Manufacturing a solar technology component from an aluminium-based alloy of an automotive component

Abstract

There is described a solar technology component (120), comprising or consisting of an aluminium-based alloy that originates from an automotive component (110). Further, there is described a method (100) of manufacturing a solar technology component, the method comprising: providing an automotive component (110), in particular a motor block, that comprises an aluminium-based alloy, melting (130) the automotive component (110) to obtain a melt product, and forming (140, 150) the solar technology component (120) from the melt product.

Description

[0001] Manufacturing a solar technology component from an aluminium-based alloy of an automotive component

[0002] Field of the Invention

[0003] The invention relates to a solar technology component, comprising or consisting of an aluminium-based alloy that originates from an automotive component. The invention further relates to a method of manufacturing the solar technology component, the method comprising: providing the automotive component, in particular a motor block, that comprises the aluminium-based alloy, melting the automotive component to obtain a melt product, and forming the solar technology component from the melt product. Further, the invention relates to the use of an automotive component, comprising an aluminium-based alloy, as a starting material to manufacture a solar technology component.

[0004] Technical Background

[0005] Renewable energies are sustainable power sources derived from natural processes that are constantly replenished, for example solar technologies such as photovoltaic. Unlike conventional energy sources (such as combustion motors), renewable energy sources generate clean energy with minimal environmental impact, reducing greenhouse gas emissions and contributing to climate change mitigation. Solar technologies like solar panels convert the natural resources into electricity, offering reliable and increasingly cost-effective alternatives. As global energy needs grow, renewable energies are essential to creating a sustainable and resilient energy future. Accordingly, there is a high demand of solar technology components, for example frames or under-constructions.

[0006] Such solar technology components are often made of aluminium, due to its durability, lightweight, and corrosion resistance, which are ideal for outdoor energy systems. For example, in solar panels, aluminium frames provide structural support and protect the solar cells from environmental factors, extending the solar panel lifespan. Mounting systems (under-constructions), another essential component, are typically crafted from aluminium to securely position solar panels at optimal angles for sunlight exposure. Additionally, aluminium can be used in the housings and heat sinks of solar inverters, which convert DC to AC power for household use.

[0007] However, the process of producing aluminium is very energy intensive, thereby contradicting the sustainable and environmentally-friendly character of renewable energies such as solar technology. Even though aluminium is in principle completely recyclable without loss of quality, usually only a small part of aluminium waste is reused. This is often due to the fact that aluminium product are often alloys, so that it is difficult and cumbersome to separate the aluminium with reasonable effort.

[0008] Summary of the Invention

[0009] There may be a need to provide a solar technology component in an efficient and sustainable manner.

[0010] A component, a method, and a use are described in the following.

[0011] According to an aspect of the invention, there is described a solar technology component (e.g. a frame, a mounting structure, an under-construction, a housing), comprising or consisting of an aluminium-based alloy (in particular a Al-Si-based alloy) that originates from an automotive component (e.g. a motorblock or a mega-casting).

[0012] According to a further aspect of the invention, there is described a method of manufacturing a solar technology component, the method comprising:

[0013] i) providing an automotive component that comprises an aluminium-based alloy; ii) (at least partially) melting the automotive component to obtain a melt product; and

[0014] iii) forming (in particular casting and pressing) the solar technology component from the melt product.

[0015] According to a further aspect of the invention, there is described a use (method of using) of an automotive component, comprising an aluminium-based alloy, as a starting material to manufacture / produce a solar technology component. In the present document, the term "solar technology component" may in particular refer to a component that is associated with a solar technology application and / or suitable to be used in the solar technology sector (preferably outdoor). The term "solar technology" may hereby in particular refer to technology that is used to turn sunlight into (electric) energy. A specific example of solar technology would be solar panels (photovoltaic cells) that convert sunlight directly into electricity. A further example may be a solar inverter that converts direct current from solar panels into alternating current. In order to harvest sunlight, solar technology components may generally be installed outdoors, so that the material may have to fulfil certain durability requirements (e.g. anti-corrosion). Examples of solar technology components may be for example construction profiles for the solar panels, e.g. a frame, a mounting structure or an under-construction. Further, also the inverter associated with the solar panels may be seen as a solar technology component, so that a housing or package associated with solar technology may be a solar technology component. A solar technology component according to the present invention is made from an aluminium-based alloy from the automotive sector. Accordingly, the specific (chemical) composition of the alloy may still be present (and measurable) within the solar technology component.

