channels 111 may be configured to allow a fluid to flow through the internal cooling channels 111 in the die assembly 100, the bridge 106, and the internal mandrel 105 to the outlet 112. The outlet 112 can be configured to distribute the fluid from the internal cooling channels 111 to cool the interior of the extrusion profile.

[0053] In some examples, the die assembly 100 may further include a temperature sensor channel extending into the die assembly 100 from an opening in the exterior surface 108 of the die assembly 100. The temperature sensor channel may be configured to accommodate a temperature sensor. The temperature sensor channel may be configured such that a sensing end of the temperature sensor is within or adjacent to one of the various components of the die assembly 100. For example, the temperature sensor channel may be configured such that a sensing end of the temperature sensor is within or adjacent to the die assembly 100, the inner mandrel 105, or the bridge 106. In some examples, two or more temperature sensor channels may be formed in the die assembly 100. In some examples, the temperature sensor may be a thermocouple.

[0054] The die assembly 100 may include a steel alloy. For example, the die assembly 100 may include an H-13 steel alloy. The die assembly 100 may be heat treated. In some examples, the die assembly 100 described herein may be formed using 3D printing (e.g., direct metal laser sintering, direct laser metal melting, etc.). In other examples, the die assembly 100 may be formed by drilling the internal cooling channels 111 from the inlet 107 and / or the outlet 112. In still other examples, the die assembly 100 may be formed from two parts on either side of a plane that includes the internal cooling channels 111, and the internal cooling channels 111 may be machined into each part prior to joining the two parts of the die assembly 100. Any insulation 116 or hoses 145 may be inserted into the cooling channels prior to joining the two parts of the die assembly 100. In some examples, the die assembly 100 described herein may include two or more components, including the components of the die assembly 100 described above. In other examples, the die assembly 100 described herein and its components may be integrally formed as one unit (ie, monolithic).

[0055] In some examples, the die assembly 100 described above may be comprised of two parts or portions (i.e., subparts of the die assembly 100) configured to abut, mate, or otherwise join with one another. The first part is the die mandrel 131, which includes the bridge 106 and forms the internal shape of the extrusion profile. The second part is the die cap 132, which is downstream (with respect to the flow of the billet material) from the die mandrel 131 and forms the external shape of the extrusion profile. Figures 4 and 5 show an example of a two-part die assembly 130 comprised of the die mandrel 131 and the die cap 132. Figure 4 shows an exploded perspective view of the die assembly 130, and Figure 5 shows an exploded cross-sectional view of the die assembly 130 of Figure 4. The various components of the die assembly 130 shown in Figures 4 and 5 may be the same as those described above with respect to Figures 1 and 2. For example, the inlet end 101, the outlet end 110, the internal cavity 102, and the internal mandrel 105 shown in Figures 4 and 5 may be the same as those described above with respect to Figures 1 and 2. Additionally, the inner surface 104, the outlet 112, the bridge 106, and the outer surface 108 shown in Figures 4 and 5 may be the same as those described above with respect to Figures 1 and 2. However, the internal cooling channel 111 and its inlet 107 in Figures 4 and 5 are slightly different from those in Figures 1 and 2. As shown in Figures 4 and 5, the inlet 107 of the internal cooling channel 111 is located on the outer surface of the outlet end 110 of the die assembly 100, rather than being located on the outer surface 108 adjacent the inlet end 101 of the die assembly 100.

[0056] 4 and 5, the die mandrel 131 may have a first surface 140 corresponding to the inlet end 101 of the die assembly 130 and a second surface 141 opposite the first surface 140. The die mandrel 131 may include the inlet end 101 of the die assembly 130, a first (i.e., upper or upstream) portion of the internal cavity 102 extending from the inlet end 101 of the die assembly 130 to the second surface 141 of the die mandrel 131, the internal mandrel 105, and a portion of the internal cooling channel 111 extending from the second surface 141 of the die mandrel 131 to an outlet 112 disposed at an end 113 of the internal mandrel 105. In some examples, the die mandrel 131 may include the entire internal cooling channel 111 extending from an inlet 107 located on an outer surface 108 of the die mandrel 131 to an outlet 112 located on the internal mandrel 105. In some examples, the die mandrel 131 may further include one or more bridges 106 connecting the inner mandrel 105 to an inner surface 104 of the die mandrel 131 and one or more port holes 103 located within the inner cavity 102 and extending around the one or more bridges 106. A second surface 141 of the die mandrel 131 may be configured to be received by or coupled to the die cap 132.

[0057] The die cap 132 may have a first surface 142 configured to receive, mate with, or be coupled to the second surface 141 of the die mandrel 131. The die cap 132 may also have a second surface 143 opposite the first surface 142, the second surface 143 of the die cap 132 corresponding to the outflow end 110 of the die assembly 130. The die cap 132 may include a second (i.e., lower or downstream) portion of the internal cavity 102 that extends from the first surface 142 of the die cap 132 to the outflow end 110 of the die assembly 130. The die cap 132 may further include a portion of the internal cooling channel 111 that extends from the inlet 107 located on the second surface 143 of the die cap 132 to the first surface 142 of the die cap 132.

[0058] The die mandrel 131 and the die cap 132 can be configured to mate or be coupled to one another to form the die assembly 130. The second surface 141 of the die mandrel 131 and the first surface 142 of the die cap 132 may be configured to abut one another when the die mandrel 131 and the die cap 132 are mated or coupled to one another. The inner mandrel 105 of the die mandrel 131 can extend beyond the second surface 141 of the die mandrel 131 into a second portion of the inner cavity 102 formed in the die cap 132 when the die mandrel 131 and the die cap 132 are mated or coupled to one another. When the die mandrel 131 and the die cap 132 are mated or coupled to one another to form the die assembly 130, the inlet end 101 located on the die mandrel 131 and the outlet end 110 located on the die cap 132 are fluidly coupled to one another (i.e., in fluid communication with one another). Thus, an internal cavity 102 can be formed that extends from the inlet end 101, through the die mandrel 131, around the bridge 106 to form a porthole 103, into the welding chamber 114, through the die cap 132, around the internal mandrel 105 to the outlet end 110 of the die cap 132.

