US20060219331A1 - Exothermic Wire for Bonding Substrates - Google Patents
Exothermic Wire for Bonding Substrates Download PDFInfo
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- US20060219331A1 US20060219331A1 US11/278,449 US27844906A US2006219331A1 US 20060219331 A1 US20060219331 A1 US 20060219331A1 US 27844906 A US27844906 A US 27844906A US 2006219331 A1 US2006219331 A1 US 2006219331A1
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- wires
- exothermic
- assembly
- wire
- gasket
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F1/00—Cylinders; Cylinder heads
- F02F1/002—Integrally formed cylinders and cylinder heads
Definitions
- the invention relates to an improved method of forming exothermic materials for various applications, and for use of exothermic material to permanently seal a cylinder head to a block in an internal combustion engine.
- Reactive multilayer foils and coatings are used in a wide variety of applications requiring the generation of intense, controlled amounts of heat in a planar region.
- Such structures conventionally comprise a succession of substrate-supported layers that, upon appropriate excitation, undergo an exothermic chemical reaction that spreads across the area covered by the layers and thus generate precisely controlled amounts of heat.
- exothermic chemical materials are particularly useful as sources of heat for specialized welding, soldering, and brazing operations. However, they can also be used in other applications requiring controlled local generation of heat, such as primers for incendiary devices.
- Reactive multilayer materials permit exothermic reactions with controlled and consistent heat generation.
- the basic driving force behind such reactions is a reduction in atomic bond energy.
- the reactive materials are ignited, the distinct layers mix atomically, generating heat locally. This heat ignites adjacent regions of the structure, thereby permitting the reaction to travel the entire length of the structure, generating heat until all the material is reacted.
- Nickel-Aluminum multilayer reactive foils have been formed by cold-rolling bi-layer sheets of Ni and Al, followed by repeated manual folding and repeated cold rolling. After the first bi-layer strip is rolled to half its original thickness, it is folded once again to regain its original thickness and to double the number of layers. This process is repeated many times.
- the invention comprises a method for producing a multi-stranded exothermic assembly of the type for propagating an exothermic reaction between the strands in response to an initial thermal impulse.
- the method comprises the steps of providing elongated first and second wires of respective constituent metallic materials each having a generally round cross-section, cold drawing the first and second wires through respective reduction dies in a non-oxidizing atmosphere, bringing the first and second wires into contact with one another in a non-oxidizing atmosphere, and simultaneously plastically deforming the first and second wires together into a unitary cord so that the surfaces of the first and second wires are pressed into contact to facilitate a sustained propagating exothermic reaction in response to an initiating thermal impulse.
- a one-time use gasket is provided of the type for sealing a cylinder head to a cylinder block in an internal combustion engine.
- the one-time use gasket comprises a sheet-like body, at least one cylinder bore opening formed in the body, and at least one fluid flow passage formed in the body.
- the fluid passage is isolated from the cylinder bore opening.
- the body is fabricated from a reactive multi-stranded exothermic assembly of the type for propagating an exothermic reaction in response to an initiating thermal impulse. The heat produced during the exothermic reaction is sufficient to metallurgically fuse the cylinder head to the cylinder block while maintaining fluidic isolation between the cylinder bore opening and the fluid flow passage.
- a method for establishing a fluid-tight seal between opposing surfaces having formed therebetween at least two discrete flow passages comprises the steps of forming a gasket from a reactive multi-stranded exothermic assembly of the type for propagating an exothermic reaction in response to an initiating thermal impulse, forming at least two spaced and isolated flow passages in the gasket for conducting fluid material between the two opposing surfaces, aligning the openings in the gasket with the flow passages in the opposing surfaces, compressing the gasket between the opposing surfaces, initiating a propagating exothermic reaction in the gasket body, melting the opposing surfaces in response to the heat generated during the exothermic reaction, and metallurgically fusing the opposing surfaces together while permitting fluid exchange between the isolated flow passages.
- the subject invention provides an exothermic cord, foil, ribbon or cloth produced in a manner that is particularly conducive for large-scale production applications.
