The present invention relates to light alloy profiled sec¬ tions, and more particularly to sections made of aluminium or an aluminium alloy, comprising one or more insulated electrical conductors.

Profiled sections obtained by extruding or drawing aluminium or an aluminium alloy have a cross-sectional shape defined by their own function/application, e.g. structural elements as beams and frames, rails, ducts, vehicle body elements etc. For some of these profiled sections it is particularly desirable to have one or more insulated electrical conduc¬ tors integrated with the sections to provide energy or signal transport circuits. Currently this is obtained by introducing commercial electrical cables into said sections, namely cables having one or more conductors with generally at least one insulating sheath. It is obvious that the in¬ sertion of such an electrical cable into a profiled section constitutes a time-consuming, fastidious and extremely ex¬ pensive operation comprising several steps which can not be entirely mechanized and automated.

From GB 2 003 675 it is known an electrical supply track co prising a channel shaped steel casing lined inwardly and outwardly with a synthetic resin and provided with a pair of supporting members moulded integrally with the inner resin layer for embedding of exposed (bare) conductive members.

Obviously there is no possibility for an integrated in-line low cost manufacturing of supply tracks by the disclosed method comprising separate steps of bending of a steel plate into a channel shape, coating of shape surfaces providing integrally moulded supporting members and finally insertion of the exposed conductive members into the supporting members.

FR 1.253.131 discloses, in connection with a provision of an improved trolley line, a band comprising a series of parallel electrical conductors with exposed surfaces being cast into an insulating matrix and subsequently fastened by gluing to a metallic section. Once again, this is a laborous manufacturing multi-step process resulting in expensive products and probably also an inferior contact between the band and metallic section.

The object of the present invention is to overcome the above drawbacks and to provide a light alloy profiled section having one or more insulated electrical conductors, the assembly of the profiled section and the conductors being integrally formed during manufacturing using a process with several operating phases which may be entirely mechanized and automated.

Another object of the present invention is to provide an improved intimate adhesion between the insulated conductors and the surrounding profile section.

In accordance with the invention a light alloy profiled section comprises at least one linear electrical conductor extending parallel in the longitudinal direction of the profiled section, being formed from the same material as said profiled section, and is insulated electrically in a

solid filling exhibiting a bare surface and which itself has a bare surface oriented in the same general direction as that of the filling.

Also in accordance with the invention, when the profiled section is at an intermediate stage corresponding to its being drawn or extruded, it comprises at least two perman¬ ent walls and a temporary dividing wall, whose inner faces form a cavity for receiving the filling in a non-solid state, the inner face of the temporary dividing wall having longitudinal parallel sections for forming the insulated electrical conductors retained in the filling in the solid state after removal of said dividing wall, the inner face of at least one of the two wallls having parallel longitudinal projections ensuring an intimate and firm contact between the walls and the solid state filling.

According to other features of the invention the bare sur¬ face of one or more electrical conductors may be flush with, project from or be retracted with respect to the bare sur¬ face of the insulating filling. Furthermore, at its end opposite its bare surface, each electrical conductor may have in cross-section an enlarged portion in the filling.

According to yet another feature of the invention the bare surface of the electrical conductors may be insulated wholly or partly by means of a second filling, the latter being possibly formed by an electrically insulating material iden¬ tical to that of the first filling.

Other features and advantages of the present invention will be more apparent from the following description of several possible embodiments, given by way of examples only, with reference to the accompanying drawings where

Figure 1 shows a cross-sectional view of a pro¬ filed section with a single electrical conductor;

Figure 2 shows a cross-sectional view of a pro¬ filed section with a plurality of electric conductors;

Figure 3 shows a partial cross-sectional view of another embodiment of a profiled section symmetrically disposed with respect to axis AA;

Figure 4 shows a partial cross-sectional view of a conductor projecting with respect to the filling; and

Figure 5 shows a partial cross-sectional view of a conductor retracted with respect to the filling.

In these drawings the same references designate the same elements.

Referring to Figures 1-3, a light alloy profiled section is designated generally by 1 and obtained by extruding or draw¬ ing aluminium or an aluminium alloy. As mentioned above this profiled section has a cross-sectional shape defined by its own function, e.g. structural members, as shown schematic¬ ally in Figure 1.

This profiled section comprises at least one longitudinal cavity for receiving a filling 2 formed of an electrically insulating material, e.g. a polymer resin such as quick

setting polyurethane resin, said insulated filling being poured into the cavity and hardened in situ. For this pur¬ pose each cavity of the profiled section 1 is formed by the inner faces of two permanent walls 3, 4 and a temporary dividing wall 5, the latter being subsequently removed by mechanical machining, e.g. by grinding, planing or by mill¬ ing and being shown simply defined by the dot-dash lines in Figures 1-3.

It should be noted that, before pouring the electrically insulating filling 2, it is possible to subject the profiled section 1 to all the usual surface treatments, such as e.g. the application of a primer or a lacquer or the formation of an anodic oxidation.