[0059] FIG. 5 illustrates an exploded cross-sectional view of the die assembly 130 of FIG. 4 according to an example. FIG. 5 illustrates internal cooling passages 144 that can carry fluid to cool the internal hollow section of the extrusion profile. In some examples, when the die assembly 130 includes a die mandrel 131 and a die cap 132, the internal cooling channels 111 can extend through both the die mandrel 131 and the die cap 132. In some examples, the internal cooling channels 111 can extend through the die cap 132 from an inlet 107 located on a second surface 143 of the die cap 132 to a first surface 142 of the die cap 132. The internal cooling channels 111 can extend from the second surface 141 of the die mandrel 131 through the die mandrel 131 to an outlet 112 located at an end 113 of the internal mandrel 105. When the die cap 132 and the die mandrel 131 are joined together, the portion of the internal cooling channel 111 formed in the die cap 132 and the portion of the internal cooling channel 111 formed in the die mandrel 131 are fluidly connected to each other (i.e., fluidly coupled).

[0060] In some examples, a hose 145 may be provided within the internal cooling channel 111. A single or single length of hose 145 may extend through a portion of the internal cooling channel 111 formed within the die cap 132 and a portion of the internal cooling channel 111 formed within the die mandrel 131. In this manner, fluid (e.g., coolant) delivered through the internal cooling channel 111 may be provided through the hose 145. In some examples, the hose 145 may facilitate the transfer of fluid from the die cap 132 to the die mandrel 131 (i.e., aid the fluid in crossing the interface between the first surface 142 of the die cap 132 and the second surface 141 of the die mandrel 131). In some examples, the hose 145 may be disposed within the internal cooling channel 111 such that an air gap exists between the hose 145 and the walls of the internal cooling channel 111. The air gap may be provided to reduce heat transfer between the die assembly 130 and the fluid conveyed through the hose 145 within the internal cooling channel 111. In some examples, the interior of the interior cooling channel 111 may include insulation (e.g., 116) disposed between the hose 145 and the interior cooling channel 111. In some examples, the exterior of the hose 145 may be constructed from an insulating material to prevent excessive heating of the fluid and / or excessive cooling of the die assembly 130.

[0061] A die assembly including suitable cooling channels 111 may also be used to externally quench the extrusion profile very close to the outflow end 110 (i.e., die exit). This may help to reduce distortion problems and quench curtain scrap problems resulting from the inability to quench the last portion of the extrusion billet, as discussed above. Figures 6 and 7 show one such example die assembly 150. Figure 6 shows an exploded perspective view of the die assembly 150. The die assembly 150 may include a die mandrel 131 and a die cap 132. The die mandrel 131 and the die cap 132 and some of their respective components may be the same as those described above with respect to the die assembly 130 of Figures 4 and 5. For example, the inlet end 101, the outlet end, the internal cavity 102, the inner surface 104, the bridge 106, the internal mandrel 105, the outer surface 108, the first surface 140 and the second surface 141 of the die mandrel 131, and the first surface 142 and the second surface 143 of the die cap 132 may be the same as those described above with respect to the die assembly 130 of Figures 4 and 5.

[0062] As shown in FIGS. 6 and 7 , the internal cooling channels 111 can be disposed entirely within the die cap 132. The internal cooling channels 111 can have one or more inlets 107 disposed on the second surface 143 of the die cap 132 and one or more outlets 112 disposed on the second surface 143 of the die cap 132. The outlets 112 can be closer to an opening formed in the outflow end 110 (i.e., the second surface 143 of the die cap 132) than the inlets 107. The outlets 112 can be the same as those described above with respect to the die assembly 100 of FIG. 2, except for their location on the die assembly 150. For example, the outlets 112 can include nozzles and / or can be configured to direct fluid to a surface of the extrusion profile. In some examples, the inlets 107 for the internal cooling channels 111 can be disposed at different locations on the die assembly 150. In one example, the inlets 107 can be disposed on the outer surface 108 of the die mandrel 131, and a portion of the internal cooling channels 111 can be formed within the die mandrel 131.

[0063] FIG. 7 illustrates a cross-sectional view of the die cap 132 of FIG. 6 according to an example. As shown in FIG. 7, the die cap 132 may have an external cooling passage 160 formed therein. The internal cooling channel 111, and thus the external cooling passage 160, may extend from an inlet 107 located on the second surface 143 of the die cap 132, through a portion of the die cap 132, to an outlet 112 also located on the second surface 143 of the die cap 132. In this example, the internal cooling channel 111 may be configured to convey a fluid to the outlet 112 such that the fluid cools the exterior surface of the extrusion profile. The internal cooling channel 111 may further include a hose 145, as described above with respect to the die assembly 130 of FIGS. 4 and 5. In addition to conveying the fluid to the outlet 112 located on the second surface 143 of the die cap 132, the fluid traveling through the internal cooling channel 111 may also cool the die cap 132. The internal cooling channels 111 and outlets 112 located on the second surface 143 of the die cap 132 can cool the exterior surface of the extrusion profile as it exits the exit end 110 of the die assembly 150. Thus, in addition to minimizing distortion, it can maintain a length of the extrusion profile that passes through the die assembly 150 but does not reach the separate spaced apart quench curtains between the billet pushes, which are typically discarded.