- the subject intention allows an exothermic assembly to be produced at lower cost as compared with prior art exothermic foils and the like.
- the subject methods enable substantially faster throughput of finished product.
- the subject invention provides a lower cost, higher production rate technique for creating reactive multi-layer assemblies for use in any of the known applications, including welding, soldering, brazing, and as primers for incendiary devices.
- FIG. 1 is a simplified cross-sectional view of a prior art internal combustion engine having a traditional gasket positioned in the interface between the cylinder head and cylinder block;
- FIG. 2 is a cross-sectional view as in FIG. 1 , but showing an exothermic gasket assembly disposed in the region once occupied by the prior art gasket in preparation for an exothermic reaction which will result in permanent attachment of the cylinder head to the cylinder block;
- FIG. 3 is a view as in FIG. 2 , but showing the cylinder head permanently affixed to the cylinder block following the exothermic reaction;
- FIG. 4 is a simplified schematic view showing the formation of the subject exothermic assembly in a cold-drawing operation on bulk wires
- FIG. 5 is a cross-sectional view of a single wire taken generally along lines 5 - 5 of FIG. 4 ;
- FIG. 5A is a cross-sectional view of an alternative cross-section of a single wire, with representative bundled wires shown in phantom;
- FIG. 6 is a cross-section of the cord taken along lines 6 - 6 of FIG. 4 ;
- FIG. 7 is an end view of a completed exothermic ribbon as taken along lines 7 - 7 of FIG. 4 ;
- FIGS. 8A and 8B are simplified views showing an exothermic assembly disposed between two substrates in the sequence of before and then during a welding or joining operation;
- FIG. 9 is a simplified schematic view as in FIG. 4 but showing an optional application of a braze or other coating material applied to the cord and beneficial in a later joining application;
- FIG. 10 is a schematic view as in FIG. 4 yet showing another method of tightly bundling the wires through a twisting operation to form the exothermic cord;
- FIG. 11 is yet another alternative method of tightly packing the wires by rotary swaging
- FIG. 12 is an illustrative cross-sectional view of the swaging die taken generally along lines 12 - 12 of FIG. 11 ;
- FIG. 13 is still another alternative method of tightly combining the wires using an ultrasonic friction welding technique.
- FIG. 1 a prior art engine assembly is shown in FIG. 1 including a cylinder head 10 affixed to a cylinder block 12 via head bolts 14 .
- a gasket 16 is disposed between the head 10 and block 12 , clamped under pressure from the head bolts 14 .
- the gasket 16 seals the internal pressure and fluids cycling within the cylinder bore to prevent leakage and maximize combustion efficiency.
- FIGS. 2 and 3 The subject invention overcomes these issues in the manner shown in FIGS. 2 and 3 in which an exothermic assembly, generally indicated at 18 , is strategically routed around all of the various passages, as well as the combustion chambers.
- the strategically routed exothermic assembly 18 can be in the form of a continuous, snake-like ribbon of material laid in a course, or formed into a sheet-like or cloth-like body member similar in appearance to modern gasket bodies.
- the exothermic assembly 18 is ignited to accomplish a weld of the cylinder head 10 to the cylinder block 12 and thus form a fully sealed, integral engine assembly without the use of a gasket 16 .
- FIG. 2 does not show continued use of the head bolts 14 , it may be desirable to retain use of some or all of the head bolts 14 for added integrity.
- An energy source such as the representative match 20 shown in FIG. 2 , ignites an exposed wick portion 21 of the exothermic assembly 18 , thus initiating a propagating exothermic reaction between its interstitial layers.
- an electric sparking device, laser beam, or other device capable of producing the requisite thermal impulse can be used.
- ignition from the flame source 20 causes the atoms or molecules of the constituent materials to rapidly mix and combine in a highly exothermic reaction.
- the heat is generated locally at the ignition point, it is conducted along the assembly 18 and initiates additional mixing, thereby sustaining the reaction.
