CA1217092A - Extruded container with a dissimilar metal welding insert - Google Patents

Extruded container with a dissimilar metal welding insert

Info

Publication number
CA1217092A
CA1217092A CA000435383A CA435383A CA1217092A CA 1217092 A CA1217092 A CA 1217092A CA 000435383 A CA000435383 A CA 000435383A CA 435383 A CA435383 A CA 435383A CA 1217092 A CA1217092 A CA 1217092A
Authority
CA
Canada
Prior art keywords
aluminum
insert
container
metal insert
dissimilar
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000435383A
Other languages
French (fr)
Inventor
Gordon E. Kaye
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Duracell Inc USA
Original Assignee
Duracell International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Duracell International Inc filed Critical Duracell International Inc
Application granted granted Critical
Publication of CA1217092A publication Critical patent/CA1217092A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50Current conducting connections for cells or batteries
    • H01M50/543Terminals
    • H01M50/552Terminals characterised by their shape
    • H01M50/559Terminals adapted for cells having curved cross-section, e.g. round, elliptic or button cells
    • H01M50/56Cup shaped terminals
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00Extruding metal; Impact extrusion
    • B21C23/22Making metal-coated products; Making products from two or more metals
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C33/00Feeding extrusion presses with metal to be extruded ; Loading the dummy block
    • B21C33/004Composite billet
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Sealing Battery Cases Or Jackets (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Extrusion Of Metal (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)

Abstract

EXTRUDED CONTAINER HAVING A METAL INSERT
ABSTRACT
This invention relates to a method and apparatus for forming an aluminum can and, more particularly, pertains to a novel method and apparatus for forming an aluminum container which has a metallic insert incorporated into one end thereof.

Description

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The present invention arrangement effectively provides a novel apparatus and method for providing a compatible welding surface at one end of an extruded aluminum container. A metallic insert is incorporated into an end of an extruded container by placing the insert in-to an extrusion die prior to extrusion. The present invention is particularly adapted for battery containers and, in particular, for providing a dissimilar welding surface for spot welding intercell connectors to an extruded aluminum can.
As is well known in the electrochemical battery art, spot welding of steel intercell connectors to battery cells which have an aluminum cell container is extremely difficult. Spot welding of the intercell connectors, which are normally comprised of steel or similar metal, to the aluminum container is inhibited by the aluminum oxide film inherently present on the surface of the aluminum container or housing. In order to effectively bond the intercell connector to the aluminum housing, the oxide film must be somehow removed prior to, or during, the welding operation.
In response to this need of attaching intercell connectors to an extruded aluminum batter cell container, ultrasonic welding, a method well known in the prior art, has been adapted for use in the electrochemical battery art. To weld a metal intercell connector to the aluminum housing, the housing is first formed.
!0 In a secondary operation, which also requires the cell container to be totally empty of electrochemical components, the connector is ultrasonically welded to the base of the aluminum cell container. A pressure mandrel is inserted within the aluminum cell housing to resist the force of the externally applied ultra-sonic vibrations which vibrate the steel plate, which is to be welded thereto, and aluminum housing the vibrations causing the formation of an effective bond.
Ultrasonic welding, considered to be a form of cold welding, applies vibratory energy to the container by a transducer which is arranged to produce shear vibra-tions at the interface of the parts to be welded. A solid-state bond occurs by 7Q~

rupture of the aluminum oxide film and subsequent localized plastic deformation with interpenetration oE the metals taking place.
However~ the secondary ultrasonic welding operation greatly increases the per item cost of each unit so produced because it is a time-consuming operation and additionally, because the cell itself must be prepared (i.e. the removal of all electrochemical components), and the entire method is considerably more complex and more lengthy than the more desirable spot-welding operation.
Consequently, the present inventive concept provides a relatively simple solution to the problem of providing an integrally formed compatible welding surface to the aluminum housing to allow another metal, and particularly intercell connectors, to be easily and inexpensively spot welded to the aluminum can.
Accordingly, it is a primary objective of the present invention to provide a novel, improved method and apparatus for forming an aluminum cell housing having one end thereof incorporating therein a dissimilar metal insert to enable a steel intercell connector to be easily spot welded thereto.
The term "aluminum" herein shall be understood to include aluminum metal per se as well as alloys predominantly made up of aluminum. The term "intercell connector" defines a well known device which electrically connects two or more cells and is typically fabricated of steel for reasons of economy. The expression 'dissimilar metal" as used herein refers to a metal other than aluminum or a metal alloy containing at most minor amounts of aluminum said metal or metal alloy being capable readily spot welded to an intercell connector employing known and conventional techniques. Steel itself provides an excellent dissimilar metal insert in accordance with this invention when the intercell connector is made of steel.
Another object of the present invention is to incorporate a dissimilar metal into the aluminum housing during the extrusion process so as to provide a spot ~Z~'7~