[0064] In some examples, the die assembly can include one or more internal cooling channels 111 as described above with respect to the die assembly 130 of Figures 4 and 5, and one or more internal cooling channels 111 as described above with respect to the die assembly 150 of Figures 6 and 7. Thus, the die assemblies 130, 150 can include internal cooling channels 111 and respective outlets 112 configured to provide fluid to both a surface of the internal hollow section of the extrusion profile (e.g., the outlet 112 disposed at the end 113 of the internal mandrel 105) and an outer surface of the extrusion profile (e.g., the outlet 112 disposed at the second surface 143 of the die cap 132), thereby cooling both the surface of the internal hollow section of the extrusion profile and the outer surface of the extrusion profile. In some embodiments, the internal cooling channels 111 having outlets 112 located on the end 113 of the internal mandrel 105 and the internal cooling channels 111 having outlets 112 located on the second surface 143 of the die cap 132 can each have their own respective inlets 107 located on the die assemblies 130, 150. In other embodiments, the internal cooling channels 111 having outlets 112 located on the end 113 of the internal mandrel 105 and the internal cooling channels 111 having outlets 112 located on the second surface 143 of the die cap 132 can be connected to each other and share the same inlet 107. Thus, fluid can be provided through the inlet 107 and the internal cooling channels 111 can be split, with one portion of the internal cooling channels 111 directing fluid to one outlet 112 located on the end 113 of the internal mandrel 105 and another portion of the internal cooling channels 111 directing fluid to another outlet 112 located on the second surface 143 of the die cap 132.

[0065] FIG. 8 shows a flow chart illustrating a method of cooling an extrusion profile using a die assembly according to an example. The method of FIG. 8 can be implemented using any of the die assemblies 100, 120, 130, and 150 described above. For example, the method of cooling an extrusion profile can be used with a die assembly 100 having an inlet end 101, an outlet end 110 opposite the inlet end 101, an internal cavity 102 extending from the inlet end 101 to the outlet end 110, an internal mandrel 105 disposed within the internal cavity 102, the internal mandrel 105 having an end proximate the outlet end 110 of the die assembly 100, and internal cooling channels 111 within the internal mandrel 105, the internal cooling channels 111 extending from an inlet 107 disposed on an exterior surface 108 of the die assembly 100 to an outlet 112 disposed on an end 113 of the internal mandrel 105. In other examples, a different die assembly 100 can be used. The methods may be performed in the order shown, but may also be performed in any number of different orders or according to which additional, different, or fewer operations may be provided.

[0066] A method of cooling an extrusion profile using a die assembly 100 can include feeding (S180) a billet of material through an internal cavity 102 of the die assembly 100 such that the billet of material is extruded through an outflow end 110 of the die assembly 100 to form an extrusion profile, the extrusion profile having an internal hollow section formed by an internal mandrel 105. The billet material can be the same as described above with respect to the die assembly 100 of FIGS. 1 and 2. The inflow end 101 of the die assembly 100 can receive the billet material. The billet material can pass through the inflow end 101, through the porthole 103, around the bridge 106 and into the welding chamber 114. A dummy block can feed (e.g., push, urge) the billet material through the internal cavity 102 of the die assembly 100. In some examples, the billet material can be hot as it is fed through the internal cavity 102 of the die assembly 100.

[0067] The method of cooling an extrusion profile with the die assembly 100 may also include supplying (S181) a fluid to the internal cooling channels 111. The internal cooling channels 111 may be configured to convey a fluid from an inlet 107 of the internal cooling channels 111 to an outlet 112 thereof, such that the fluid is dispersed within an internal hollow section on the extrusion profile at an outlet 112 of the internal cooling channels 111 within the internal mandrel 105 to cool the extrusion profile. In some examples, supplying the fluid may include supplying the fluid through the internal cooling channels 111 extending through the die assembly 100, a bridge 106 connecting the internal mandrel 105 to an internal surface 104 of the die assembly 100, the internal surface 104 of the die assembly 100 being formed by the internal cavity 102 and the internal mandrel 105. In some examples, the fluid may be uniformly distributed within the internal hollow section of the extrusion profile. In other examples, the fluid may be non-uniformly distributed within the internal hollow section of the extrusion profile. In some examples, the fluid may be conveyed by a plurality of internal cooling channels 111. In this case, each internal cooling channel 111 of the plurality of internal cooling channels 111 may have an outlet 112 disposed at an end 113 of the internal mandrel 105 such that the fluid is conveyed to a respective outlet 112 of the respective internal cooling channel 111. In some examples, the fluid may be dispersed within the internal hollow section of the extruded profile at the respective outlet 112 of the respective internal cooling channel 111.

[0068] In some examples, the method of cooling an extrusion profile with the die assembly 100 can further include conveying a fluid by the internal cooling channels 111 from an inlet 107 to an outlet 112 of the internal cooling channels 111. The fluid may be the same as described above with respect to the die assembly 100 of FIGS. 1 and 2. In some examples, conveying can include transporting the fluid through the internal cooling channels 111 extending through the internal mandrel 105. In some examples, as described above, the die assembly 100 can further include one or more bridges 106 connecting the internal mandrel 105 to the inner surface 104 of the die assembly 100, and the internal cooling channels 111 can further include an inlet 107 located on the outer surface 108 of the die assembly 100. In these examples, conveying may include receiving fluid from a fluid source via an inlet 107 of the internal cooling channel 111 and transporting the fluid through the internal cooling channel 111 extending through a bridge 106 connecting the die assembly 100, the internal mandrel 105 to the inner surface 104 of the die assembly 100, the inner surface 104 of the die assembly 100 being formed by the internal cavity 102 and the internal mandrel 105.

[0069] In some examples, the method of cooling an extrusion profile using the die assembly 100 may further include extruding the billet material through the outflow end 110 of the die assembly 100 to form an extrusion profile having an internal hollow section formed by the internal mandrel 105. A dummy block may be used to extrude (e.g., push, press) the billet material through the opening in the outflow end 110 of the die assembly 100. The outflow end 110 of the die assembly 100 may have a shape that corresponds to a desired outer surface of the extrusion profile. As the billet material moves through the opening in the outflow end 110 of the die assembly 100, the billet material moves around the internal mandrel 105 of the die assembly 100 and forms a hollow interior channel or section in the extrusion profile. The billet material may be at a high temperature while extruding the billet material through the outflow end 110 of the die assembly 100.