[0016] In the present document, the term "automotive component" may in particular refer to a component related to the automotive sector, in particular a component associated with a vehicle. Such a vehicle may be for example a car, a bus, a truck, etc. The automotive component may hereby preferably comprise or consist of an aluminium-based alloy, in particular a standardized Al-Si-based alloy. In an embodiment, an automotive component comprises a combustion motor / engine, in particular a motor block. In a further embodiment, the automotive component comprises an electric motor or a generator. In another embodiment, the automotive component comprises a casting. Such a casting may be termed an advanced body structure casting or simply mega / giga casting. Such an automotive component may be produced by an advanced manufacturing process, where large, single aluminium castings are used to form significant portions of a vehicle structure, such as an entire car body frame or chassis section. In an embodiment, the casting may comprise at least one of front / rear underbody, battery housing. In the present document, the term "aluminium-based alloy" may in particular refer to an alloy that comprises aluminium (in particular as the main / primary component) and at least one further element. In a preferred embodiment, the aluminium-based alloy may be an aluminium-silicon-based alloy. In a preferred embodiment, the Al-based alloy may be standardized, so that a specific (preknown) composition of elements is present. In an embodiment, the alloy comprises a plurality of further elements, for example, copper, magnesium, iron, zinc, manganese, etc.

[0017] A specific example of such an Al-Si-based alloy from the automotive industry may be as follows: 2.1 bis 12.5 weight percent Si, 0.3 to 1.9 weight percent Mg, 0.2 to 1.5 weight percent Cu (may also be 3% or higher), 0.2 to 2.0 weight percent Fe, 0.1 to 4 weight percent Zn, 0.2 to 1.5 weight percent Mn. Optionally, there may be for example 0.5 weight percent Ni, 0.35 weight percent Cr, 0.2 weight percent Ti, 0.2 weight percent Zr, 0.35 weight percent Sn. The rest may be aluminium and eventually unavoidable residues, e.g. in the range 0.1 to 0.5 weight percent.

[0018] In the present document, the term "melt product" may in particular refer to a product of a melting process. Such a melt product may be fully or partially molten. In an example, a melt product may be used for a casting / pouring. In this manner, the melt product may be cast into a mould to thereby produce a cast product that can then cool-down and / or made subject of a pressing process. In a melt process, a starting / raw material such as an automotive component may be provided, e.g. into a furnace. By raising the temperature, the aluminium-based alloy of the automotive component (e.g. a motor block) may be (partially) liquefied, thereby enabling the casting into a desired form.

[0019] According to an exemplary embodiment, the invention may be based on the idea that a solar technology component can be provided in an efficient and sustainable (in particular environmentally friendly) manner, when an automotive component is recycled by melting (the aluminium-based alloy) and casting it into the form of the solar technology component. In the automotive sector, a considerable amount of aluminium-based alloy is used for producing components such as the motor block. Due to the increase of electric mobility (and accompanying decrease of combustion motors), there is a decreasing demand for these motor blocks, and the cast alloys they are made of, in the automotive sector. The number of possible uses for these cast alloys is yet very limited, in particular since i) they are not suitable for the production of standardized wrought alloys and ii) the alloy has a complex chemical composition of diverse elements, making recycling (and separation of the aluminium) nearly impossible. Accordingly, an imminent surplus of scrap / waste is to be expected from automotive components, such as motor blocks, in the near future.