weldable surface on the aluminum housing without the requirement of any secondary treatment of the housing.
A further object of the present invention is to provide an aluminum battery cell which can easily and inexpensively have a metal disc weldable thereto.
Still, a further object of the present invention is to provide an improved configuration to the metal disc to be incorporated into the cell housing to facilitate the disc's permanent incorporation therein.
The present invention, unlike the prior art, provides a relatively simple and inexpensive process and apparatus for providing a dissimilar metal surface on the end of an extruded aluminum cell. A metal insert, normally specially designed, is placed in t~e extrusion die beneath the aluminum slug which is to be extruded. A punch is subsequently lowered into the die causing the aluminum to be extruded, and consequently the aluminum is caused to flow around, and in some cases through, the metal insert. This process effectively physically and chemically entraps and bonds the insert to the aluminum cell. The insert is incorporated into the cell, yet has a surface exposed and flush with the end of the can. An intercell connector can then easily be subsequently spot welded to the exposed surface of the insert.
The foregoing and other objects, advantages and characteri~ing features of the inventive process and apparatus herein described will become more readily apparent from the following detailed description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings wherein like reference numerals denote similar parts throughout the various views in which:
Figure 1 is a partial side sectional view of the configuration of the present invention showing the entirety of the components thereof;
Figure 2 is a side view of a typical disc used as the insert in the con-figuration of Figure l;

~f ~7~

Figure 3 is a p~rspective view of an alternative shape of the metal insert;
Figure 4 is a perspective view of an insert having a star lock washer configuration;
Figure 5 is a perspective view of an insert having perforations which extend therethrough;
Figure 5a is a cross-sectional view of another insert which can be used in the present invention;
Figure 6 is a partial cross sectional view of another configuration of the present invention which is normally used when the insert shown in Figure 3 is used; and Figure 7 is a side view of the aluminum cell housing having the metal inser~
of Figure 2 bonded therein.
Figure 1 depicts the use of an extrusion die 10 and a forcing punch 12.
Typically, a metal insert 14 is placed at the bottom 16 of the extrusion die lO
with an aluminum slug 18 positioned in spaced relation immediately thereabove.
The metallic insert 14 is composed of a metal, e.g., steel, which can easily be spot welded to another metal, such as an intercell connector. The forcing punch 12 is subsequently lowered into the extrusion die 10 thereby causing the aluminu~
slug 18 to plastically deform and flow around, and in some cases through, steel metal insert 14, thereby partially encapsulating and retaining said insert. The flow of the extruded aluminum material 18 inherently ruptures the aluminum oxidefilm formed on the aluminum slug 18 and consequently provides not only a physical bonding of metal insert 14 to extruded aluminum slug 18, which as been extruded into the form of an aluminum housing 20, but will also provide a chemical bond bond as well. After this severe deformation, which preferably occurs a~ highier than ambient temperature and pressure, the container and insert is cooled to permanently affix the insert to the container.
. .

'7~9~

It should, of course, be realized that a number of different configurations can be given to the metal insert to ensure that a sufficient chemical and/or physical bond will occur between the insert and the extruded aluminum cell housing 20. The insert 14 need not be simply a thin punched disc, but may also be of sufficient thickness or shape to permit a flow of extruded aluminum around or through the outer edges or perforations which may be undercut in relation to the upper surface of the steel disc to permit a partial encapsulation or retentio~
by virture of the flow of aluminum into the undercut regions. It should also be realized that the insert can have undercuts on either side of the disc to further permit indifferent placement of the insert in the die. The typical inserts which are disclosed herein considered merely as examples and are not to be construed as limiting the present invention in anyway. In a preferred embodiment, the inserts are made of cold rolled steel.
Figure 2 discloses a metal insert 22 having ends 24 around which the extruded aluminum can easily flow to partially encapsulate the insert. This insert is also shown in Figure 7 in its attached configuration to the extruded aluminum cell container 20. Figures 4 and 5 show other types of inserts which can be utilized in the present invention. Figure 4 depicts a star lock washer insert 28 which has numerous cuts and edges which enables the deformed aluminum 18, to effectively chemically and physically bond the insert 28. Figures 5 and 5a show a disc insert 32 having openings 34 therein to allow the aluminum 18 to flow through the disc 32. The openings 34 are further provided with holes 36 which are cut into the disc 32 and radially extend into the disc transversely in respect to the openings 34. These holes 36 are provided to allow additional aluminum 18 to flow into and partially throughout the disc 32 in order to more firmly retain the insert 32 in the aluminum cell housing.

