WO2025199386A1 - Current interrupt device including high strength and high recycled content aluminum alloy - Google Patents

Abstract

Described herein are current interrupt devices that include high recycled content and high strength aluminum alloys. The current interrupt devices include a body produced using a 3xxx series aluminum alloy having a recycled aluminum content of at least 70 wt.%. The body includes one or more recesses that can deform the body in response to an applied gas pressure exceeding a predefined threshold, thereby interrupting electrical communication between a terminal and an electrochemical cell through the body. Also described herein are methods of producing the current interrupt devices. Further described herein are batteries including the current interrupt devices described herein and methods of producing the same.

Description

CURRENT INTERRUPT DEVICE INCLUDING HIGH STRENGTH

AND HIGH RECYCLED CONTENT ALUMINUM ALLOY

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/568,062, filed March 21, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.

FIELD

[0002] The present disclosure relates to metallurgy generally and more specifically to battery device components including a high strength and high recycled content aluminum alloy.

BACKGROUND

[0003] Many batteries employ metallic current interrupt devices (CIDs) as a safety mechanism for preventing overpressure in the batteries. The CIDs can prevent hazardous events, such as thermal runaway, from occurring, thereby lowering a risk of battery fires or explosions. Typically, the CIDs in the batteries, such as electric vehicle batteries, are produced using an AA3003 aluminum alloy, which is a prime-based deep drawing alloy. As a result, aluminum alloys used for producing parts in battery applications are often produced from aluminum alloys including a high content of primary aluminum (e.g., greater than 97% primary aluminum) to provide good formability properties.

[0004] There has been an interest in using recycled aluminum alloy materials for producing aluminum alloys used in battery applications. However, recycled aluminum alloy materials may be unsuitable for use in preparing CIDs as the recycled aluminum alloy materials may contain high levels of certain alloying elements (e.g., Mn, Si, and/or Fe) in amounts that affect the formability properties of an aluminum alloy. For these reasons, it is not practical to use high amounts of recycled aluminum alloy materials in aluminum alloys for producing CIDs without substantial modifications.

SUMMARY

[0005] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0006] In an aspect, described herein are current interrupt devices including a high strength and high recycled content aluminum alloy. In some embodiments, the current interrupt device includes a body comprising a 3xxx series aluminum alloy having a recycled aluminum content of at least 70 wt.%, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold and interrupt electrical communication between a terminal and an electrochemical cell through the body. In some embodiments, the 3xxx series aluminum alloy comprises an AA3104 aluminum alloy. In some embodiments, the recycled aluminum content comprises used beverage can scrap, runaround scrap, automotive scrap, electronics scrap, lithographic scrap, or industrial product scrap. In some embodiments, the 3xxx series aluminum alloy has a primary aluminum content of less than 25 wt.%.

[0007] In some embodiments, the body has a cup-type structure comprising a disc having a side wall that defines a perimeter of the disc. In some embodiments, the side wall has a side wall length ranging from 0.5 mm to 20 mm. In some embodiments, the one or more recesses comprise a circular groove or notch in the body. In some embodiments, the one or more recesses are further configured to generate at least one opening in the body to vent the applied gas pressure through the body. In some embodiments, the predefined threshold of the applied gas pressure ranges from 5 kgf-cm'² to 30 kgf-cm'². In some embodiments, the predefined threshold of the applied gas pressure ranges from 15 kgf-cm'² to 30 kgf-cm'² with respect to rupture pressure. In some embodiments, the predefined threshold of the applied gas pressure ranges from 5 kgf-cm'² to 15 kgf-cm'² with respect to reverse pressure.

[0008] In some embodiments, the one or more recesses are positioned in a first surface of the body, and the applied gas pressure is applied to a second surface of the body that is opposite the first surface. In some embodiments, each of the one or more recesses defines a respective residual length between a respective recess end and the second surface. In some embodiments, each residual length ranges from 30 microns to 250 microns. In some embodiments, at least one of the one or more recesses is a V-shaped notch having a pointed notch tip. In some embodiments, the V-shaped notch has a notch angle ranging from 10 degrees to 60 degrees. In some embodiments, the one or more recesses comprise a plurality of recesses, wherein each recess of the plurality of recesses is separated from an adjacent recess by a lateral distance ranging from 0.05 mm to 2.0 mm.

[0009] In some embodiments, the one or more recesses each define a respective notch area in the body immediately adjacent to and including a recess and one or more normal areas in the body between or surrounded by notch areas. In some embodiments, each respective notch area exhibits or is configured to exhibit an ultimate tensile strength ranging from 100 MPa to 350 MPa. In some embodiments, each respective notch area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 350 MPa. In some embodiments, each respective notch area exhibits or is configured to exhibit an elongation from 0.5% to 15.0%. In some embodiments, each normal area exhibits or is configured to exhibit an ultimate tensile strength ranging from 150 MPa to 250 MPa. In some embodiments, each normal area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 250 MPa. In some embodiments, each normal area exhibits or is configured to exhibit an elongation from 2.0% to 18.0%. In some embodiments, the body has a thickness ranging from 0.1 mm to 2.0 mm.

[0010] In another aspect, batteries including the current interrupt devices described herein are described. In some embodiments, in addition to a current interrupt device, a battery of this aspect includes an electrode terminal and an electrochemical cell including an electrode electrically coupled to the electrode terminal via the current interrupt device, wherein an internal pressure of the battery exceeding the predefined threshold is configured to deform the body of the current interrupt device and interrupt electrical communication between the electrode terminal and the electrode through the body.

[0011] In yet another aspect, methods of producing a current interrupt device are described herein. In some embodiments, a method of this aspect includes processing a molten metal mixture comprising a 3xxx series aluminum alloy to create an aluminum alloy product, wherein the 3xxx series aluminum alloy has a recycled aluminum content of at least 70% and forming the aluminum alloy product to generate the current interrupt device, the current interrupt device comprising a body comprising the 3xxx series aluminum alloy, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold. In some embodiments, forming the aluminum alloy product includes stamping the aluminum alloy product to form the one or more recesses in a first surface of the body. In some embodiments, forming the aluminum alloy product further includes heat treating the stamped aluminum alloy product using a heat treatment temperature from 60° C to 400° C for up to 3 hours. In some embodiments, the heat treatment step is configured to reduce a yield strength or ultimate tensile strength of the body.

[0012] In an additional aspect, methods of producing a battery are described. In some embodiments, a method of this aspect includes providing an electrochemical cell including a first electrode and a second electrode, providing a current interrupt device comprising a 3xxx series aluminum alloy body having a recycled aluminum content of at least 70 wt.%, positioning the current interrupt device between the electrochemical cell and an electrode terminal in a battery casing such that the current interrupt device provides electrical communication between the first electrode and the electrode terminal, wherein the 3xxx series aluminum alloy body includes one or more recesses configured to deform the 3xxx series aluminum alloy body in response to an applied gas pressure within the battery exceeding a predefined threshold and interrupt electrical communication between the electrode terminal and the first electrode through the current interrupt device. In some embodiments, a battery formed using the method of this aspect is an electric vehicle battery. [0013] Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF THE FIGURES

[0014] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0015] FIG. 1 provides a schematic overview of an example method for making a rolled aluminum alloy product.

