As we all know, Tesla continues to innovate, from the software of the car to the chemical composition of the battery that powers the car. If the newly published patent application shows any signs, then Tesla’s innovation seems to actually extend to the metal used to make cars. For example, by using the aluminum alloy developed by the company, Tesla may launch a new type of electric car that is very sturdy and cheaper to produce.
The patent entitled "Die-cast aluminum alloy for structural components" describes an aluminum alloy that is both extremely tough and ductile. The aluminum alloy also does not require further processing, allowing the company to increase its production costs.
In the patent description, Tesla pointed out that commercial cast aluminum alloys (such as those used in electric vehicle chassis) need to be both strong and ductile. Aluminum alloy parts are usually formed by casting. If produced well, castings can be produced quickly and reliably, and their structural properties can be well maintained. However, alloys that cannot be cast well can cause hot tearing, which can cause problems.
Tesla emphasized that many structural parts made of aluminum alloy today may require heat treatment and other processes to improve strength, hardness, ductility and corrosion resistance. These processes ensure quality, but they also require large capital expenditures, extended processing times and potential yield losses. With this in mind, Tesla pointed out that it is best to produce aluminum alloys with high yield strength and sufficient ductility without heat treatment.
Tesla describes some of its ideas in the following section.
"In one embodiment, the alloy, as cast and without further processing, has a yield strength of at least about 130 MPa and a bending angle of at least about 20° at a cross-sectional thickness of 3 mm. In one embodiment The aluminum alloy contains vanadium to provide many of these enhancements. In another embodiment, the aluminum alloy has a specific weight ratio of copper to magnesium to provide many of these enhancements of the alloy with the desired characteristics. In one embodiment, the aluminum alloy has Cu:Mg weight ratio of about 4:1 to about 1:1. In one embodiment, the aluminum alloy has a Cu:Mg weight ratio of about 4:1 to about 2:1: 1.
"As described below, compared with existing aluminum alloys, aluminum alloys with these components have been found to have high yield strength and high ductility. As described below, aluminum alloys are used herein by the weight percentage of total elements and particles in the alloy (wt %) and the specific properties of the alloy. It should be understood that the remaining components of any alloy described herein are aluminum and incidental impurities."
If Tesla can effectively introduce new aluminum alloys to its vehicles, the company may be able to increase its production costs and the overall quality of its products. Stronger aluminum alloy parts may pave the way for safer vehicles than ever before, and the lack of heat treatment can ensure that Tesla's operating costs are further optimized. Aluminum alloy components may also help increase production, especially if they are fully compatible with the company's large-scale broadcasting strategy.
Read Tesla's full patent below.
Simon Alvarez's Tesla Die Cast Aluminum Patent on Scribd
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