As an alternative embodiment of the present invention, Figure 3 is a stee' metal insert 26 which can also be used according to the teachings of the present invention. As shown in Figure 6, the steel metal insert 26 is placed in a conical or centrally depressed region of the die, and will, accordingly, be positioned by the aluminum 18 flowing around the major diameter of the insert leaving only a small portion of the insert 26 protruding from the end of the container 20, with the remainder of the insert 26 being retained in the relatively thick bottom of the aluminum housing.
It should be realized that in all the embodiments of the present invention the inserts, after extrusion, have a surface 40 which is substantially flush with the end of the container so as to provide an even surface for easy spot welding of an intercell connector, or other metal, thereto.
A]though a preferred embodiment of the principles of this invention has been described and illustrated in detail herein, it should be realized-that the same are not limited to the particular configuration shown in the drawings, and that modifications thereof are contemplated and can be made without departing from the scope of this invention as defined in the appended claims.

Claims (17)

WHAT IS CLAIMED IS:
1. A method for forming an aluminum container having a dissimilar metal insert therein comprising:
a) placing a dissimilar metal insert in an extrusion die;
b) positioning an aluminum slug above said metal insert;
and c) lowering a punch into the die so as to deform said aluminum slug to form an open top container; and d) causing the aluminum to bond to said dissimilar metal insert, while exposing a lower surface portion of said insert in substantially flush relation with the lower surface of said container.
2. A method for forming a container as defined in claim 1, said deforming of said aluminum occuring at higher than ambient temperature and pressure.
3. A method of forming an aluminum container as defined in claim 1, said bonding comprising causing deformation of said aluminum slug to rupture the aluminum oxide film formed thereon to chemically bond said metal insert to said aluminum container.
4. A method for forming an aluminum container as defined in claim 1, said bonding comprising causing the aluminum slug to flow so as to physically encapsulate and retain said metal insert.
5. A method as defined in claim 1 or 2, said bonding of said aluminum container to said insert comprising cooling said aluminum container with said insert so that said insert has an exposed surface which is substantially flush with an end of said aluminum container.
6. A method for forming an aluminum container having a dissimilar metal insert comprising:
a) placing a solid spherical dissimilar metal insert into an extrusion die, said die having a conical or centrally depressed region therein;
b) positioning an aluminum slug above said metal insert;
c) lowering a punch into said die so as to deform said aluminum slug; and d) causing the aluminum to bond to said dissimilar metal insert by deforming the aluminum so that it flows around a major diameter of the insert whereby the insert is chemically and physically bonded to said aluminum container, while leaving exposed a minor surface portion of said insert.
7. An apparatus for providing an aluminum container having a dissimilar metal insert therein comprising:
a) a substantially aluminum container having a generally cylindrical configuration said container having an end plate at one end thereof;
b) a metal insert bonded to said end plate; and c) said metal insert having an exposed end surface and a generally coplanar configuration with said end plate.
8. An apparatus as defined in claim 7, said end plate being integrally formed with said aluminum container.
9. An apparatus as defined in claim 7, said bonding comprising a chemical bond between the interfaces of the aluminum container and said metal insert.
10. An apparatus as defined in claim 7, said bonding comprising physically retaining said metal insert within the aluminum container.
11. An apparatus as defined in claim 7, said metal insert having a portion thereof not covered by said aluminum housing.
12. An apparatus as defined in claim 7, said metal insert comprising a spherical shaped configuration.
13. An apparatus as defined in claim 7, said metal insert comprising a star lock washer shaped configuration.
14. An apparatus as defined in claim 7, said metal insert comprising a disc shaped configuration.
15. An apparatus as defined in claim 14, said disc shaped configuration comprising a thin metal disc having openings which transversely extend through said disc.
16. An apparatus as defined in claim 15, said openings having holes which extend transversely from said openings whereby the aluminum is positioned thereby further retaining said insert in the aluminum container.
17. An apparatus container as defined in claim 7, said container comprising a battery cell container whereby an intercell connector can be spot welded to said dissimilar insert.
CA000435383A 1982-09-13 1983-08-25 Extruded container with a dissimilar metal welding insert Expired CA1217092A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US416,798 1982-09-13
US06/416,798 US4792081A (en) 1982-09-13 1982-09-13 Extruded container with dissimilar metal welding insert