[0016] FIG. 2 is a schematic cross-sectional illustration of an example battery including a current interrupt device produced using a high strength and high recycled content aluminum alloy having a recycled aluminum content of at least 70 wt.%.

[0017] FIG. 3 is a schematic cross-sectional illustration of an example current interrupt device produced using a high strength and high recycled content aluminum alloy having a recycled aluminum content of at least 70 wt.%. [0018] FIGS. 4 A, 4B, and 4C are photographs depicting a respective cross-sectional view of example current interrupt devices in various configurations.

[0019] FIG. 5 is a plot indicating reverse pressure and rupture pressure for an example AA3003 aluminum alloy and example AA3104 aluminum alloys before and after heat treatment.

[0020] FIG. 6 is a plot indicating simulated vent pressure (kgf-cnT²) and residual thickness (pm) data for current interrupt devices prepared using an example AA3003 aluminum alloy or an example AA3104 aluminum alloy.

DETAILED DESCRIPTION

[0021] Described herein are current interrupt devices (CIDs) produced using a high strength and high recycled content aluminum alloy. The CIDs described herein comprise “recycle-friendly” aluminum alloys that can replace conventional aluminum alloys produced from a high content of primary aluminum. Compared to conventional AA3003 aluminum alloys used to produce CIDs, the aluminum alloys used to produce the CIDs described herein incorporate higher amounts of recycled aluminum alloy materials and less primary aluminum while still exhibiting suitable mechanical properties for practical use in batteries that employ CIDs. The aluminum alloys and CID configurations described herein can tolerate higher amounts of alloying elements, such as copper (Cu), magnesium (Mg), iron (Fe), and silicon (Si), than conventional AA3003 aluminum alloys, thereby enabling the use of recycled aluminum alloy materials. Accordingly, the CIDs described herein can be more sustainable than conventional CIDs produced using AA3003 aluminum alloys.

[0022] Additionally, the aluminum alloys described herein exhibit higher strength (e.g., yield strength, tensile strength, etc.) compared to conventional AA3003 aluminum alloys. Thus, the aluminum alloys used to produce the CIDs described herein can enable lightweighting through downgauging. Furthermore, the higher strength of the aluminum alloys described herein can correspond to a higher bulging resistance compared to conventional AA3003 aluminum alloys, thereby reducing a likelihood of hazards associated with battery rupture or malfunction. By modifying one or more parameters (e.g., geometric arrangements or dimensions) associated with the CIDs, the high strength and high recycled content aluminum alloys described herein can be used to produce CIDs that exhibit suitable mechanical properties for a pressure-activated safety mechanism while improving sustainability through reduced primary aluminum usage. In various examples, the high strength and high recycled content aluminum alloys used in methods and products described herein include 3xxx series aluminum alloys, such as AA3104 aluminum alloys.

Definitions and Descriptions:

[0023] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0024] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0025] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0026] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A TI condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0027] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi -continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0028] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between. [0029] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt.%).

[0030] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0031] In the following examples, aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt.%). In each alloy, the remainder is aluminum, with a maximum wt.% of 0.15% for the sum of all impurities.

[0032] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0033] Unavoidable impurities, including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.25 wt.% of any element besides the alloying elements, incidental elements, and unavoidable impurities.

Methods of Producing the Alloys and Aluminum Alloy Products

[0034] The current interrupt devices (CIDs) described herein can be prepared using suitable methods to process 3xxx series aluminum alloys, such as AA3104 aluminum alloy, that exhibit high strength and include high recycled content. For example, the aluminum alloys may be cast, homogenized, hot-rolled, cold-rolled, heat treated, formed, or the like to generate the CIDs. In certain aspects, the method(s) of preparation for the CIDs may influence or even determine whether the CIDs will have properties adequate for a desired application (e.g., as part of an energy storage device used for transportation electrification). [0035] FIG. 1 provides an overview of an example method of making an aluminum alloy product. The method of FIG. 1 begins at 105, where an aluminum alloy 106 is cast to form a cast aluminum alloy product 107, such as an ingot or other cast product. At 110, the cast aluminum alloy product 107 is homogenized to form a homogenized aluminum alloy product

111. At 115, the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes and/or one or more cold rolling passes to form a rolled aluminum alloy product

112, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet. Optionally, the rolled aluminum alloy product 112 is subjected to additional processing steps, as described below, to form an aluminum alloy article.

[0036] Non-limiting examples of casting processes include a direct chill (DC) casting process or a continuous casting (CC) process. For example, FIG. 1 depicts a schematic illustration of a DC casting process at 105, but other casting processes can be used. A continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0037] A molten metal mixture including a 3xxx series aluminum alloy (e.g., AA3104 aluminum alloy) can be processed by any desirable techniques to create an aluminum alloy product. For example, processing the molten metal mixture can involve casting to form a cast aluminum alloy product, such as a cast ingot, cast slab, or other suitable cast product. In some embodiments, recycled aluminum content, such as used beverage can (UBC) scrap, runaround scrap, automotive scrap, electronics scrap, lithographic scrap, industrial product scrap, or a combination thereof, can be added to the molten metal mixture. Optionally, the processing steps can be used to prepare rolled aluminum alloy products, such as aluminum alloy sheets. The rolled aluminum alloy products can be further processed to produce the CIDs. Example optional processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, annealing, heat treatment, pre-aging, drawing, or stamping.

[0038] In a homogenization step, a cast product may be heated to a temperature ranging from about 400 °C to about 600 °C. For example, the cast product can be heated to a temperature of about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, about 540 °C, about 550 °C, about 560 °C, about 570 °C, about 580 °C, about 590 °C, or about 600 °C. In some examples, homogenization is performed at a temperature within 50 °C of a solidus temperature of the cast product or alloy thereof. The product may then be allowed to soak (i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 24 hours. For example, the product can be heated up to 500 °C to 600 °C, and soaked, for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated to below 490 °C and soaked, for a total time of greater than 18 hours for the homogenization step. In some cases, the homogenization step comprises multiple processes. In some non-limiting examples, the homogenization step includes heating a cast product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, a cast product can be heated to about 465 °C for about 3.5 hours and then heated to about 480 °C for about 6 hours.

[0039] Following the homogenization step, a hot rolling step can be optionally performed. Prior to the start of hot rolling, the homogenized product can be allowed to cool to a temperature between 500 °C to 600 °C. For example, the homogenized product can be allowed to cool to a temperature of between 500 °C to 550 °C or from 550 °C to 600 °C. The homogenized product can then be hot rolled at a temperature between 300 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 1.0 mm and 4.0 mm (e.g., 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm,

1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm,

3.9 mm, 4.0 mm, or anywhere in between).