- the speed at which the reaction front proceeds depends upon the physical properties of the constituent materials and how they are arranged. The reaction front causes atoms to diffuse normal to the layers themselves, with heat being conducted parallel to the layers.
- the engine exhaust ports can be permanently sealed to the exhaust manifold
- the intake ports can be permanently sealed to the intake manifold
- any of the various covers or housings can be fixed in a permanently sealed condition. Anywhere a gasket has been used in the past, and even in non-automotive applications, the component parts can instead be permanently fixed and sealed using the exothermic assembly 18 and techniques here described.
- the exothermic assembly 18 thus applied to permanently seal engine components can be accomplished using prior art type exothermic materials.
- the invention also contemplates a novel technique for producing an exothermic assembly 18 using bulk wires of constituent materials, as shown in FIG. 4 .
- the constituent materials can be Ni and Al or alloys thereof, but other materials can be used as well, including titanium-aluminides and the like.
- any of the currently known and available materials used in reactive multilayer foil applications may be used in the context of this invention.
- bulk wires of commercial grade Ni 22 and Al 24 are readily available from numerous commercial sources. These bulk wires 22 , 24 are typically formed with a generally round cross-section. These commercially available wires 22 , 24 are first cold-drawn (below 100° C.) through respective reducing dies 26 . The bulk wires 22 , 24 may be of any effective size, but diameters in the range of 50 microns have proven satisfactory. This first drawing operation, conducted under a cover gas (such as nitrogen or argon), removes all oxides and other contaminates from the wires 22 , 24 , thus providing clean surfaces that are suited for an exothermic reaction.
- cover gas such as nitrogen or argon
- the first draw dies 26 may simply reduce the original diameter of the bulk wires, thus resulting in a smaller circular cross-section.
- the dies 26 can alternatively impart a full or partial geometric shape to the wires 22 , 24 , such as shown in FIG. 5A .
- the first dies 26 impart a hexagonal cross-section to the wires 22 , 24 which may aid in better nesting and increased surface contact as represented by the phantom adjacent wires.
- other wire shapes are possible.
- wires 22 , 24 are merged and drawn as a bundle through a second die 28 which squeezes the wires 22 , 24 into a cord 30 .
- a representative cross-section of the chord 30 is shown in FIG. 6 to illustrate that the surfaces of the wires 22 , 24 have been brought into substantial contact with one another through plastic deformation so that a large interfacial surface area is established between the respective wires 22 , 24 .
- the number of strands of wires 22 , 24 can be varied substantially, and that the five strands shown in the figures are merely illustrative. On the minimum side, there must be at least two such wires 22 , 24 , whereas there is not an effective maximum limit. Wire bundles with strand numbers in the 10's or 100's may be used.
- the cord 30 exiting the second draw die 28 can be used immediately in an exothermic reaction in the form thus created, or can be further shaped by progressive rolling dies 32 to create a ribbon similar to the configuration illustrated in FIG. 7 .
- the cord 30 can be shaped into other designs or configurations and is not limited to the flat ribbon shape shown in FIG. 7 .
- the cord 30 can be shaped by any other means known to those skilled in the art, including stamping, further drawing, forging, and the like.
- FIGS. 8A and 8B illustrate, in simplified terms, the sequence of welding upper 34 and lower 36 substrates using the exothermic assembly 18 ignited by a flame source 20 . Once ignited at the wick 21 , the exothermic reaction propagates along the assembly 18 , fusing together the opposing surfaces along the way.
- FIG. 9 illustrates a supplemental application technique of the subject forming process.
- the result is a slightly modified exothermic assembly 118 .
- the constituent bulk wires 122 , 124 are pulled through the first draw dies 126 as in the preceding embodiment, and then merged and pulled through the second drawing die 128 as in FIG. 4 .
- the cord 130 emerging from the second draw die 128 is then directed to a coating operation where a braze material 138 , contained as a suspension or powder in a hopper 140 , is applied to the exterior surface of the cord 130 to thus encase the exothermic assembly 11 ′ for benefit in a later joining operation.