The inner face of the temporary dividing wall 5 has longi¬ tudinal parallel projections 6 and the inner face of at least one of the two permanent walls 3, 4 also has longi¬ tudinal parallel projections 7, the dividing wall 5 and the two walls 3 and 4 being integrally and simultaneously formed with their associated projections during the drawing or extrusion process. Each projection 6 or 7 has a cross-sec¬ tion perpendicularly enlarging from the walls, e.g. in the form of a T, a dovetail or a half dovetail to ensure a rigid and intimate connection between the projections and the filling 2 when this latter has hardened and has become solid. This configuration is especially important for the projections 6 associated with the temporary dividing wall 5 being intended to form insulated electrical conductors after removal of said dividing wall 5 by mechanical machining, as mentioned above. Consequently, the projections 6 must have a cross-section not only with a sufficiently large area to allow the current to pass (proper dimension) , but also an appropriate form so that they are held in position with

respect to the filling, i.e. a generally trapezoidal cross- section.

Furthermore, apart from providing the necessary mechanical strength, it is important that an intimate adhesion between the electrical conductors, insulating filling and the sur¬ rounding permanent walls of the profiled sections is achieved in order to improve the thermal conductivity and thus the dissipation of heat generated in the conductors under transport of electrical energy.

After complete hardening of the filling, the temporary dividing wall 5 shown with dash-dot lines in Figures 1-3 may be entirely removed by mechanical machining, particularly grinding, planing or milling, or by any other suitable pro¬ cess which simultaneously eliminates any protective layer previously applied by a surface treatment. This operation bares both the surface 8 of the electrically insulating filling 2 and the surface 9 of the projections 6. Each pro¬ jection 6 is thus transformed into a linear electrical con¬ ductor parallel to the longitudinal direction of the pro¬ filed section 1 and insulated electrically in filling 2 which holds it firmly retained because of the shape of its cross-section.

It is obvious that the surface 9 of each conductor 6 is oriented in the same general direction as the bare surface 8 of the insulating filling 2. Furthermore, the bare surfaces 9 and 8 are usually flush with each other, which simplifies machining. However, it may be desirable for the bare surface 9 of one or more conductors 6 to project from the bare sur¬ face 8 of the insulating filling 2, as shown in Figure 4, or on the contrary, the bare surface 9 of one or more conduc¬ tors 6 to be retracted with respect to the bare surface 8 of

filling 2. These results may be obtained in one or more machining passes with particular suitable grinding or mill¬ ing tools.

By way of example, referring more particularly to Figure 1, the permanent walls 3 and 4 are parallel or disposed facing one another and are joined together by a temporary dividing wall 5 forming a bridge, the whole having the approximate shape of a U or H. In this case, the two walls 3 and 4 must obviously have facing projections 7 so as to remain fast with the filling 2 after removal of dividing wall 5. In the case shown the profiled section has a single electrical conductor 6 parallel to the profiled section.

Referring to Figure 2, the permanent walls 3 and 4 form a right angle and it is then sufficient for a single wall to comprise projections 7, preferably the wall which is parallel to the dividing wall 5 forming the third face of the cavity. In the case shown in this Figure 2, the profiled section comprises a set of five small electrical conductors parallel to each other and parallel to the other elements of the profiled section.

Referring to Figure 3, showing a profiled section 1 sym¬ metrically disposed with respect to axis AA, the walls 3 and 4 form an obtuse angle. In this case the right-hand half of the profiled section which is shown comprises two electrical power conductors and the complementary left-hand half, not shown, could also comprise two conductors, the assembly cor¬ responding for example to a star connection with neutral lead-out. Furthermore, it is possible to apply, by clipping or sliding at the level of a hook means 10, an insulating protective cover, not shown, covering the left and right- hand parts of the profiled section.

It is then apparent that the parallel electrical conductors thus formed may fulfil numerous functions relative to elec¬ trical energy transport circuits or to control, safety, biassing or other circuits.

It should be noted that in the particular case where the two walls 3, 4 and the dividing wall 5 form an H shaped assemb¬ ly, it is possible for special applications to pour a second insulating filling 11 (defined by broken lines in Figure 1) so that the bare surface 9 of the conductor(s) can be over the entire section length or partially insulated by a fill¬ ing layer, being formed, if required, by a material identic¬ al to that of the first filling 2.

In this connection it may be useful to give the temporary dividing wall 5 a curved or angular shape, not shown, so that after removal of said dividing wall by machining, the bare surface of filling 2 and of conductor 6 forms a second cavity with a sufficient depth to allow a second filling to be poured entirely covering the bare surfaces of the conduc¬ tors retained in the first filling.

Furthermore, it is obvious that all the above operations, namely drawing or extrusion, surface treatment, pouring and hardening of the filling, mechanical machining and, possib¬ ly, pouring and hardening of a second filling, are opera¬ tions which may be entirely mechanized and automated and conducted in-line with the extrusion process.

The present invention has of course been described and shown solely by way of non-limitative example and that any useful modifications may be made thereto, particularly in the field of technical equivalences, without departing from its scope and spirit.