[0040] Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature between 300 °C to 450 °C. For example, the continuously cast product can be allowed to cool to a temperature of between 325 °C to 425 °C or from 350 °C to 400 °C. The continuously cast products can then be hot rolled at a temperature between 300 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is no more than 470 °C, no more than 450 °C, no more than 440 °C, or no more than 430 [0041] Cast, homogenized, or hot-rolled products can be optionally cold rolled using cold rolling mills into thinner products, such as a cold rolled sheet. The cold rolled product can have a gauge between about 0.2 mm to 2.0 mm (e.g., 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, or anywhere in between). The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 85% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, or up to 85% reduction) as compared to a gauge prior to the start of cold rolling.

[0042] Optionally, an interannealing step can be performed during the cold rolling step, such as where a first cold rolling process is applied, followed by an annealing process (interannealing), followed by a second cold rolling process. The interannealing step can be performed at a temperature of from about 300 °C to about 450 °C (e.g., about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, about 360 °C, about 370 °C, about 380 °C, about 390 °C, about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, or about 450 °C). In some cases, the interannealing step comprises multiple processes. In some non-limiting examples, the interannealing step includes heating the partially cold rolled product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, the partially cold rolled product can be heated to about 410 °C for about 1 hour and then heated to about 330 °C for about 2 hours.

[0043] Subsequently, a rolled product can undergo one or more forming steps to produce a stamped product that has a body with one or more recesses. In some examples, the stamped product can be assembled in an energy storage device (e.g., a battery) as or part of the CID. The forming step can involve employing one or more techniques, such as a blanking step, a piercing step, a drawing step, an embossing step, a stamping step, or a combination thereof. In some examples, forming the rolled product can implement a punch, die, stamp, mold, or the like to define one or more recesses in the rolled product, such as by removing or deforming a portion of the rolled product based on a predefined shape. In certain embodiments, the forming step can shape the rolled product to form a stamped product that has a three-dimensional structure. As one example, the forming step may involve stamping or drawing the rolled product to form a stamped product with a cup-type structure including a side wall with a side wall length ranging from 0.5 mm to 20 mm. For example, the side wall length of the side wall can range from 0.5 mm to 1 mm, from 1 mm to 2 mm, from 2 mm to 3 mm, from 3 mm to 4 mm, from 4 mm to 5 mm, from 5 mm to 6 mm, from 6 mm to 7 mm, from 7 mm to 8 mm, from 8 mm to 9 mm, from 9 mm to 10 mm, from 10 mm to 11 mm, from 11 mm to 12 mm, from 12 mm to 13 mm, from 13 mm to 14 mm, from 14 mm to 15 mm, from 15 mm to 16 mm, from 16 mm to 17 mm, from 17 mm to 18 mm, from 18 mm to

19 mm, or from 19 mm to 20 mm. In some examples, the stamped product may be a planar or substantially planar structure (e.g., not a cup or drawn shape), but with one or more recesses therein.

[0044] In some examples, the stamped product may optionally undergo a heat treatment step. In some examples, the heat treatment step can be any suitable treatment for the stamped product that results in recovery or recrystallization annealing, such as to control mechanical properties of the stamped product. The stamped product can be heated to a heat treatment temperature from 60 °C to 400 °C (e.g., from 60 °C to 100 °C, from 100 °C to 200 °C, from 200 °C to 300 °C, from 300 °C to 325 °C, from 325 °C to 375 °C, or from 350 °C to 400 °C) and soaked for a period of time at the heat treatment temperature to form a hot product. For example, the stamped product can be soaked at the heat treatment temperature for a soak time of up to 3 hours (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes,

20 minutes, 25 minutes, 30 minutes, 1 hour, 2 hours, or 3 hours). After heating and soaking, the hot product is rapidly cooled to form a heat-treated product. In some embodiments, the heat treatment step can modify material properties (e.g., reduce a yield strength or an ultimate tensile strength) of the stamped product, such as with respect to a respective notch area corresponding to each recess formed in the body of the stamped product. Each recess formed using the forming step can define a respective notch area immediately adjacent to and including each recess. By reducing the strength of the notch areas, the heat treatment step can reduce a predefined threshold of an applied gas pressure at which the recesses of the stamped product deform.

[0045] The cast products described herein can be used to make products in the form of sheets, plates, or other suitable products. For example, plates including the products as described herein can be prepared by processing an ingot in a homogenization step or casting a product in a continuous caster followed by a hot rolling step. In the hot rolling step, the cast product can be hot rolled to a 200 mm thick gauge or less (e.g., from about 10 mm to about 200 mm). For example, the cast product can be hot rolled to a plate having a final gauge thickness of about 10 mm to about 175 mm, about 15 mm to about 150 mm, about 20 mm to about 125 mm, about 25 mm to about 100 mm, about 30 mm to about 75 mm, or about 35 mm to about 50 mm. In some cases, plates may be rolled into thinner metal products, such as sheets. Methods of Using the Disclosed Current Interrupt Device

[0046] The current interrupt devices (CIDs) described herein can be implemented as a battery component, which may be suitable in energy storage applications, including electric vehicle battery applications. In some examples, the CID may be provided as a stamped or formed aluminum alloy product. For example, a 3xxx series aluminum alloy having a recycled aluminum content of at least 75% can undergo a forming process to generate the stamped or formed aluminum alloy product through stamping a surface of the 3xxx series aluminum alloy to include one or more recesses.

[0047] FIG. 2 provides a schematic cross-sectional illustration of an example battery 200 including a current interrupt device (CID) 202 produced using a high strength and recycled content aluminum alloy. In some examples, the battery 200 can include a casing 204 (e.g., a battery can) that encloses components of the battery 200. As illustrated in FIG. 1, the battery 200 can include a terminal 206 (e.g., a positive terminal of the battery 200) that is electrically coupled to an electrochemical cell 208 by the CID 202. In other words, the CID 202 provides an electrical connection between the terminal 206 and the electrochemical cell 208. In certain embodiments, the electrochemical cell 208 can include a respective set of electrodes (e.g., cathodes and anodes) and separators suitably arranged to generate an electrical current that can flow through the CID 202 to the terminal 206. In some cases, the cathodes and anodes of the electrochemical cell 208 can be referred to as a first electrode and a second electrode. The electrochemical cell 208 may include electrolyte dispersed throughout and/or between the electrodes and separators to facilitate ion and electron transport used to generate the electrical current. In some cases, the electrolyte can include one or more lithium salts (e.g., lithium hexafluorophosphate) dissolved in a solvent (e.g., an organic carbonate).