- the braze material 138 other coatings can be applied, such as solder, flux, or other beneficial treatments.
- FIG. 10 illustrates yet another alternative forming technique for the exothermic assembly 218 .
- the bulk wires 222 , 224 are drawn through the first set of dies 226 and then brought together in a twisting device, generally shown at 242 .
- the twisting device 242 includes a collar 244 driven by a gear wheel 246 via a motor 248 .
- the twisting operation takes the place of the second draw die 228 as in FIGS. 4 and 9 , to effectively bring the wires 222 , 224 tightly together to form a bulk exotherm with good interfacial contact between the constituent wires 222 , 224 .
- the resulting cord 230 of twisted construction is ready for use in an exothermic reaction, or can be coated with a braze material as described in the preceding example.
- the resulting cord 230 of twisted construction can be rolled or shaped using progressive rollers like that shown in FIG. 4 , or other post-forming techniques, to achieve a desired shape in the resulting exothermic assembly 218 .
- a cloth may be readily formed by weaving or felting a number of exothermic cords.
- FIG. 11 illustrates the use of rotary swaging to assemble the reactants.
- the second die 328 is formed in sections 350 that can be separately actuated to “hammer” the bundle of wires 322 , 324 into a tightly packed condition, as shown in FIG. 12 .
- the swaging die 328 can be simultaneously rotated to impart a twist to the emerging cord 330 or simply allow the wires to remain parallel.
- FIG. 13 illustrates the use of ultrasonic welding for joining the reactants.
- the second die 428 is vibrated at high frequency to surface weld the individual wires 422 , 424 together.
- the die 428 may also be rotated to introduce a twist in the resulting cord 430 as in preceding examples.
Abstract
Description
- This invention claims priority to U.S. Provisional Application No. 60/667,999 filed Apr. 4, 2005.
- 1. Field of the Invention
- The invention relates to an improved method of forming exothermic materials for various applications, and for use of exothermic material to permanently seal a cylinder head to a block in an internal combustion engine.
- 2. Related Art
- Reactive multilayer foils and coatings are used in a wide variety of applications requiring the generation of intense, controlled amounts of heat in a planar region. Such structures conventionally comprise a succession of substrate-supported layers that, upon appropriate excitation, undergo an exothermic chemical reaction that spreads across the area covered by the layers and thus generate precisely controlled amounts of heat. Such exothermic chemical materials are particularly useful as sources of heat for specialized welding, soldering, and brazing operations. However, they can also be used in other applications requiring controlled local generation of heat, such as primers for incendiary devices.
- Reactive multilayer materials permit exothermic reactions with controlled and consistent heat generation. The basic driving force behind such reactions is a reduction in atomic bond energy. When the reactive materials are ignited, the distinct layers mix atomically, generating heat locally. This heat ignites adjacent regions of the structure, thereby permitting the reaction to travel the entire length of the structure, generating heat until all the material is reacted.
- In addition to reactive coatings, efforts have been made to develop free-standing reactive layers by cold rolling. Nickel-Aluminum multilayer reactive foils have been formed by cold-rolling bi-layer sheets of Ni and Al, followed by repeated manual folding and repeated cold rolling. After the first bi-layer strip is rolled to half its original thickness, it is folded once again to regain its original thickness and to double the number of layers. This process is repeated many times.
- The fabrication of rolled foils is time consuming and difficult. The rolling passes introduce lubricating oil and other contaminants, such that the surfaces of the rolled materials must be cleaned after every pass. In addition, the manual folding of sheet stock does not easily lend itself to large-scaled production. When many metal layers are rolled at once, these layers can spring back, causing separation of the layers and degradation of the resulting foil. Such separations also permit undesirable oxidation of interlayer surfaces and impedes unification of the layers by cold welding.
- Accordingly, there is a need for improved methods of fabricating reactive multilayer structures, particularly for large-scale production applications.