[0070] In some examples, the method of cooling an extrusion profile using the die assembly 100 may further include dispersing a fluid into an interior hollow section of the extrusion profile at an outlet 112 of the interior cooling channel 111 in the interior mandrel 105 to cool the extrusion profile. In one example, dispersing may include dispersing the fluid evenly within the interior hollow section of the extrusion profile. In some examples, dispersing the fluid at the outlet 112 of the cooling channel 111 in the interior mandrel 105 may include directing the fluid to impinge on one or more surfaces of the interior hollow section of the extrusion profile. In some examples, dispersing the fluid at the outlet 112 of the interior cooling channel 111 may further include dispersing the fluid through one or more nozzles located at the outlet 112. In some examples, dispersing the fluid at the outlet 112 of the interior cooling channel 111 may occur simultaneously with extruding the billet material at the outflow end 110 of the die assembly 100.

[0071] In some examples, the internal mandrel 105 can include a plurality of internal cooling channels 111, each of the plurality of internal cooling channels 111 having an outlet 112 disposed at an end 113 of the internal mandrel 105. In these examples, conveying can include conveying the fluid by the plurality of internal cooling channels 111 to a respective outlet 112 of each internal cooling channel 111. In these examples, dispersing can include dispersing the fluid at the respective outlet 112 of each internal cooling channel 111 within the internal hollow section of the extrusion profile.

[0072] In some examples, the method of cooling an extrusion profile using the die assembly 100 can further include insulating the fluid within the internal cooling channel 111 via insulation 116 lining the interior of the internal cooling channel 111. The insulation lining 116 can be the same as that described above with respect to the die assembly 100 of FIGS. 1 and 2. The fluid within the internal cooling channel 111 can be insulated to prevent excessive heating of the fluid as it is conveyed from the inlet 107 to the outlet 112 of the cooling channel. In other examples, a hose can be routed through the internal cooling channel 111 to supply the fluid (i.e., coolant). The hose can be the same as that described above with respect to the die assembly 100 of FIGS. 4 and 5.

[0073] In some examples, the method of cooling an extrusion profile using the die assembly 100 may further include controlling a flow rate of a fluid in the internal cooling channels 111. The flow rate of a fluid in the internal cooling channels 111 may be controlled to control the rate at which the extrusion profile is cooled. Specifically, the flow rate of a fluid in the internal cooling channels 111 may be controlled to control the rate at which the surface of the internal hollow section of the extrusion profile is cooled. In some examples, the flow rate of a fluid in the internal cooling channels 111 may be controlled such that the surface of the internal hollow section is cooled at a rate corresponding to the rate at which the exterior surface of the extrusion profile is cooled. The exterior surface of the extrusion profile may be cooled with any currently known or later developed cooling method, such as the quench curtain described above. In some examples, the flow rate of a fluid may be controlled such that the fluid is dispersed from the outlet 112 only when the billet material is being extruded through the outlet end 110 of the die assembly 100.

[0074] In some examples, the method of cooling an extruded profile using the die assembly 100 may further include supplying fluid to an outlet 112 of an internal cooling channel 111 disposed at the outflow end 110 of the die assembly 100 to cool the exterior of the extruded profile.

[0075] Figure 9 illustrates a system 220 for cooling an extrusion profile 191 according to an example. In one example, as shown in Figure 9, the system 220 includes a die assembly 100 and a fluid source 190. The system 220 of Figure 9 may include the die assembly 100 described above with respect to Figures 1 and 2, the die assembly 120 described with respect to Figure 3, the die assembly 130 described with respect to Figures 4 and 5, or the die assembly 150 described with respect to Figures 6 and 7. For example, the system 220 for cooling the extrusion profile 191 can be used with a die assembly 100 having an inlet end 101, an outlet end 110 opposite the inlet end 101, an internal cavity 102 extending from the inlet end 101 to the outlet end 110, an internal mandrel 105 disposed within the internal cavity 102, the internal mandrel 105 having an end proximate the outlet end 110 of the die assembly 100, and internal cooling channels 111 within the internal mandrel 105, the internal cooling channels 111 extending from an inlet 107 disposed on an exterior surface 108 of the die assembly 100 to an outlet 112 disposed on an end 113 of the internal mandrel 105. In other examples, different die assemblies 100 can be used. The system 220 of FIG. 9 can use the method described above with respect to FIG. 8. In other examples, different methods may be used.

[0076] Some components of the die assembly 100 and / or extrusion profile 191 are not shown in Figure 9 but may be present in the system 220 as described with respect to Figure 9. For example, the inner mandrel 105, the inner cooling channels 111, the bridges 106, the insulator lining, and the inner hollow section are not shown in Figure 9 but may be present in the system 220 as described with respect to Figure 9.

[0077] The system 220 for cooling the extrusion profile 191 further includes a fluid source 190. The fluid source 190 may be in communication with the internal cooling channels 111 of the die assembly 100 and configured to provide a flow of fluid to and through the internal cooling channels 111. In some examples, a hose, tube, or other conduit may connect the fluid source 190 to the internal cooling channels 111 formed in the die assembly 100. The fluid may be the same as that described above with respect to the die assembly 100 of FIGS. 1 and 2 and the method of FIG. 8. In some examples, the fluid source 190 may be a tank that contains a fluid. In some examples, the fluid source 190 may be pressurized such that the fluid flows from the fluid source 190 to and through the internal cooling channels 111. In other examples, the fluid source 190 may be a water line connected to a commercial building. In some examples, a supply line 192 may be disposed between the fluid source 190 and the die assembly 100. In these examples, the fluid may flow from a fluid source 190 through a supply line 192 into the die assembly 100. The fluid source 190 may be configured to supply or provide a flow of the fluid through the internal cooling channels 111.

[0078] The outlets 112 of the internal cooling channels 111 can be configured to distribute a fluid within the internal hollow section of the extrusion profile 191 to cool the extrusion profile 191. The outlets 112 can be configured to distribute a fluid within the internal hollow section of the extrusion profile 191 as described above with respect to the method of FIG. 8. In another example, the outlets 112 of the internal cooling channels 111 can be configured to distribute a fluid onto an exterior surface of the extrusion profile 191 as the extrusion profile 191 exits the die assembly 100.