[0048] In the battery 200 depicted in FIG. 2, the CID 202 is shown as contacting a metal disc 210 coupled with a tab 212 providing an electrical connection to the electrochemical cell 208, but other configurations may be used, such as where the CID 202 is directly contacting the tab 212 providing the electrical connection to the electrochemical cell 208. In some cases, the metal disc 210 can be referred to as a bottom disc that is part of the CID 202. As shown in FIG. 2, the metal disc 210 can include one or more discontinuities to enable gases in the battery 200 to be released from the casing 204 of the battery 200. The high strength and high recycled content aluminum alloy used to prepare the CID 202 is electrically conductive such that the CID 202 can be part of the electrical circuit including the electrochemical cell 208 and the terminal 206. For example, current can flow from the electrochemical cell 208 through the CID 202 to the terminal 206. [0049] In some embodiments, the battery 200 can be susceptible to thermal runaway caused by chain exothermic reactions within the battery 200. The exothermic reactions can increase an internal temperature or an internal pressure of the battery 200, resulting in degradation or failure of the battery 200. For example, the exothermic reactions can cause gas buildup in the battery 200, thereby increasing internal pressure of the battery 200 and potentially causing explosion or fire associated with the battery 200. Non-limiting examples of gases that may be generated in the battery 200 include fluoride gases (e.g., hydrogen fluoride, phosphoryl fluoride), hydrogen gas, or a combination thereof. The exothermic reactions can result in gas generation that can cause the casing 204 of the battery 200 to swell or rupture. In some cases, electrolyte decomposition may contribute to the generation of the gases (e.g., the fluoride gases) in the battery 200. For example, if overcharging of the battery 200 occurs, electrochemical oxidation of electrolyte solvents can result in gas generation that increases the internal pressure of the battery 200. The internal pressure of the battery 200 is also referred to herein as an applied gas pressure of the battery 200. In some applications, the battery 200 may be adjacent to one or more neighboring batteries positioned in a battery pack. Once thermal runaway occurs in an individual battery of the battery pack, thermal runaway can propagate through other batteries in the battery pack, increasing the magnitude and likelihood of safety hazards related to thermal runaway.

[0050] To prevent or mitigate a risk of thermal runaway occurring, the battery 200 can include one or more safety devices. In response to an increase in the applied gas pressure of the battery 200, the CID 202 can be activated to interrupt the electrical connection between the terminal 206 and the electrochemical cell 208 of the battery 200. For example, the CID 202 can include one or more recesses 214 that can deform the CID 202 once the applied gas pressure of the battery 200 exceeds a predefined threshold, and the deformation can interrupt or otherwise limit current from flowing between the terminal 206 and the electrochemical cell 208. In other words, the deformation of the CID 202 can result in an interruption of current flow between the terminal 206 and the electrochemical cell 208, hindering or preventing thermal runaway. Additionally, the deformation of the CID 202 can form one or more openings that can enable accumulated gases in the battery 200 to be released, reducing the applied gas pressure and preventing battery rupture.

[0051] As depicted in FIG. 2, the CID 202 includes two recesses 214 that can deform the CID 202 in response to the applied gas pressure of the battery 200 exceeding the predefined threshold. In any examples, the predefined threshold of the applied gas pressure can range from 15 kgf-cm'² to 30 kgf-cm'² with respect to rupture pressure and can range from 5 kgf- cm'² to 15 kgf-cm'² with respect to reverse pressure. For example, the predefined threshold of rupture pressure can range from 15 kgf-cm'² to 15.5 kgf-cm'², from 15.5 kgf-cm'² to 16 kgf-cm'², from 16 kgf-cm'² to 16.5 kgf-cm'², from 16.5 kgf-cm'² to 17 kgf-cm'², from 17 kgf- cm'² to 17.5 kgf-cm'², from 17.5 kgf-cm'² to 18 kgf-cm'², from 18 kgf-cm'² to 18.5 kgf-cm'², from 18.5 kgf-cm'² to 19 kgf-cm'², from 19 kgf-cm'² to 19.5 kgf-cm'², from 19.5 kgf-cm'² to 20 kgf-cm'², from 20 kgf-cm'² to 20.5 kgf-cm'², from 20.5 kgf-cm'² to 21 kgf-cm'², from 21 kgf-cm'² to 21.5 kgf-cm'², from 21.5 kgf-cm'² to 22 kgf-cm'², from 22 kgf-cm'² to 22.5 kgf- cm'², from 22.5 kgf-cm'² to 23 kgf-cm'², from 23 kgf-cm'² to 23.5 kgf-cm'², from 23.5 kgf- cm'² to 24 kgf-cm'², from 24 kgf-cm'² to 24.5 kgf-cm'², from 24.5 kgf-cm'² to 25 kgf-cm'², from 25 kgf-cm'² to 25.5 kgf-cm'², from 25.5 kgf-cm'² to 26 kgf-cm'², from 26 kgf-cm'² to

26.5 kgf-cm'², from 26.5 kgf-cm'² to 27 kgf-cm'², from 27 kgf-cm'² to 27.5 kgf-cm'², from

27.5 kgf-cm'² to 28 kgf-cm'², from 28 kgf-cm'² to 28.5 kgf-cm'², from 28.5 kgf-cm'² to 29 kgf-cm'², from 29 kgf-cm'² to 29.5 kgf-cm'², from 29.5 kgf-cm'² to 30 kgf-cm'², or anywhere in between. As another example, the predefined threshold of reverse pressure can range from 5 kgf-cm'² to 5.5 kgf-cm'², from 5.5 kgf-cm'² to 6 kgf-cm'², from 6 kgf-cm'² to 6.5 kgf-cm'², from 6.5 kgf-cm'² to 7 kgf-cm'², from 7 kgf-cm'² to 7.5 kgf-cm'², from 7.5 kgf-cm'² to 8 kgf- cm'², from 8 kgf-cm'² to 8.5 kgf-cm'², from 8.5 kgf-cm'² to 9 kgf-cm'², from 9 kgf-cm'² to 9.5 kgf-cm'², from 9.5 kgf-cm'² to 10 kgf-cm'², from 10 kgf-cm'² to 10.5 kgf-cm'², from 10.5 kgf- cm'² to 11 kgf-cm'², from 11 kgf-cm'² to 11.5 kgf-cm'², from 11.5 kgf-cm'² to 12 kgf-cm'², from 12 kgf-cm'² to 12.5 kgf-cm'², from 12.5 kgf-cm'² to 13 kgf-cm'², from 13 kgf-cm'² to

13.5 kgf-cm'², from 13.5 kgf-cm'² to 14 kgf-cm'², from 14 kgf-cm'² to 14.5 kgf-cm'², from

14.5 kgf-cm'² to 15 kgf-cm'², or anywhere in between. If the applied gas pressure exceeds the predefined threshold, the deformation of the CID 202 with respect to the recesses 214 can result in one or more openings in the CID 202 through which the gases of the battery 200 can leave the battery 200, thereby decreasing the applied gas pressure.