- The invention comprises a method for producing a multi-stranded exothermic assembly of the type for propagating an exothermic reaction between the strands in response to an initial thermal impulse. The method comprises the steps of providing elongated first and second wires of respective constituent metallic materials each having a generally round cross-section, cold drawing the first and second wires through respective reduction dies in a non-oxidizing atmosphere, bringing the first and second wires into contact with one another in a non-oxidizing atmosphere, and simultaneously plastically deforming the first and second wires together into a unitary cord so that the surfaces of the first and second wires are pressed into contact to facilitate a sustained propagating exothermic reaction in response to an initiating thermal impulse.
- According to another aspect of this invention, a one-time use gasket is provided of the type for sealing a cylinder head to a cylinder block in an internal combustion engine. The one-time use gasket comprises a sheet-like body, at least one cylinder bore opening formed in the body, and at least one fluid flow passage formed in the body. The fluid passage is isolated from the cylinder bore opening. The body is fabricated from a reactive multi-stranded exothermic assembly of the type for propagating an exothermic reaction in response to an initiating thermal impulse. The heat produced during the exothermic reaction is sufficient to metallurgically fuse the cylinder head to the cylinder block while maintaining fluidic isolation between the cylinder bore opening and the fluid flow passage.
- According to yet another aspect of this invention, a method for establishing a fluid-tight seal between opposing surfaces having formed therebetween at least two discrete flow passages, is provided. The method comprises the steps of forming a gasket from a reactive multi-stranded exothermic assembly of the type for propagating an exothermic reaction in response to an initiating thermal impulse, forming at least two spaced and isolated flow passages in the gasket for conducting fluid material between the two opposing surfaces, aligning the openings in the gasket with the flow passages in the opposing surfaces, compressing the gasket between the opposing surfaces, initiating a propagating exothermic reaction in the gasket body, melting the opposing surfaces in response to the heat generated during the exothermic reaction, and metallurgically fusing the opposing surfaces together while permitting fluid exchange between the isolated flow passages.
- The subject invention, as expressed through these various methods and apparatus, provides an exothermic cord, foil, ribbon or cloth produced in a manner that is particularly conducive for large-scale production applications. Utilizing commercially available wire products, the subject intention allows an exothermic assembly to be produced at lower cost as compared with prior art exothermic foils and the like. The subject methods enable substantially faster throughput of finished product. By controlling the size ratio between the cross-sections of the constituents, a degree of control can be exercised over the exothermic reaction characteristics and, therefore, tuned to particular applications. Accordingly, the subject invention provides a lower cost, higher production rate technique for creating reactive multi-layer assemblies for use in any of the known applications, including welding, soldering, brazing, and as primers for incendiary devices.
- These and other features and advantages and applications of the present invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
-
FIG. 1 is a simplified cross-sectional view of a prior art internal combustion engine having a traditional gasket positioned in the interface between the cylinder head and cylinder block; -
FIG. 2 is a cross-sectional view as inFIG. 1 , but showing an exothermic gasket assembly disposed in the region once occupied by the prior art gasket in preparation for an exothermic reaction which will result in permanent attachment of the cylinder head to the cylinder block; -
FIG. 3 is a view as inFIG. 2 , but showing the cylinder head permanently affixed to the cylinder block following the exothermic reaction; -
FIG. 4 is a simplified schematic view showing the formation of the subject exothermic assembly in a cold-drawing operation on bulk wires; -
FIG. 5 is a cross-sectional view of a single wire taken generally along lines 5-5 ofFIG. 4 ; -
FIG. 5A is a cross-sectional view of an alternative cross-section of a single wire, with representative bundled wires shown in phantom; -
FIG. 6 is a cross-section of the cord taken along lines 6-6 ofFIG. 4 ; -
FIG. 7 is an end view of a completed exothermic ribbon as taken along lines 7-7 ofFIG. 4 ; -
FIGS. 8A and 8B are simplified views showing an exothermic assembly disposed between two substrates in the sequence of before and then during a welding or joining operation; -