[0079] In some examples, the system 220 further includes an extrusion chamber 193. The extrusion chamber 193 may be coupled to the inlet end 101 of the die assembly 100. The extrusion chamber 193 may be configured to accommodate a billet 194 of material to be extruded through the die assembly 100. The extrusion chamber 193 may have a shape corresponding to a shape of the billet 194 of material. In some examples, the extrusion chamber 193 may have a cylindrical shape (i.e., circular cross-section) or a rectangular prism or cuboid shape (i.e., square or rectangular cross-section). Other shapes are possible. The extrusion chamber 193 may include chamber walls that surround the billet 194 of material as it is fed to the die assembly 100 and extruded through the die assembly 100.

[0080] In some examples, the system 220 may further include a dummy block 195. The extrusion chamber 193 may include a dummy block 195. The dummy block 195 may be configured to extrude a billet 194 of material from inside the extrusion chamber 193 through the die assembly 100 to form an extrusion profile 191, the extrusion profile 191 having an internal hollow section formed by the internal mandrel 105. In some examples, the extrusion chamber 193 may further include a stem 196 attached to the dummy block 195. The stem 196 may extend telescopically (i.e., linearly within the extrusion chamber 193). As the stem 196 extends, the dummy block 195 may extrude the billet 194 material from inside the extrusion chamber 193 through the die assembly 100 to form the extrusion profile 191.

[0081] 9 may further include a bridge 106 connecting the internal mandrel 105 to an interior surface 104 of the die assembly 100. The interior surface 104 of the die assembly 100 may be formed by the interior cavity 102 of the die assembly 100. In these examples, a portion of the interior cooling channel 111 may be formed in the bridge 106. In these examples, the fluid source 190 may be configured to provide a flow of fluid through the portion of the interior cooling channel 111 formed in the bridge 106.

[0082] In some examples, the die assembly 100 of the system 220 of FIG. 9 can further include an inlet 107 of an internal cooling channel 111 located at the exterior surface 108 of the die assembly 100. In these examples, the internal cooling channel 111 can extend through the die assembly 100, the bridge 106, and the internal mandrel 105. The fluid source 190 can be configured to provide a flow of fluid to the inlet 107 of the internal cooling channel 111. In one example, the fluid source 190 can provide a flow of fluid through the die assembly 100, the bridge 106, and the internal mandrel 105 to an outlet 112 located at an end 113 of the internal mandrel 105. In another example, the fluid source 190 can provide a flow of fluid to an outlet 112 located at an outflow end 110 of the die assembly 100.

[0083] In some examples, the system 220 for cooling the extrusion profile 191 may further include a thermocouple 197 disposed within the die assembly 100. In some examples, the thermocouple 197 may be inserted into a temperature sensor channel that extends from an opening in the exterior surface 108 of the die assembly 100 into the die assembly 100. The thermocouple 197 may be disposed within the die assembly 100 such that an end of the thermocouple 197 is within and / or adjacent to one of the various elements of the die assembly 100. The thermocouple 197 may be configured to determine a temperature of an element of the die assembly 100 adjacent to or disposed therein. For example, an end of the thermocouple 197 may be disposed within and / or adjacent to and configured to determine a temperature of the die assembly 100, the bridge 106, or the inner mandrel 105.

[0084] In some examples, the system 220 for cooling the extrusion profile 191 can further include a controller 199 configured to control the flow rate of the fluid from the fluid source 190. The controller 199 can control the flow rate of the fluid passing from the source such that the flow of the fluid is only provided to the die assembly 100 and thus dispersed from the outlet 112 as the billet 194 material is extruded through the outflow end 110 of the die assembly 100. In some examples, the controller 199 can be connected to actuators and / or valves to control the flow rate of the fluid from the fluid source 190. In some examples, the controller 199 can be connected to a pump to control the flow rate of the fluid from the fluid source 190. The flow rate through the various cooling channels disclosed herein can be determined in a number of different ways. In one example, the flow rate can be determined through offline process planning. In another example, the flow rate can be determined by run-to-run adjustments in the field (i.e., the flow rate can be determined / adjusted during the billet push). In yet another example, the flow rate may be determined in real time by the online process controller 199 using feedback based on temperature measurements and / or profile temperature and shape measurements of the die assembly 100.

[0085] In some examples, the controller 199 can control the flow rate of fluid from the fluid source 190 to control the rate at which the extruded profile 191 is cooled. In some examples, the controller 199 can control the flow rate of fluid from the fluid source 190 to control the rate at which one or more surfaces of an interior hollow section of the extruded profile 191 are cooled. In some examples, the flow rate of fluid from the fluid source 190 can be controlled such that the surfaces of the interior hollow section of the extruded profile 191 can be cooled corresponding to (e.g., at a similar rate to) the rate at which the exterior surface of the extruded profile 191 is cooled. The exterior surface of the extruded profile 191 can be cooled by any method now known or later developed for cooling the extruded profile 191.

[0086] In some examples, the system 220 for cooling the extrusion profile 191 may further include a controller 199 configured to control the dummy block 195 in the extrusion chamber 193 to force the billet 194 of material through the die assembly 100. In some examples, a single controller 199 may be configured to control the flow rate of the dummy block 195 and the fluid source 190. In other examples, a separate controller 199 may be provided for each of the dummy block 195 and the fluid source 190. In some examples, the controller 199 may control the rate at which the billet 194 material is extruded at the outflow end 110 of the die assembly 100. In some implementations, the rate at which the billet 194 material is extruded through the outflow end 110 of the die assembly 100 may be controlled in conjunction with the rate of flow of the fluid from the fluid source 190 to control the rate at which the extruded profile 191 is cooled.