[0052] Due to the applied gas pressure in the battery 200 exceeding the predefined threshold, the recesses 214 can deform to generate at least one opening in the CID 202 to decrease the applied gas pressure. For instance, the opening in the CID 202 can vent the gases causing the increase in the applied gas pressure of the battery 200. As depicted in FIG.

2, the terminal 206 defines two openings through which the gases can vent to atmosphere, but other configurations for venting can be used, either through the terminal 206 or elsewhere. Accordingly, the CID 202 can function as a pressure relief device that can disable the battery 200 to prevent thermal runaway if the applied gas pressure in the battery 200 is above the predefined threshold. In some cases, the deformation of the CID 202 may be irreversible such that the applied gas pressure exceeding the predefined threshold can cause the CID 202 to permanently disable the battery 200. Thus, the CID 202 can provide a failsafe mechanism in case of malfunction of or damage to the battery 200.

[0053] As another example of a safety device in the battery 200, as illustrated in FIG. 2, the battery 200 can include a positive temperature coefficient (POTC) device 216 positioned between the terminal 206 of the battery 200 and the CID 202. In response to an increase in the internal temperature of the battery 200, a resistance of the POTC device 216 can increase, thereby inhibiting the current flow through the terminal 206 and the electrochemical cell 208 and decreasing the risk of thermal runaway occurring. In other words, the POTC device 216 can reversibly limit the current flow in an electrical circuit of the battery 200 under overheating conditions to prevent thermal runaway. In some embodiments, one or more components of the battery 200 can be enclosed in a holder 218 made of an insulating material, such as plastic. For example, as depicted in FIG. 2, the holder 218 can surround at least a portion of the terminal 206, the CID 202, and the POTC device 216. The holder 218 can provide structural support and protection to the components of the battery 200 while preventing short circuiting.

[0054] FIG. 3 provides a schematic cross-sectional illustration of an example CID 300 comprising a high strength and high recycled content aluminum alloy having a recycled aluminum content of at least 70 wt.%. The CID 300 depicted in FIG. 3 can correspond to or be part of the CID 202 shown in the battery 200 of FIG. 2. A body 302 of the CID 300 includes a first surface 304a in which one or more recesses 306a-b are formed and a second surface 304b opposite to the first surface 304a. Applied gas pressure P can be applied to the second surface 304b of the body 302. In some examples, the CID 300 can be positioned in a battery (e.g., the battery 200 of FIG. 2) such that the second surface 304b of the CID 300 is farther from an electrode terminal of the battery than the first surface 304a of the CID 300. [0055] In any examples, the CID 300 can have a thickness 308 from 0.1 mm to 2 mm (e.g., from 0.1 mm to 0.4 mm, from 0.4 mm to 0.6 mm, from 0.6 mm to 0.8 mm, from 0.8 mm to 1.0 mm, from 1.0 mm to 1.2 mm, from 1.2 mm to 1.4 mm, from 1.4 mm to 1.6 mm, from 1.6 mm to 1.8 mm, or from 1.8 mm to 2.0 mm). In certain embodiments, the thickness 308 of the CID 300 can correspond to a gauge of the recycled content aluminum alloy used to prepare the CID 300. In any examples, the recycled content aluminum alloy of the CID 300 can comprise a 3xxx series aluminum alloy. In any examples, the 3xxx series aluminum alloy used to prepare the CID 300 can have a primary aluminum content of less than 25 wt.% (e.g., less than 24 wt.%, less than 23 wt.%, less than 22 wt.%, less than 21 wt.%, less than 20 wt.%, less than 19 wt.%, less than 18 wt.%, less than 17 wt.%, less than 16 wt.%, less than 15 wt.%, less than 14 wt.%, less than 13 wt.%, less than 12 wt.%, less than 11 wt.%, less than 10 wt.%, less than 9 wt.%, less than 8 wt.%, less than 7 wt.%, less than 6 wt.%, less than 5 wt.%, less than 4 wt.%, less than 3 wt.%, less than 2 wt.%, or less than 1 wt.%). For example, the 3xxx series aluminum alloy can be AA3104 aluminum alloy or a modified AA3104 aluminum alloy.

[0056] In any examples, the high strength and high recycled content aluminum alloy of the CID 300 may comprise at least 70 wt.% recycled aluminum content. For example, the recycled content aluminum alloy used to produce the CID 300 can include at least 71 wt.% recycled aluminum content, at least 72 wt.% recycled aluminum content, at least 73 wt.% recycled aluminum content, at least 74 wt.% recycled aluminum content, at least 75 wt.% recycled aluminum content, at least 76 wt.% recycled aluminum content, at least 77 wt.% recycled aluminum content, at least 78 wt.% recycled aluminum content, at least 79 wt.% recycled aluminum content, at least 80 wt.% recycled aluminum content, at least 81 wt.% recycled aluminum content, at least 82 wt.% recycled aluminum content, at least 83 wt.% recycled aluminum content, at least 84 wt.% recycled aluminum content, at least 85 wt.% recycled aluminum content, at least 86 wt.% recycled aluminum content, at least 87 wt.% recycled aluminum content, at least 88 wt.% recycled aluminum content, at least 89 wt.% recycled aluminum content, at least 90 wt.% recycled aluminum content, at least 91 wt.% recycled aluminum content, at least 92 wt.% recycled aluminum content, at least 93 wt.% recycled aluminum content, at least 94 wt.% recycled aluminum content, at least 95 wt.% recycled aluminum content, at least 96 wt.% recycled aluminum content, at least 97 wt.% recycled aluminum content, at least 98 wt.% recycled aluminum content, at least 99 wt.% recycled aluminum content, or 100 wt.% recycled aluminum content. Non-limiting examples of recycled aluminum content include used beverage can (UBC) scrap, runaround scrap, automotive scrap, electronics, lithographic scrap, industrial product scrap, or a combination thereof.

[0057] The recesses 306a-b of the CID 300 can include a first recess 306a and a second recess 306b adjacent to the first recess 306a. The recesses 306a-b can be separated by a lateral distance 310 ranging from 0.05 mm to 2 mm (e.g., from 0.05 mm to 0.1 mm, from 0.1 mm to 0.5 mm, from 0.5 mm to 1.0 mm, from 1.0 mm to 1.5 mm, from 1.5 mm to 2.0 mm, from 2.0 mm to 2.5 mm, or from 2.5 mm to 3.0 mm). Although two recesses 306a-b are shown in FIG. 3, it will be appreciated that the recesses 306a-b can be part of a single depression (e.g., a groove, a notch, a score, etc.) formed in the body 302 of the CID 300. For example, the depression may be shown as two recesses 306a-b due to the cross-sectional view of the CID 300 provided in FIG. 3. In some embodiments, the depression associated with the recesses 306a-b may be circular. For example, the recesses 306a-b can be part of a depression formed as a closed loop in the body 302 of the CID 300. As another example, the recesses 306a-b may be part of an open loop (e.g., a C-shaped loop) formed in the body 302 of the CID 300.