FIG. 9 is a simplified schematic view as inFIG. 4 but showing an optional application of a braze or other coating material applied to the cord and beneficial in a later joining application; -
FIG. 10 is a schematic view as inFIG. 4 yet showing another method of tightly bundling the wires through a twisting operation to form the exothermic cord; -
FIG. 11 is yet another alternative method of tightly packing the wires by rotary swaging; -
FIG. 12 is an illustrative cross-sectional view of the swaging die taken generally along lines 12-12 ofFIG. 11 ; and -
FIG. 13 is still another alternative method of tightly combining the wires using an ultrasonic friction welding technique. - Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a prior art engine assembly is shown in
FIG. 1 including acylinder head 10 affixed to acylinder block 12 viahead bolts 14. Agasket 16 is disposed between thehead 10 andblock 12, clamped under pressure from thehead bolts 14. Thegasket 16 seals the internal pressure and fluids cycling within the cylinder bore to prevent leakage and maximize combustion efficiency. - In some engine applications, it may be desirable to permanently seal the
cylinder head 10 to thecylinder block 12 without the aid of agasket 16. Reminiscent of prior art fixed head engines, in which the cylinder head and cylinder block form one inseparable unit, an engine assembly thus formed has the advantage of eliminating the expense of agasket 16 and its vulnerability as a leak path over time. However, sealing acylinder head 10 to acylinder block 12 without the aid of agasket 16 is a very difficult undertaking because there aremany flow passages 17 which must be sealed. For example, liquid coolant and liquid oil are routed inrespective passages 17 between thecylinder head 10 and thecylinder block 12 for proper lubrication and cooling. There are also sometimes passages provided for valve train components. The cylinder bore itself can even be considered a flow passage If these passages are not independently sealed in isolation from one another, then the engine will leak fluids and there can be contamination between the various fluids and passages. - The subject invention overcomes these issues in the manner shown in
FIGS. 2 and 3 in which an exothermic assembly, generally indicated at 18, is strategically routed around all of the various passages, as well as the combustion chambers. The strategically routedexothermic assembly 18 can be in the form of a continuous, snake-like ribbon of material laid in a course, or formed into a sheet-like or cloth-like body member similar in appearance to modern gasket bodies. With thecylinder head 10 firmly held in compression as suggested by the force arrows, theexothermic assembly 18 is ignited to accomplish a weld of thecylinder head 10 to thecylinder block 12 and thus form a fully sealed, integral engine assembly without the use of agasket 16. AlthoughFIG. 2 does not show continued use of thehead bolts 14, it may be desirable to retain use of some or all of thehead bolts 14 for added integrity. - An energy source, such as the
representative match 20 shown inFIG. 2 , ignites an exposedwick portion 21 of theexothermic assembly 18, thus initiating a propagating exothermic reaction between its interstitial layers. As an alternative to thematch 20, an electric sparking device, laser beam, or other device capable of producing the requisite thermal impulse can be used. Because theexothermic assembly 18 has such large interfacial areas between alternating layers of the constituent materials (typically Ni and Al), ignition from theflame source 20 causes the atoms or molecules of the constituent materials to rapidly mix and combine in a highly exothermic reaction. Once the heat is generated locally at the ignition point, it is conducted along theassembly 18 and initiates additional mixing, thereby sustaining the reaction. The speed at which the reaction front proceeds depends upon the physical properties of the constituent materials and how they are arranged. The reaction front causes atoms to diffuse normal to the layers themselves, with heat being conducted parallel to the layers. - In addition to joining a
cylinder head 10 to ablock 12 using theexothermic assembly 18, it is possible to permanently seal other components in an internal combustion engine using these techniques. For example, the engine exhaust ports can be permanently sealed to the exhaust manifold, the intake ports can be permanently sealed to the intake manifold, or any of the various covers or housings can be fixed in a permanently sealed condition. Anywhere a gasket has been used in the past, and even in non-automotive applications, the component parts can instead be permanently fixed and sealed using theexothermic assembly 18 and techniques here described. - The