[0087] In some examples, the system for cooling the extruded profile can further include an auxiliary conduit configured to cool the outer surface of the extruded profile. Figure 10 shows a system 230 for cooling the extruded profile including a conduit 121 (e.g., extending from the inner mandrel 105) and an auxiliary conduit 231 including an opening 232 configured to cool the outer surface of the extruded profile. Some of the system 230 and its respective components may be the same as those described above with respect to the system 220 of Figure 9. For example, the system 230 can include the fluid source 190, the supply line 192, the extrusion chamber 193, the billet 194, the dummy block 195, the stem 196, and the controller 199, as described above with respect to Figure 9.

[0088] The system 230 shown in FIG. 10 may include any of the die assemblies 100, 120, 130, and 150 described herein. As shown in FIG. 10, the system 230 includes the die assembly 120 including the conduit 121, as described above with respect to FIG. 3. Although two conduits 121 are shown in FIG. 10, any number of conduits 121 may be used, as described above. The system 230 further includes an auxiliary conduit 231. The auxiliary conduit 231 may be fluidly coupled (i.e., in fluid communication) with an internal cooling channel (e.g., the internal cooling channel 111) of the die assembly 120 such that fluid from a fluid source supplying fluid to the internal cooling channel 111 also supplies fluid to the auxiliary conduit 231. In some examples, the auxiliary conduit 231 may be connected to the outer surface 108 of the die assembly 120. In some examples, the auxiliary conduit 231 may be threadably connected to the outer surface 108 of the die assembly 120. In other examples, the auxiliary conduit 231 may be welded to the outer surface 108 of the die assembly 120. In yet another example, the auxiliary conduit 231 may not be in fluid communication with the internal cooling channel 111 and may not be coupled to the die assembly 120. In one example, the auxiliary conduit 231 may be in fluid communication with a fluid source, either the same fluid source 190 that supplies fluid to the internal cooling channel 111 or a separate fluid source. Thus, in some examples, fluid may be supplied to the auxiliary conduit 231 through the internal cooling channel 111 of the die assembly. In other examples, the fluid supplied to the auxiliary conduit 231 may not flow through the internal cooling channel 111 or the die assembly 120. The auxiliary conduit 231 may extend along the extrusion direction of the system 230. The auxiliary conduit 231 may include openings 232 configured to disperse, distribute, or emit a flow of fluid onto an exterior surface of the extruded profile. In some examples, the auxiliary conduit 231 may include two or more openings 232. In some examples, the auxiliary conduit 231 may include one or more openings 232 disposed along a length of the auxiliary conduit 231.

[0089] In some examples, the or each opening 232 may include a nozzle (e.g., nozzle 125). Various types of nozzles may be used. For example, flat fan nozzles, hollow cone nozzles, full cone nozzles, etc. In some examples, the openings 232 may be configured to direct the fluid flow so that it impinges on the exterior surface of the extruded profile. In some examples, the fluid may be emitted in a directional manner to direct the fluid flow to a particular area or location of the exterior surface of the extruded profile. For example, the openings 232 may be shaped to direct the fluid flow to a particular side of the exterior surface of the extruded profile. A particular type of nozzle or fitting may also be used for this purpose. In examples including multiple openings 232, each of the openings 232 may direct the fluid flow toward a different surface (or different portions of the same surface) of the exterior of the extruded profile. Although a single auxiliary conduit 231 is shown in FIG. 10, the system 230 may include additional auxiliary conduits 231 located at different points around the extruded profile. For example, the second auxiliary conduit 231 may be located at the bottom of Figure 10, i.e., on the opposite side of the die assembly from the auxiliary conduit 231 shown at the top of Figure 10. In this example, the exterior surface of the extrusion profile may be cooled from opposite directions by the various auxiliary conduits 231.

[0090] In some examples, the auxiliary conduit 231 and the conduit 121 may be configured to distribute fluid at the same or substantially the same location along the extrusion direction of the system 230. Thus, the auxiliary conduit 231 may cool the exterior surface of the extrusion profile at the same or substantially the same location as the conduit 121 cools the interior hollow section of the extrusion profile. Thus, the system 230 may advantageously provide more uniform cooling of the extrusion profile, improving the material strength of the extrusion profile and reducing deformation of the extrusion profile.

[0091] In some examples, the system 230 can further include a quench box 235. The quench box 235 can be disposed downstream of the die assembly 120 in an extrusion direction of the system 230. In some examples, the quench box 235 can be disposed downstream of the conduit 121 and the auxiliary conduit 231 in the extrusion direction. The extruded profile can travel through the quench box 235. As the extrusion profile travels through the quench box 235, the quench box 235 can apply a quench curtain to an outer surface of the extrusion profile to cool the extrusion profile. The quench curtain can be a spray of a fluid, such as water, that contacts the outer surface of the extrusion profile.

[0092] In some examples, the system 229 can further include a straightener 237. The straightener 237 may be disposed downstream of the die assembly 120 in the extrusion direction. In some examples, the straightener 237 may be disposed downstream of the conduit 121 and / or the auxiliary conduit 231 in the extrusion direction. In other examples, such as shown in FIG. 10, the straightener 237 may be disposed downstream of the quench box 235 in the extrusion direction. The straightener 237 is configured to contact the extruded profile and straighten the extruded profile as it is extruded.

[0093] In some examples, the straightening device 237 can include a dummy die including an internal component and an external component. The internal component can have the same shape as the internal hollow section of the extrusion profile. In some examples, each internal hollow section of the extrusion profile can be provided with an internal component. The external component can be configured to surround or circumscribe the outer surface of the extrusion profile. In some examples, the external component can include multiple elements, each element configured to surround the outer surface of the extrusion profile. As the extrusion profile moves in the extrusion direction, the extrusion profile can receive the internal component within the internal hollow section of the extrusion profile and the external component can contact the outer surface of the extrusion profile. Thus, the dummy die can apply a force to the extruded profile to straighten the extruded profile. In some examples, the dummy die can contact the extrusion profile after the extrusion profile has cooled.