[0020] Yet, as discussed above, the solar technology sector is facing a shortage of raw materials in the field of construction materials.

[0021] It has been found by the inventors that this gap can be closed in a surprisingly efficient and sustainable manner by using the motor block waste of the automotive sector as a raw material for the solar technology sector. Thus, the disclosure may counteract the surplus in the automotive industry and the shortage in the solar technology industry by diverting the material flow from the conventional energy sector to the renewable energy sector, thereby promoting the sustainable development of society.

[0022] Since the alloys of the motor blocks are made of casting alloy, their components are often undesirable "impurities" during recycling, in particular when certain wrought alloys are to be produced. Therefore, one would assume that the aluminium-based alloys of automotive components are not suitable for recycling, since extensive processing and depletion of "impurities" would be necessary. Further, a casting alloy is generally not suitable as a stating material for producing wrought alloys.

[0023] However, it has been surprisingly found that the aluminium alloy of automotive components can be directly used for the production of the solar technology components. In fact, the automotive component may be directly molten and cast into the solar technology form without further processing steps, e.g. by extrusion / pressing. It has been surprisingly turned out that no cumbersome separation of elements is required, and the extremely complex composition of the aluminium-based alloy may be directly re-used. Since (essentially) no further processing is required, the final solar technology component may comprise the same (or at least a comparable) chemical composition as the original automotive component. Solar technology components with such a material composition are not known at all, but show surprisingly positive effects in their intended (outdoor) use.

[0024] Exemplary Embodiments

[0025] In an embodiment, the automotive component is at least a part of at least one of a combustion motor, an electric motor, a generator. In an embodiment, the automotive component is at least part of an advanced body structure casting (mega casting). This may provide the advantage that automotive components that are produced in enormous amounts (the scale is millions of tons) can be directly used in a straightforward manner for recycling and produce components for the renewable energy sector. The aluminium-based alloys of the automotive industry are generally complex mixtures of different elements and extremely difficult to recycle. Therefore, it may be most surprising that an easy and efficient re-use as solar technology components is possible at all.

[0026] In an embodiment, the automotive component is at least a part of a (combustion) motor block. Especially motor blocks may be a waste product present in enormous amounts in the near future. Since these motor blocks are hard to recycle (into something different than a motor block), the present solution may be most welcome.

[0027] In an embodiment, the aluminium-based alloy is a casting alloy. In the present context, a casting alloy may be seen as a type of alloy specifically designed to be melted and poured / cast into moulds to create complex shapes and components. These alloys may be formulated to have excellent fluidity and low melting points, which may make them suitable for precise casting processes.

[0028] In contrast, in the present context, a wrought alloy may be seen as an alloy designed to be mechanically processed or shaped through wrought processes like rolling, forging, or extrusion, rather than casting. These alloys may be formulated for strength and ductility, which may make them suitable for wrought processes.

[0029] Since casting alloys and wrought alloys may have a fundamentally different formulation (in particular fluidity vs. ductility), optimized for different processes, it may be a challenge (or even technically not reasonable) to form a wrought alloy from a casting alloy.

[0030] Solar technology components are generally made of wrought alloys, so it would not be considered to form a solar technology component from a casting alloy (such as the casting alloy of a motor block). However, it has been surprisingly found by the inventors that an efficient and robust solar technology component can be formed by a further casting process. Accordingly, the casting alloy of the automotive component may be directly made subject of a process for forming the solar technology component.

[0031] In an embodiment, the aluminium-based alloy is standardized and based on aluminium-silicon. This may provide the advantage that standardized Al-Si alloys from the automotive sector may be directly used for the solar technology component production. Due to the straightforward process, the final solar technology component product may comprise as a fingerprint (for retracing) the standardized Al-Si alloy (chemical) composition of the automotive component.