[0058] In certain embodiments, forming the recesses 306a-b in the body 302 of the CID 300 involves stamping the body 302 to generate a recessed pattern or shape in the first surface 304a of the body 302. After stamping the body 302 to form the recesses 306a-b, residual material of the body 302 can remain between a recess end 312 and the second surface 304b of the body 302. A distance between the recess end 312 and the second surface 304b can be referred to as a residual length 314. In some examples, the residual length 314 can range from 30 pm to 250 pm (e.g., from 30 pm to 40 pm, from 40 pm to 50 pm, from 50 pm to 60 pm, from 60 pm to 70 pm, from 70 pm to 80 pm, from 80 pm to 90 pm, from 90 pm to 100 pm, from 100 pm to 110 pm, from 110 pm to 120 pm, from 120 pm to 130 pm, from 130 pm to 140 pm, from 140 pm to 150 pm, from 150 pm to 160 pm, from 160 pm to 170 pm, from 170 pm to 180 pm, from 180 pm to 190 pm, from 190 pm to 200 pm, from 200 pm to 210 pm, from 210 pm to 220 pm, from 220 pm to 230 pm, from 230 pm to 240 pm, from 240 pm to 250 pm, or anywhere in between).

[0059] In some examples, the stamping step used to form the recesses 306a-b can result in at least one of the recesses 306a-b being a V-shaped notch that has a pointed notch tip. As depicted in FIG. 3, recesses that are V-shaped notches can be formed in the first surface 304a of the body 302 such that the recesses 306a-b taper to a point as the recess end 312. Additionally, the V-shaped notches may define a notch angle 316 within the recesses 306a-b. In some examples, the notch angle 316 can range from 10 degrees to 60 degrees (e.g., from 10 degrees to 20 degrees, from 20 degrees to 30 degrees, from 30 degrees to 40 degrees, from 40 degrees to 50 degrees, or from 50 degrees to 60 degrees). Although the recesses 306a-b in FIG. 3 are depicted as V-shaped notches, it will be appreciated that other shapes for the recesses 306a-b are possible. For example, the stamping step may form U-shaped notches or semicircular (e.g., C-shaped) notches with round notch tips. As another example, the stamping step may form notches that have a multi-layered shape. These notches can be referred to as multi-angled notches. The multi-angled notches may start with a width that narrows or tapers to the pointed notch tip in one or more tiers or steps. Rather than narrowing gradually, such as in the case of the V-shaped notches, the width of the multi- angled notches may decrease at one or more predefined points between the first surface 304a and the second surface 304b. As an example, a sectional view of the multi-angled notches may have a funnel shape with a pointed notch tip for a stem of the funnel shape. As another example, the sectional view of the multi-angled notches can have a multi-layered shape with a width that decreases from a trapezoidal shape to the pointed notch tip.

[0060] The recesses 306a-b can function as predefined points in the body 302 of the CID 300 at which the CID 300 can break in response to the applied gas pressure P exceeding a predefined threshold as described above with respect to FIG. 2. The recesses 306a-b can each define a respective notch area (e.g., notch area 318) in the body 302 that is immediately adjacent to and includes a corresponding recess. If the applied gas pressure P increases past the predefined threshold, the body 302 of the CID 300 can deform at or within each notch area 318 to form one or more openings in the CID 300, providing a pathway for gas venting to decrease the applied gas pressure P. The predefined threshold associated with the applied gas pressure P can correspond to a mechanical limit of the notch area 318 at which the notch area 318 is unable to resist further deformation. The applied gas pressure P exceeding the predefined threshold can result in a mechanical failure (e.g., breakage, deformation, etc.) of the body 302 of the CID 300 at the notch area 318. Additionally, the recesses 306a-b can define one or more normal areas (e.g., normal area 320) in the body 302 that is between or surrounded by notch areas. In some examples, the normal areas can correspond to portions of the body 302 of the CID 300 that may remain intact after deformation of the CID 300. In some examples, deformation due to the applied gas pressure P exceeding the predefined threshold can result in disrupting a circuit path between an electrode of the battery and a terminal, so as to limit discharge of the battery.

[0061] Mechanical strength of the notch area 318 and the normal area 320 can differ, at least in part due to the recesses 306a-b being included in the notch area 318. For example, each respective notch area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 350 MPa (e.g., from 50 MPa to 100 MPa, from 100 MPa to 150 MPa, from 150 MPa to 200 MPa, from 200 MPa to 250 MPa, from 250 MPa to 300 MPa, or from 300 MPa to 350 MPa). Additionally, each respective notch area exhibits or is configured to exhibit an ultimate tensile strength (UTS) ranging from 100 MPa to 350 MPa (e.g., from 100 MPa to 150 MPa, from 150 MPa to 200 MPa, from 200 MPa to 250 MPa, from 250 MPa to 300 MPa, or from 300 MPa to 350 MPa). Further, each respective notch area exhibits or is configured to exhibit an ultimate elongation from 0.5% to 15% (e.g., from 0.5% to 1%, from 1% to 2%, from 2% to 3%, from 3% to 4%, from 4% to 5%, from 5% to 6%, from 6% to 7%, from 7% to 8%, from 8% to 9%, from 9% to 10%, from 10% to 11%, from 11% to 12%, from 12% to 13%, from 13% to 14%, or from 14% to 15%). On the other hand, each normal area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 250 MPa (e.g., from 50 MPa to 100 MPa, from 100 MPa to 150 MPa, from 150 MPa to 200 MPa, or from 200 MPa to 250 MPa). Additionally, each normal area exhibits or is configured to exhibit an UTS ranging from 150 MPa to 250 MPa (e.g., from 150 MPa to 160 MPa, from 160 MPa to 170 MPa, from 170 MPa to 180 MPa, from 180 MPa to 190 MPa, from 190 MPa to 200 MPa, from 200 MPa to 210 MPa, from 210 MPa to 220 MPa, from 220 MPa to 230 MPa, from 230 MPa to 240 MPa, or from 240 MPa to 250 MPa). Further, each normal area exhibits or is configured to exhibit an elongation from 2% to 18% (e.g., from 2% to 3%, from 3% to 4%, from 4% to 5%, from 5% to 6%, from 6% to 7%, from 7% to 8%, from 8% to 9%, from 9% to 10%, from 10% to 11%, from 11% to 12%, from 12% to 13%, from 13% to 14%, from 14% to 15%, from 15% to 16%, from 16% to 17%, or from 17% to 18%).

[0062] The examples disclosed herein will serve to further illustrate aspects of the invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. The examples and embodiments described herein may also make use of conventional procedures, unless otherwise stated. Some of the procedures are described herein for illustrative purposes.