[0094] In some examples, the straightening device 237 comprises a clamp configured to grip the extruded profile. In some examples, the clamp may be configured to grip an end of the extrusion. The clamp may be configured to pull the extruded profile in the extrusion direction such that the extruded profile is placed in tension. In some examples, the straightening device 237 can apply a tensile stress to the extruded profile that is less than the yield stress of the extruded profile. In some examples, the straightening device 237 can apply a tensile stress to the extruded profile that is close to the yield stress of the extruded profile. For example, the straightening device 237 can apply a tensile stress that is within 15%, 30%, or 50% of the yield stress of the extruded profile. In some examples, the straightening device 237 can include multiple clamps to grip the extruded profile at multiple locations to apply a uniform or substantially uniform tension to the extruded profile. In some examples, the clamp can grip the extruded profile after the extruded profile has cooled.

[0095] FIG. 11 illustrates a simple extrusion profile 200 according to an example. The extrusion profile 200, as shown in FIG. 11, is a hollow rectangular extrusion profile. The extrusion profile 200 of FIG. 11 includes a single internal hollow profile 201. The simple extrusion profile 200 as shown in FIG. 11 may be extruded using a die assembly 100 as described above with respect to FIGS. 1, 2, 4, and 5, a method as described above with respect to FIG. 8, and / or a system 220 as described above with respect to FIG. 9. The extrusion profile 200 shown in FIG. 11 may be extruded using a die assembly that includes a single internal mandrel 105.

[0096] FIG. 12 illustrates a cross-section of a complex extrusion profile 210 according to an example. The extrusion profile 210 includes multiple internal hollow sections 211 or channels, as shown in FIG. 12. As shown in FIG. 12, there are 14 internal hollow sections 211. FIG. 12 may illustrate a complex extrusion profile 210, such as one that may be used in the automotive industry. Considering the number of internal hollow sections 211, using internal cooling channels 111 to gain access to these internal profile sections allows for quenching and cooling of various internal surfaces of the extrusion profile 210, which allows for more uniform cooling of the extrusion profile 210. For example, in addition to the quench curtain that cools the exterior of the profile shown in FIG. 12, the die assembly apparatus, methods, and systems described herein allow the inside of multiple internal cavities to be sprayed with a cooling fluid, such as water, as the profile emerges from the extrusion die assembly, which allows the extrusion profile 210 to be more uniformly cooled and avoids the problems discussed above.

[0097] While the present invention has been described with reference to specific embodiments, it will be apparent to those skilled in the art that these embodiments are intended to be illustrative only and not limiting of the invention, and that modifications, additions, and / or deletions can be made to the disclosed embodiments without departing from the spirit and scope of the invention.

[0098] The foregoing description has been given for clarity of understanding only, and no unnecessary limitations should be understood therefrom, since modifications within the scope of the invention may be apparent to those skilled in the art.

Claims

1. 1. A die assembly comprising: An inlet end; an outlet end opposite the inlet end; an interior cavity extending from the inlet end to the outlet end; an inner mandrel disposed within the inner cavity and having an end proximate the outflow end of the die assembly; an internal cooling channel within the inner mandrel, the internal cooling channel having an exit located at or near the end of the inner mandrel.

2. The die assembly of claim 1 , wherein the internal cooling channel includes another outlet disposed at the outflow end of the die assembly.

3. The die assembly of claim 1 , further comprising a bridge connecting said inner mandrel to an inner surface of said die assembly, said inner surface of said die assembly being defined by said inner cavity.

4. 4. The die assembly of claim 3, wherein the internal cooling channel extends from an inlet disposed on an exterior surface of the die assembly to the outlet such that the internal cooling channel extends through the die assembly, the bridge, and the internal mandrel.

5. an inlet of the internal cooling channel configured to receive a fluid within the internal cooling channel; the internal cooling channel is configured to allow fluid to flow through the internal cooling channel in the die assembly, the bridge, and the internal mandrel to an outlet; The die assembly of claim 4 , wherein the outlet is configured to disperse the fluid from the interior cooling channels to cool the interior channels of the extrusion profile.

6. The die assembly of claim 1 , further comprising insulation lining the interior of said internal cooling channels.

7. 2. The die assembly of claim 1, wherein the die assembly includes two or more internal mandrels disposed within the internal cavity, the two or more internal mandrels being connected to an inner surface of the die assembly by one or more bridges, the inner surface of the die assembly being formed by the internal cavity.

8. The die assembly of claim 1 , further comprising a temperature sensor channel extending into the die assembly from an opening on an exterior surface of the die assembly, the temperature sensor channel configured to accommodate a temperature sensor.

9. 1. A method of cooling an extrusion profile using a die assembly, the die assembly including an inlet end, an outlet end opposite the inlet end, an internal cavity extending from the inlet end to the outlet end, an internal mandrel disposed within the internal cavity and having an end proximate the outlet end of the die assembly, and an internal cooling channel within the internal mandrel, the internal cooling channel extending from an inlet disposed on an exterior surface of the die assembly to an outlet disposed at or near the end of the internal mandrel; The method comprises: feeding a billet of material through an internal cavity of the die assembly such that the billet of material is extruded through an outlet end of the die assembly to form an extruded profile; the extrusion profile having an internal hollow section formed by the internal mandrel; The method further comprises: providing a fluid to the internal cooling channel; The method, wherein the internal cooling channel is configured to convey the fluid from the inlet to the outlet of the internal cooling channel such that the fluid is dispersed within the internal hollow section of the extruded profile at the outlet of the internal cooling channel within the internal mandrel to cool the extruded profile.

10. The step of supplying a fluid includes: providing the fluid through the interior cooling channels extending through the die assembly and through bridges connecting the interior mandrel to an interior surface of the die assembly; The method of claim 9 , wherein the inner surface of the die assembly is defined by the internal cavity and the internal mandrel.

11. The method of claim 9 , wherein the fluid is uniformly distributed within the interior hollow section of the extruded profile.

12. The method of claim 9 , further comprising insulating the fluid within the interior cooling channel via insulation lining the interior of the interior cooling channel.