exothermic assembly 18 thus applied to permanently seal engine components can be accomplished using prior art type exothermic materials. However, the invention also contemplates a novel technique for producing anexothermic assembly 18 using bulk wires of constituent materials, as shown inFIG. 4 . As mentioned above, the constituent materials can be Ni and Al or alloys thereof, but other materials can be used as well, including titanium-aluminides and the like. In fact, any of the currently known and available materials used in reactive multilayer foil applications may be used in the context of this invention. - In
FIG. 4 , bulk wires ofcommercial grade Ni 22 andAl 24, for example, are readily available from numerous commercial sources. Thesebulk wires available wires bulk wires wires - As shown in
FIG. 5 , the first draw dies 26 may simply reduce the original diameter of the bulk wires, thus resulting in a smaller circular cross-section. However, the dies 26 can alternatively impart a full or partial geometric shape to thewires FIG. 5A . In this example, the first dies 26 impart a hexagonal cross-section to thewires - Once drawn through the first dies 26, the
wires second die 28 which squeezes thewires cord 30. A representative cross-section of thechord 30 is shown inFIG. 6 to illustrate that the surfaces of thewires respective wires wires such wires - The
cord 30 exiting the second draw die 28 can be used immediately in an exothermic reaction in the form thus created, or can be further shaped by progressive rolling dies 32 to create a ribbon similar to the configuration illustrated inFIG. 7 . Alternatively, thecord 30 can be shaped into other designs or configurations and is not limited to the flat ribbon shape shown inFIG. 7 . Likewise, it is not necessary that the resulting cross-section be continuous. Thus, thecord 30 can be shaped by any other means known to those skilled in the art, including stamping, further drawing, forging, and the like. -
FIGS. 8A and 8B illustrate, in simplified terms, the sequence of welding upper 34 and lower 36 substrates using theexothermic assembly 18 ignited by aflame source 20. Once ignited at thewick 21, the exothermic reaction propagates along theassembly 18, fusing together the opposing surfaces along the way. -
FIG. 9 illustrates a supplemental application technique of the subject forming process. The result is a slightly modifiedexothermic assembly 118. Here, the constituentbulk wires FIG. 4 . Thecord 130 emerging from the second draw die 128 is then directed to a coating operation where abraze material 138, contained as a suspension or powder in ahopper 140, is applied to the exterior surface of thecord 130 to thus encase the exothermic assembly 11′ for benefit in a later joining operation. Instead of thebraze material 138, other coatings can be applied, such as solder, flux, or other beneficial treatments. Once the sprayedmaterial 138 is sufficiently solidified or dried, theexothermic assembly 118 is ready for use in any conceivable application (i.e., not limited to internal combustion engines). -
FIG. 10 illustrates yet another alternative forming technique for theexothermic assembly 218. In this situation, thebulk wires twisting device 242 includes acollar 244 driven by agear wheel 246 via amotor 248. The twisting operation takes the place of the second draw die 228 as inFIGS. 4 and 9 , to effectively bring thewires constituent wires cord 230 of twisted construction is ready for use in an exothermic reaction, or can be coated with a braze material as described in the preceding example. Alternatively, the resultingcord 230 of twisted construction can be rolled or shaped using progressive rollers like that shown inFIG. 4 , or other post-forming techniques, to achieve a desired shape in the resultingexothermic assembly 218. In situations where it would be advantages to work with a sheet of exothermic material, a cloth may be readily formed by weaving or felting a number of exothermic cords. -
FIG. 11 illustrates the use of rotary swaging to assemble the reactants. In this example, thesecond die 328 is formed insections 350 that can be separately actuated to “hammer” the bundle ofwires FIG. 12 . The swaging die 328 can be simultaneously rotated to impart a twist to the emergingcord 330 or simply allow the wires to remain parallel. -
FIG. 13 illustrates the use of ultrasonic welding for joining the reactants. Here, thesecond die 428 is vibrated at high frequency to surface weld theindividual wires die 428 may also be rotated to introduce a twist in the resultingcord 430 as in preceding examples. - It will be appreciated that all of the various assembly techniques can be blended to form additional hybrid variations with the resulting exothermic assembly useful in any application in which prior art reactive multilayer foils and coatings have been used. Thus, while the invention has been described in an illustrative manner, it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
- Obviously, many modifications and variations of the invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described.