[0032] In an embodiment, the aluminium-based alloy is standardized under at least one of the following: A380 alloy, A356 alloy, 319 alloy, A413 alloy, A535 alloy, alloy 226. This is a (not limiting) list of examples of Al-Si-based alloys from the automotive sector. These casting alloys are generally used / formulated due to advantages such as high strength, good castability, and good corrosion resistance. These properties may also be very advantageous for outdoor solar technology components.

[0033] In a specific example, A380 alloy and 319 alloy respectively comprise the following compositions: Si Fe Cu Mn Mg Zn

[0034] A380 8.1 1.3 3.4 0.5 0.1 2.8

[0035] 319 5.68 0.46 3.19 0.25 0.09 0.58

[0036] Furthermore, in an embodiment, alloys according to the ANSI H35.1 may be applied. ANSI H35.1 is a standard developed by the American National Standards Institute (ANSI) in collaboration with the Aluminium Association. It provides specifications and guidelines for the alloy and temper designations of aluminium and aluminium alloys.

[0037] In a further example, the composition of the Al-Si alloy according to the standards A380 and 319 is as follows (these compositions are in accordance with ANSI H35 / 1 / H35.1M):

[0038]

[0039] In an embodiment, the solar technology component is configured as a construction profile, for example associated with solar panels (photovoltaic). Such a construction profile may for example comprise a frame(work), a mounting structure, or an under-construction (for the solar panels). Further solar technology components may e.g. be configured as a housing / package for an inverter. This may provide the advantage that components that are essential for solar technology and required in high amounts may be directly produced in a (cost-) efficient manner.

[0040] In an embodiment, forming the solar technology component comprises casting the melt product to obtain a casted product. In other words, the (partially) liquefied automotive component may be poured (e.g. by using a mould) into the desired shape. In a preferred embodiment, the automotive component may be directly melted and casted without additional processing steps.

[0041] In an embodiment, casting comprises continuous casting or batch-wise (block / ingot) casting. Depending on the desired application, one of these methods may be preferred. In an example, block casting may provide at least one of the following advantages: save costs, provide a heat recovery potential, provide an increase of surface quality (improving pressing).

[0042] In an embodiment, casting comprises casting / pouring into a mould. The mould may have the shape of the final solar technology component, so that a most efficient manufacture process may be achieved. Since the automotive component is generally a casting alloy, it may be perfectly suitable for a further casting process.

[0043] In an embodiment, forming the solar technology component comprises pressing the melt product, in particular pressing / extruding the casted product. The pressing / extrusion may yield the final solar technology component in an efficient and established manner. Pressing may improve the mechanical properties and prevent drawbacks such as porosity and surface irregularities. Density, strength, and surface quality may thus be improved by pressing.

[0044] In an embodiment, pressing is done at a temperature in the range 200 to 530 °C. Such elevated temperatures may highly improve the pressing process. However, lower temperatures may lead to better fragmented phases to improve mechanical performance.

[0045] In an embodiment, pressing is done via (directly) utilizing the heat after casting, in particular less than four hours, more in particular less than one hour, after casting. In an embodiment, pressing is done directly after casting. The term "directly" may refer in this case to a time period of six hours or less, in particular four hours or less, more in particular two hours or less. In this time span, the cast product may still be hot from the casting process and this heat may be directly used for the pressing process (thereby reducing or preventing pre- heating). Thereby, energy, time, and effort may be saved. Conventionally, the cast product is cooled down and then re-heated, thereby requiring significantly more energy and time.

[0046] In an embodiment, a high proportion (the main portion) of casting heat is utilized (and hence not lost) during the process. The stored energy during casting is e.g. utilized for further processing or re-acquired as alternative energy form.

[0047] Thereby, energy management may be improved.

[0048] In a specific embodiment, the material (cast product) could be pressed directly from the casting heat, without cooling and heat loss. Usually, the cast ingots of conventional pressed alloys (wrought alloys) are reheated for homogenization and annealed for a long period (up to days). In a preferred case, pressing can be carried out directly after casting, in a temperature range of 300-530 °C.