13. 10. The method of claim 9, wherein the fluid is conveyed by a plurality of internal cooling channels, each internal cooling channel of the plurality of internal cooling channels having an outlet disposed near or at the end of the internal mandrel such that the fluid is conveyed to a respective outlet of the respective internal cooling channel.

14. The method of claim 13 , wherein the fluid is dispersed within the internal hollow section of the extruded profile at the respective outlets of the respective internal cooling channels.

15. The method of claim 9 , further comprising controlling a velocity of the fluid within the internal cooling channels.

16. 1. A system for cooling an extrusion profile, comprising: a die assembly and a fluid source; The die assembly includes: An inlet end; an outlet end opposite the inlet end; an interior cavity extending from the inlet end to the outlet end; an inner mandrel disposed within the inner cavity; and an internal cooling channel within the internal mandrel. the inner mandrel has an end proximate the outflow end of the die assembly and is configured to form an inner hollow section within the extrusion profile; the internal cooling channel has an exit located at or near an end of the internal mandrel; the fluid source is in communication with the internal cooling channel of the die assembly and configured to provide a flow of fluid through the internal cooling channel; The outlet of the interior cooling channel is configured to disperse the fluid within the interior hollow section of the extrusion profile to cool the extrusion profile.

17. The die assembly further comprises:

17. The system of claim 16, further comprising a bridge connecting the inner mandrel to an inner surface of the die assembly, the inner surface of the die assembly being defined by the internal cavity.

18. The die assembly further comprises: The system of claim 17 , wherein the interior cooling channel includes an inlet disposed on an exterior surface of the die assembly such that the interior cooling channel extends through the die assembly, the bridge, and the interior mandrel.

19. The system of claim 16 , further comprising a thermocouple disposed within the die assembly.

20. The system of claim 16 , further comprising a controller configured to control a velocity of the fluid from the fluid source.

21. 17. The system of claim 16, further comprising a controller configured to control a dummy block in an extrusion chamber to force a billet of material through the die assembly, the controller configured to control a rate at which the billet of material is forced through the die assembly by the dummy block.

22. 1. A die assembly comprising: An inlet end; an outlet end opposite the inlet end; an interior cavity extending from the inlet end to the outlet end; an inner mandrel disposed within the inner cavity and having an end proximate the outflow end of the die assembly; an internal cooling channel within the inner mandrel having an exit located at or near an end of the inner mandrel; a conduit fluidly coupled to the outlet and extending from the end of the inner mandrel, the conduit including an opening.

23. The die assembly of claim 22 , wherein the opening is located at or near a distal end of the conduit.

24. The die assembly of claim 22 , wherein the openings are disposed along a length of the conduit.

25. 23. The die assembly of claim 22, further comprising a bridge connecting the inner mandrel to an inner surface of the die assembly, the inner surface of the die assembly being defined by the internal cavity.

26. 26. The die assembly of claim 25, wherein the internal cooling channel extends from an inlet disposed on an exterior surface of the die assembly to the outlet such that the internal cooling channel extends through the die assembly, the bridge, and the internal mandrel.

27. an inlet of the internal cooling channel configured to receive a fluid within the internal cooling channel; the internal cooling channels are configured to allow fluid to flow through the internal cooling channels in the die assembly, the bridge, and the internal mandrel to an outlet and a conduit; 27. The die assembly of claim 26, wherein the conduit is configured to allow the fluid to flow from the outlet through an interior space of the conduit and disperse out of the interior space to cool an interior hollow section of the extruded profile.

28. The die assembly of claim 22 , wherein the opening comprises a nozzle.

29. 23. The die assembly of claim 22, wherein the interior space of the conduit is convergent or divergent.

30. 23. The die assembly of claim 22, wherein the openings are configured to control the flow rate and angle at which fluid impinges on a particular surface of the interior hollow section of the extrusion profile.

31. The die assembly of claim 22 , wherein the conduit has a non-circular cross-section.

32. 1. A system for cooling an extrusion profile, comprising: a die assembly, an auxiliary conduit, and a fluid source; The die assembly includes: An inlet end; an outlet end opposite the inlet end; an interior cavity extending from the inlet end to the outlet end; an inner mandrel disposed within the internal cavity, the inner mandrel having an end proximate the outflow end of the die assembly and configured to form an internal hollow section in the extrusion profile; an internal cooling channel within the inner mandrel having an exit located at or near an end of the inner mandrel; a conduit fluidly coupled to the outlet and extending from the end of the inner mandrel, the conduit including an opening; the auxiliary conduit is connected to an exterior surface of the die assembly, extends in an extrusion direction, is fluidly coupled to the interior cooling channel, and includes an opening; the fluid source is in communication with the internal cooling channel and the auxiliary conduit of the die assembly and is configured to provide a flow of fluid through the internal cooling channel and the auxiliary conduit; The opening of the conduit is configured to disperse the fluid within the interior hollow section of the extruded profile to cool the extruded profile, and the opening of the auxiliary conduit is configured to disperse the fluid outside the extruded profile to cool the extruded profile.

33. The die assembly further comprises:

33. The system of claim 32, comprising a bridge connecting the inner mandrel to an inner surface of the die assembly, the inner surface of the die assembly being defined by the internal cavity.

34. The die assembly further comprises:

34. The system of claim 33, wherein the interior cooling channel includes an inlet disposed on an exterior surface of the die assembly such that the interior cooling channel extends through the die assembly, the bridge, and the interior mandrel.

35. a quench box configured to cool an outer surface of the extrusion profile and disposed downstream in an extrusion direction from the die assembly; 33. The system of claim 32, further comprising a straightening device disposed downstream in the extrusion direction from the quench box and configured to contact and straighten the extruded profile.

36. 36. The system of claim 35, wherein the straightening device comprises a dummy die including an internal component configured to contact a surface of the internal hollow section of the extrusion profile and an external component configured to contact the outer surface of the extrusion profile.

37. 36. The system of claim 35, wherein the straightening device comprises a clamp configured to grip the extrusion profile and pull the extrusion profile in an extrusion direction such that the extrusion profile is subjected to tension.

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