EXAMPLE 1

[0063] Sample CIDs were produced using the high strength and high recycled content aluminum alloys described herein to determine the properties of the CIDs described herein. FIGS. 4 A, 4B, and 4C depict a respective cross-sectional view of example CIDs that have various configurations. The CIDs of FIGS. 4A-4C each have a cup-type structure that includes a disc with a side wall (e.g., side walls 402a-c) defining a perimeter of the disc. The CIDs depicted in FIGS. 4A-4C have different total diameters and lateral distances between adjacent recesses. FIG. 4 A shows a first example CID 410 having a total diameter of 17 mm and a lateral distance of 7 mm. FIG. 4B shows a second example CID 420 having a total diameter of 18 mm and a lateral distance of 10 mm. FIG. 4C shows a third example CID 430 having a total diameter of 19.2 mm and a lateral distance of 11.5 mm. As another example, the CIDs depicted in FIGS. 4A-4C have different parameters associated with the respective recesses of the CIDs. Compared to the second example CID 420 and the third example CID 430, the recesses of the first example CID 410 have a rounder recess end and a wider width. [0064] FIG. 5 is a plot indicating reverse pressure and rupture pressure for an example AA3003 aluminum alloy and example AA3104 aluminum alloys before and after heat treatment. The example aluminum alloys were each prepared using the configuration described above with respect to FIG. 4C. The example AA3003 aluminum alloy was prepared using a conventional AA3003 aluminum alloy in the H14 temper, whereas the example AA3104 aluminum alloys were prepared in the O temper and H12 temper, respectively. Linear fit 502 corresponds to the dataset of the example AA3003 aluminum alloy. Linear fit 504 corresponds to the dataset of the example AA3104 aluminum alloy in O temper. Linear fit 506 corresponds to the dataset of the example AA3104 aluminum alloy in H12 temper. As shown in FIG. 5, the example AA3003 aluminum alloy was generally weaker than both example AA3104 aluminum alloys based on the lower rupture pressure and reverse pressure values before and after heat treatment. Accordingly, the example AA3104 aluminum alloys being stronger than the example AA3003 aluminum alloy can enable lightweighting of the CIDs, such as by using a thinner gauge to achieve a similar rupture pressure or reverse pressure. As exhibited by a decrease in the rupture pressures and reverse pressures of the example aluminum alloys after heat treatment, applying a heat treatment step to the aluminum alloys reduces the strength (e.g., yield strength or ultimate tensile strength) of the aluminum alloys. Thus, customizing the rupture pressure or reverse pressure of the CIDs can involve adjusting conditions (e.g., heat treatment temperature, duration, etc.) of the heat treatment step.

[0065] FIG. 6 provides a plot indicating simulated vent pressure (kgf-crn'²) and residual thickness (pm) data for CIDs prepared using an example AA3003 aluminum alloy or an example AA3104 aluminum alloy. In certain aspects, vent pressure can be a vent activation pressure at which a CID is activated to interrupt an electrical connection within a battery. In some examples, the vent pressure can be referred to as rupture pressure. For example, the CID may deform or break once an internal pressure of the battery exceeds a predefined threshold. The residual thickness can correspond to a residual length as described above with respect to FIG. 3. As shown in FIG. 6, a respective linear fit was determined for a dataset corresponding to the simulated AA3003 aluminum alloy and for another dataset corresponding to the simulated AA3104 aluminum alloy. Line 602 corresponds to the linear fit for the simulated AA3003 aluminum alloy. Line 604 corresponds to the linear fit for the simulated AA3104 aluminum alloy. A linear relationship was found between the vent pressure of the CIDs and the residual length of the CIDs. As shown, the simulated vent pressure for the CID produced using the example AA3104 aluminum alloy exhibited higher strength (e.g., higher rupture strength) for similar residual thicknesses compared to the CID produced using the example AA3003 aluminum alloy. As described herein, this difference in vent pressure can enable lightweighting of the CIDs, such as by using a thinner gauge of the AA3104 aluminum alloy to achieve a vent pressure similar to that of the AA3003 aluminum alloy.

ILLUSTRATIVE ASPECTS

[0066] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4”).

[0067] Aspect l is a current interrupt device, comprising: a body comprising a 3xxx series aluminum alloy having a recycled aluminum content of at least 70 wt.%, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold and interrupt electrical communication between a terminal and an electrochemical cell through the body.

[0068] Aspect 2 is the current interrupt device of any previous or subsequent aspect, wherein the 3xxx series aluminum alloy comprises AA3104 aluminum alloy.

[0069] Aspect 3 is the current interrupt device of any previous or subsequent aspect, wherein the recycled aluminum content comprises used beverage can scrap, runaround scrap, automotive scrap, electronics scrap, lithographic scrap, or industrial product scrap.

[0070] Aspect 4 is the current interrupt device of any previous or subsequent aspect, wherein the 3xxx series aluminum alloy has a primary aluminum content of less than 25 wt.%.

[0071] Aspect 5 is the current interrupt device of any previous or subsequent aspect, wherein the body has a cup-type structure comprising a disc having a side wall that defines a perimeter of the disc.

[0072] Aspect 6 is the current interrupt device of any previous or subsequent aspect, wherein the side wall has a side wall length ranging from 0.5 mm to 20 mm.

[0073] Aspect 7 is the current interrupt device of any previous or subsequent aspect, wherein the one or more recesses comprise a circular groove or notch in the body. [0074] Aspect 8 is the current interrupt device of any previous or subsequent aspect, wherein the one or more recesses are further configured to generate at least one opening in the body to vent the applied gas pressure through the body.

[0075] Aspect 9 is the current interrupt device of any previous or subsequent aspect, wherein the predefined threshold of the applied gas pressure ranges from 5 kgf-cm-2 to 30 kgf-cm-2.

[0076] Aspect 10 is the current interrupt device of any previous or subsequent aspect, wherein the predefined threshold of the applied gas pressure ranges from 15 kgf-cm-2 to 30 kgf-cm-2 with respect to rupture pressure.

[0077] Aspect 11 is the current interrupt device of any previous or subsequent aspect, wherein the predefined threshold of the applied gas pressure ranges from 5 kgf-cm-2 to 15 kgf-cm-2 with respect to reverse pressure.

[0078] Aspect 12 is the current interrupt device of any previous or subsequent aspect, wherein the one or more recesses are positioned in a first surface of the body, and wherein the applied gas pressure is applied to a second surface of the body that is opposite to the first surface.

[0079] Aspect 13 is the current interrupt device of any previous or subsequent aspect, wherein each of the one or more recesses defines a respective residual length between a respective recess end and the second surface.

[0080] Aspect 14 is the current interrupt device of any previous or subsequent aspect, wherein each residual length ranges from 30 microns to 250 microns.

[0081] Aspect 15 is the current interrupt device of any previous or subsequent aspect, wherein at least one of the one or more recesses is a V-shaped notch having a pointed notch tip.

[0082] Aspect 16 is the current interrupt device of any previous or subsequent aspect, wherein the V-shaped notch has a notch angle ranging from 10 degrees to 60 degrees.