[0049] In an embodiment, the method is free of a homogenization phase between casting and pressing. In an embodiment, the method is free of a pre-heating phase between casting and pressing. In an embodiment, the method is free of a cooling phase between casting and pressing. In an embodiment, the method (melting) is free of an additional melting salt. By one or more of these features, the manufacture process may be made more efficient.

[0050] In an embodiment, the casting alloy may have the advantage (over a wrought alloy) that less time / energy for homogenization and / or preheating is required.

[0051] In an embodiment, a preheating process is provided, in particular free of a homogenization phase. A shortened heat treatment before pressing may be advantageous in some applications; yet, in this embodiment, no lengthy homogenization phase is necessary (thereby saving time and being more efficient). Brief Description of the Drawings

[0052] The aspects defined above, and further aspects of the invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to these examples of embodiment.

[0053] Figure 1 shows schematically a method of manufacturing a solar technology component from an automotive component, according to an exemplary embodiment of the invention.

[0054] Figure 2 shows a time-temperature diagram of a process of forming a solar technology component from an automotive component, according to an exemplary embodiment of the invention.

[0055] Figure 3 shows an experiment-based time-temperature diagram of casting a solar technology component from an automotive component with pre-heating, according to an exemplary embodiment of the invention.

[0056] Detailed Description of the Drawings

[0057] Figure 1 shows schematically a method 100 of manufacturing a solar technology component 120 from an automotive component 110, according to an exemplary embodiment of the invention. The raw material is an automotive component 110, in this example a motor block. Such a motor block is essentially made of a specific and standardized aluminium-silicon alloy. The number of possible (re-) uses of such a motor block are very limited, so that it is generally un-recyclable waste, despite the use in a motor block again.

[0058] The automotive component 110 is now made subject of a melting process 130, e.g. melting at a temperature of > 600 °C, and thereby melted into a melt product. The melt product is then casted 140 (continuously or batch-wise) into a mould to obtain a cast product. The (molten) cast product is pressed / extruded 150 at a temperature in the range 200 to 530 °C. Preferably, the pressing 150 is done via directly utilizing the heat after casting (i.e. pressing directly after casting, e.g. less than four hours in between). Yet, a pre-heating process 160 may be additionally used, e.g. up to four hours at 300 to 530 °C. By pressing the cast product, the solar technology component 120 is formed from the melt product of the automotive component 110. Figure 2 shows a time-temperature diagram of casting 140 and pressing 150 a solar technology component 120 from an automotive component 110, according to an exemplary embodiment of the invention. The Y-axis shows the temperature (here arbitrary units) and the X-axis shows the time (here also arbitrary units). In the beginning, the temperature is highest (melting 130), and the automotive component 130 is present as a melt product, which had been made subject to a melting process. The melt product is cast 140, e.g. into a mould / form, thereby constantly cooling down.

[0059] However, in the present example, the cast product is used for further processing 150, while it is still hot. The cast product may be additionally pre-heated 160, for example in the range 0 to 4 hours, at a temperature in the range 300 to 530°C. Yet, no homogenization phase is required (as in case of wrought alloys), so that heat from the casting 140 can be further used for pressing. Afterwards, an extrusion process 150 is performed to press the cast product in the final form of the solar technology component. In this example, extrusion is done in the temperature range 300 to 530 °C (comparable to pre-heating 160).

[0060] After pressing 150, the final product (e.g. bolts) is quenched, e.g. by cooling or further heating (schematically shown). In comparison to conventional wrought alloys, the present casting alloy may provide the following advantages: direct pressing from the casting heat, potential of re-using heat from mould casting, improved surface quality, improved extrusion, no need for time-consuming homogenization.

[0061] In an embodiment, homogenisation of the product may also work if more than four hours pass. Yet, such a process may be considered less economic.

