Aluminum Alloy Composition for High-Recycled Content Bottle Production
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Solution Overview
Problem
Current aluminum alloys for bottle production fail to balance formability, strength, and cost-effectiveness, with high formability alloys lacking strength and strong alloys having poor formability, and existing methods using prime aluminum are expensive and unsustainable.
Innovation Solution
Development of new aluminum alloys with optimized chemical composition and manufacturing processes that incorporate high recycled aluminum content, achieving strength, formability, and sustainability through thermomechanical processing including direct chill casting, homogenization, hot rolling, and cold rolling, allowing for high-speed production of bottles with complex shapes and variable strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If current aluminum alloys are used for bottle production, then formability or strength can be achieved, but the other property deteriorates (high formability alloys have low strength, strong alloys have poor formability)
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition parameters of the aluminum alloy, specifically controlling the content ranges of Mn (0.9-1.4 wt.%), Mg (0.65-1.2 wt.%), Cu (0.45-0.9 wt.%), Fe (0.35-0.55 wt.%), and Si (0.2-0.45 wt.%). This compositional parameter optimization enables the alloy to simultaneously achieve high strength and excellent formability, resolving the trade-off between these two properties.
2Strength
If prime aluminum is used in casting, then alloy strength can be ensured, but production cost increases and sustainability decreases
Solution Approach 1:
The patent applies parameter changes by setting the recycled aluminum content parameter to at least 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 82 wt.%, 85 wt.%, 90 wt.%, or 95 wt.%. This parameter optimization demonstrates that high recycled content can be achieved while maintaining alloy strength through controlled composition and processing parameters.
3Weight of moving object
If bottle wall thickness is reduced to achieve lower weight, then weight target is met, but mechanical performance requirements become more challenging to meet
Solution Approach 1:
The patent applies parameter changes by optimizing the alloy composition parameters (Mn: 0.9-1.4 wt.%, Mg: 0.65-1.2 wt.%, Cu: 0.45-0.9 wt.%, Fe: 0.35-0.55 wt.%, Si: 0.2-0.45 wt.%) and processing parameters to achieve superior strength properties. This enables the use of thinner wall thickness while still meeting mechanical performance targets for column strength, rigidity, and bottom dome reversal pressure.
4Productivity
If high speed production is implemented, then throughput increases, but the shaping process must be completed in very short time
Solution Approach 1:
The patent applies preliminary action by optimizing the alloy composition and processing parameters during the manufacturing stage to pre-establish the material properties needed for high-speed forming. The controlled composition (Mn: 0.9-1.4 wt.%, Mg: 0.65-1.2 wt.%, Cu: 0.45-0.9 wt.%, Fe: 0.35-0.55 wt.%, Si: 0.2-0.45 wt.%) and processing create an alloy that requires minimal shaping time, enabling throughput of 1000 bottles per minute.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new alloys achieve high deformation capabilities, strength, and cost-effectiveness by using high recycled aluminum content, enabling efficient production of bottles with complex shapes and meeting mechanical performance targets while reducing production costs and environmental impact.
Implementation Method 1
Although alloys described herein are heat treatable, the precipitation hardening is achieved concurrently with coat/paint curing
Implementation Method 2
Both the chemistry and manufacturing processes of the alloy have been optimized for the high speed production of aluminum bottles
Implementation Method 3
The resulting cylinder is then formed into a bottle shape using, for example, a sequence of full-body necking steps or other mechanical shaping
Data Source
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AI summary
The disclosure is related to new, formable and strong aluminum alloys for making packaging products such as bottles and cans.