Publications (1)

Publication Number Publication Date
CA1217092A true CA1217092A (en) 1987-01-27

Family

ID=23651351

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000435383A Expired CA1217092A (en) 1982-09-13 1983-08-25 Extruded container with a dissimilar metal welding insert

Country Status (8)

Country Link
US (1) US4792081A (en)
JP (1) JPS5981859A (en)
BE (1) BE897668A (en)
CA (1) CA1217092A (en)
DE (1) DE3332873A1 (en)
FR (1) FR2533076A1 (en)
GB (1) GB2126934B (en)
IL (1) IL69584A (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9340232B2 (en) 2013-05-03 2016-05-17 Tesla Motors, Inc. Extrusion piece with insert of dissimilar material
DE102024113758A1 (en) 2024-03-25 2025-09-25 EUBACO GmbH Extrusion forming process

Family Cites Families (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1848083A (en) * 1929-08-07 1932-03-01 Gen Motors Corp Method of forming valve tappets
US2126814A (en) * 1932-07-05 1938-08-16 Nokap Closures U S A Inc Method and apparatus for making containers
GB471512A (en) * 1936-02-04 1937-09-06 Duncan Stewart & Company Ltd Improved method of and apparatus for extruding ammunition shell and like cases
US2701483A (en) * 1950-07-12 1955-02-08 Gen Electric Co Ltd Method of securing inserts in ductile metal members by pressure welding
GB803015A (en) * 1955-01-28 1958-10-15 Mini Of Supply Improvements in or relating to the manufacture of composite members by impact extrusion
US3041718A (en) * 1957-10-18 1962-07-03 Metal Box Co Ltd Manufacture of aluminium containers
US3235946A (en) * 1957-11-18 1966-02-22 Star Machine Inc Process of fabricating piston heads for hydraulic brake cylinders
US3222761A (en) * 1957-11-29 1965-12-14 Arrowhead Eng Corp Process of forming cup-shaped articles
GB851124A (en) * 1957-11-29 1960-10-12 Bendix Aviat Corp Cup-shaped articles and process of forming same
GB843964A (en) * 1958-09-18 1960-08-10 Metal Box Co Ltd Improvements in or relating to the manufacture by extrusion of aluminium containers
GB1097332A (en) * 1963-06-24 1968-01-03 H G Sanders & Son Ltd Improvements relating to a method of cold impact-extruding a metal tube
US3489266A (en) * 1963-09-23 1970-01-13 Sylvania Electric Prod Hermetic seal for a thin-walled container
SE402229B (en) * 1973-07-16 1978-06-26 Elpag Ag Chur PROCEDURE FOR POWER AND FORMED CALL CONNECTION OF DIFFERENT PARTS
US4141484A (en) * 1976-07-26 1979-02-27 Rockwell International Corporation Method of making a metallic structure by combined flow forming and bonding
DE3017106A1 (en) * 1980-05-03 1981-11-05 Aluminium-Walzwerke Singen Gmbh, 7700 Singen METHOD FOR PRODUCING SOLIDLY FORMED LIGHT METAL ITEMS AND MOLDED BODY WITH A LIGHT METAL PART
DE3017076A1 (en) * 1980-05-03 1981-11-05 Aluminium-Walzwerke Singen Gmbh, 7700 Singen METHOD FOR PRODUCING SOLIDLY FORMED LIGHT METAL ITEMS AND MOLDED BODY WITH A LIGHT METAL PART

Also Published As

Publication number Publication date
US4792081A (en) 1988-12-20
BE897668A (en) 1984-01-02
FR2533076A1 (en) 1984-03-16
GB8324467D0 (en) 1983-10-12
GB2126934B (en) 1986-08-20
DE3332873A1 (en) 1984-03-15
GB2126934A (en) 1984-04-04
IL69584A0 (en) 1983-11-30
JPS5981859A (en) 1984-05-11
IL69584A (en) 1987-08-31

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