[0062] Figure 3 shows an experiment-based time-temperature diagram of casting a solar technology component 120 from an automotive component 110 with a preheating process 160, according to an exemplary embodiment of the invention. For the experiments described in the following, the standardized Al-Si alloys A380 und 319 have been applied. Experiments have shown that homogenization or lengthy pre-heating is not necessary for the aluminium-based alloys from the automotive components for the purpose of forming (actually this is usually necessary). Casting condition without further heat treatment between 300-450 °C is suitable for extrusion (pressing). Shown schematically in the example Figure 3 are the temperatures 300, 350, 400, and 450 °C.

[0063] Extrusion tests were carried out with a very high extrusion ratio. Specimens were pressed in the casting state as well as in the heat-treated state (30 min or 4 h at 520 °C). Test temperatures were between 300 °C and 450 °C. Before each experiment, the samples were heated for at least 1 hour to ensure that they were warmed through. The tests were carried out at different extrusion speeds.

[0064] All samples were very easy to press. Neither heat treatment condition, temperature nor pressing speed had a negative effect on the tests. Extrusion with a very high degree of deformation is possible in the temperature range of 300-450 °C without restrictions and results in a defect-free strand surface (was unexpected due to the high proportion of impurities and intermetallic phases).

Claims

Claims1. A solar technology component (120), comprising or consisting of an aluminium-based alloy that originates from an automotive component (110), wherein the aluminum-based alloy is standardized and based on aluminumsilicon.

2. The solar technology component (120) according to claim 1,wherein the automotive component (110) is at least a part of at least one of a combustion motor, an electric motor, a generator, a mega casting.

3. The solar technology component (120) according to claim 1 or 2, wherein the automotive component (110) is at least a part of a motor block.

4. The solar technology component (120) according to one of the preceding claims,wherein the aluminium-based alloy is a casting alloy.

5. The solar technology component (120) according to one of the preceding claims,wherein the aluminium-based alloy is under at least one of the following: A380 alloy, A356 alloy, alloy 319, A413 alloy, A535 alloy, alloy 226, an alloy defined by ANSI H35.1.

6. The solar technology component (120) according to one of the preceding claims,configured as a, in particular photovoltaic, construction profile, in particular a frame or under-construction, and / or a housing.

7. A method (100) of manufacturing a solar technology component (120), the method comprising:providing an automotive component (110), in particular a motor block, that comprises an aluminium-based alloy,wherein the aluminum-based alloy is standardized and based on aluminumsilicon;melting (130) the automotive component (110) to obtain a melt product; andforming (140, 150) the solar technology component (120) from the melt product.

8. The method (100) according to claim 7,wherein forming the solar technology component (120) comprises casting (140) the melt product to obtain a cast product.

9. The method (100) according to claim 8,wherein casting (140) comprises continuous casting or block / ingot casting.

10. The method (100) according to one of the claims 8 to 9,wherein casting (140) comprises pouring into a mould.

11. The method (100) according to one of the claims 7 to 10,wherein forming the solar technology component (120) comprises pressing (150) the melt product, in particular pressing the cast product,in particular wherein pressing (150) is done at a temperature in the range 200 to 530°C.

12. The method (100) according to one of the claims 7 to 11,wherein pressing (150) is done via directly utilizing the heat after casting (140), in particular less than four hours, more in particular less than one hour, after casting (140).

13. The method (100) according to one of the claims 7 to 12,wherein the method is free of at least one of the following:a homogenization phase between casting (140) and pressing (150);a pre-heating phase (160) between casting (140) and pressing (150); a cooling phase between casting (140) and pressing (150);an additional melting salt during melting (130).

14. The method according to claims 7 to 13, further comprising: using the casting heat for another process, in particular pressing (150).

15. Using an automotive component (110), in particular a motor block, comprising an aluminium-based alloy, as a starting material to manufacture a solar technology component (120),wherein the aluminum-based alloy is standardized and based on aluminumsilicon.

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