Claims (20)
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/278,449 US20060219331A1 (en) | 2005-04-04 | 2006-04-03 | Exothermic Wire for Bonding Substrates |
EP06749287A EP1871918A4 (en) | 2005-04-04 | 2006-04-04 | Exothermic wire for bonding substrates |
PCT/US2006/012573 WO2006108006A2 (en) | 2005-04-04 | 2006-04-04 | Exothermic wire for bonding substrates |
KR1020077025483A KR20070118687A (en) | 2005-04-04 | 2006-04-04 | Exothermic wire for bonding substrates |
JP2008505475A JP2008538799A (en) | 2005-04-04 | 2006-04-04 | Heating wire for bonding substrates |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US66799905P | 2005-04-04 | 2005-04-04 | |
US11/278,449 US20060219331A1 (en) | 2005-04-04 | 2006-04-03 | Exothermic Wire for Bonding Substrates |
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US20060219331A1 true US20060219331A1 (en) | 2006-10-05 |
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ID=37068908
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/278,449 Abandoned US20060219331A1 (en) | 2005-04-04 | 2006-04-03 | Exothermic Wire for Bonding Substrates |
Country Status (5)
Country | Link |
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US (1) | US20060219331A1 (en) |
EP (1) | EP1871918A4 (en) |
JP (1) | JP2008538799A (en) |
KR (1) | KR20070118687A (en) |
WO (1) | WO2006108006A2 (en) |
Cited By (6)
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US20150013634A1 (en) * | 2013-07-09 | 2015-01-15 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US20150096523A1 (en) * | 2013-07-09 | 2015-04-09 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US20170175621A1 (en) * | 2015-12-18 | 2017-06-22 | Briggs & Stratton Corporation | Engine operable in horizontal and vertical shaft orientations |
US10202938B2 (en) | 2013-07-09 | 2019-02-12 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
CN112058938A (en) * | 2020-08-11 | 2020-12-11 | 浙江久立特材科技股份有限公司 | Preparation method of molten salt corrosion resistant nickel-molybdenum-chromium alloy pipe fitting |
US11761402B2 (en) | 2020-03-02 | 2023-09-19 | Briggs & Stratton, Llc | Internal combustion engine with reduced oil maintenance |
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Publication number | Priority date | Publication date | Assignee | Title |
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US20150013634A1 (en) * | 2013-07-09 | 2015-01-15 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
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AU2014287355B2 (en) * | 2013-07-09 | 2017-09-28 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US9856822B2 (en) | 2013-07-09 | 2018-01-02 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US9863363B2 (en) * | 2013-07-09 | 2018-01-09 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US10202938B2 (en) | 2013-07-09 | 2019-02-12 | Briggs & Stratton Corporation | Welded engine block for small internal combustion engines |
US20170175621A1 (en) * | 2015-12-18 | 2017-06-22 | Briggs & Stratton Corporation | Engine operable in horizontal and vertical shaft orientations |
US11761402B2 (en) | 2020-03-02 | 2023-09-19 | Briggs & Stratton, Llc | Internal combustion engine with reduced oil maintenance |
CN112058938A (en) * | 2020-08-11 | 2020-12-11 | 浙江久立特材科技股份有限公司 | Preparation method of molten salt corrosion resistant nickel-molybdenum-chromium alloy pipe fitting |
Also Published As
Publication number | Publication date |
---|---|
JP2008538799A (en) | 2008-11-06 |
KR20070118687A (en) | 2007-12-17 |
WO2006108006A3 (en) | 2007-10-04 |
WO2006108006A2 (en) | 2006-10-12 |
EP1871918A2 (en) | 2008-01-02 |
EP1871918A4 (en) | 2008-06-04 |
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