[0083] Aspect 17 is the current interrupt device of any previous or subsequent aspect, wherein the one or more recesses comprise a plurality of recesses, and wherein each recess of the plurality of recesses is separated from an adjacent recess by a lateral distance ranging from 0.05 mm to 2.0 mm.

[0084] Aspect 18 is the current interrupt device of any previous or subsequent aspect, wherein the one or more recesses each define a respective notch area in the body immediately adjacent to and including a recess and one or more normal areas in the body between or surrounded by notch areas. [0085] Aspect 19 is the current interrupt device of any previous or subsequent aspect, wherein each respective notch area exhibits or is configured to exhibit an ultimate tensile strength ranging from 100 MPa to 350 MPa.

[0086] Aspect 20 is the current interrupt device of any previous or subsequent aspect, wherein each respective notch area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 350 MPa.

[0087] Aspect 21 is the current interrupt device of any previous or subsequent aspect, wherein each respective notch area exhibits or is configured to exhibit an elongation from 0.5% to 15.0%.

[0088] Aspect 22 is the current interrupt device of any previous or subsequent aspect, wherein each normal area exhibits or is configured to exhibit an ultimate tensile strength ranging from 150 MPa to 250 MPa.

[0089] Aspect 23 is the current interrupt device of any previous or subsequent aspect, wherein each normal area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 250 MPa.

[0090] Aspect 24 is the current interrupt device of any previous or subsequent aspect, wherein each normal area exhibits or is configured to exhibit an elongation from 2.0% to 18.0%.

[0091] Aspect 25 is the current interrupt device of any previous or subsequent aspect, wherein the body has a thickness ranging from 0.1 mm to 2.0 mm.

[0092] Aspect 26 is a battery comprising the current interrupt device of any of any previous or subsequent aspect.

[0093] Aspect 27 is the battery of any previous or subsequent aspect, further comprising: an electrode terminal; and an electrochemical cell including an electrode electrically coupled to the electrode terminal via the current interrupt device, wherein an internal pressure of the battery exceeding the predefined threshold is configured to deform the body of the current interrupt device and interrupt electrical communication between the electrode terminal and the electrode through the body.

[0094] Aspect 28 is a method of producing a current interrupt device, wherein the method comprises: processing a molten metal mixture comprising a 3xxx series aluminum alloy to create an aluminum alloy product, wherein the 3xxx series aluminum alloy has a recycled aluminum content of at least 70%; and forming the aluminum alloy product to generate the current interrupt device, the current interrupt device comprising: a body comprising the 3xxx series aluminum alloy, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold.

[0095] Aspect 29 is the method of any previous or subsequent aspect, wherein forming the aluminum alloy product comprises: stamping the aluminum alloy product to form the one or more recesses in a first surface of the body.

[0096] Aspect 30 is the method of any previous or subsequent aspect, wherein forming the aluminum alloy product further comprises: heat treating the stamped aluminum alloy product using a heat treatment temperature from 60° C to 400° C for up to 3 hours.

[0097] Aspect 31 is the method of any previous or subsequent aspect, wherein the heat treatment step is configured to reduce a yield strength or ultimate tensile strength of the body. [0098] Aspect 32 is a method of producing a battery, comprising: providing an electrochemical cell including a first electrode and a second electrode; providing a current interrupt device comprising a 3xxx series aluminum alloy body having a recycled aluminum content of at least 70 wt.%; and positioning the current interrupt device between the electrochemical cell and an electrode terminal in a battery casing such that the current interrupt device provides electrical communication between the first electrode and the electrode terminal, wherein the 3xxx series aluminum alloy body includes one or more recesses configured to deform the 3xxx series aluminum alloy body in response to an applied gas pressure within the battery exceeding a predefined threshold and interrupt electrical communication between the electrode terminal and the first electrode through the current interrupt device.

[0099] Aspect 33 is a battery formed using the method of any previous or subsequent aspect.

[00100] Aspect 34 is the battery of any previous or subsequent aspect, wherein the battery is an electric vehicle battery.

[00101] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1. A current interrupt device, comprising: a body comprising a 3xxx series aluminum alloy having a recycled aluminum content of at least 70 wt.%, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold and interrupt electrical communication between a terminal and an electrochemical cell through the body.

2. The current interrupt device of claim 1, wherein the 3xxx series aluminum alloy comprises AA3104 aluminum alloy.

3. The current interrupt device of claim 1, wherein the recycled aluminum content comprises used beverage can scrap, runaround scrap, automotive scrap, electronics scrap, lithographic scrap, or industrial product scrap.

4. The current interrupt device of claim 1, wherein the 3xxx series aluminum alloy has a primary aluminum content of less than 25 wt.%.

5. The current interrupt device of claim 1, wherein the body has a cuptype structure comprising a disc having a side wall that defines a perimeter of the disc.

6. The current interrupt device of claim 5, wherein the side wall has a side wall length ranging from 0.5 mm to 20 mm.

7. The current interrupt device of claim 1, wherein the one or more recesses comprise a circular groove or notch in the body.

8. The current interrupt device of claim 1, wherein the one or more recesses are further configured to generate at least one opening in the body to vent the applied gas pressure through the body.

9. The current interrupt device of claim 1, wherein the predefined threshold of the applied gas pressure ranges from 5 kgf-cm'² to 30 kgf-cm'².

10. The current interrupt device of claim 9, wherein the predefined threshold of the applied gas pressure ranges from 15 kgf-cm'² to 30 kgf-cm'² with respect to rupture pressure.

11. The current interrupt device of claim 9, wherein the predefined threshold of the applied gas pressure ranges from 5 kgf-cm'² to 15 kgf-cm'² with respect to reverse pressure.

12. The current interrupt device of claim 1, wherein the one or more recesses are positioned in a first surface of the body, and wherein the applied gas pressure is applied to a second surface of the body that is opposite to the first surface.

13. The current interrupt device of claim 12, wherein each of the one or more recesses defines a respective residual length between a respective recess end and the second surface.

14. The current interrupt device of claim 13, wherein each residual length ranges from 30 microns to 250 microns.

15. The current interrupt device of claim 1, wherein at least one of the one or more recesses is a V-shaped notch having a pointed notch tip.

16. The current interrupt device of claim 15, wherein the V-shaped notch has a notch angle ranging from 10 degrees to 60 degrees.

17. The current interrupt device of claim 1, wherein the one or more recesses comprise a plurality of recesses, and wherein each recess of the plurality of recesses is separated from an adjacent recess by a lateral distance ranging from 0.05 mm to 2.0 mm.

18. The current interrupt device of claim 1, wherein the one or more recesses each define a respective notch area in the body immediately adjacent to and including a recess and one or more normal areas in the body between or surrounded by notch areas.

19. The current interrupt device of claim 18, wherein each respective notch area exhibits or is configured to exhibit an ultimate tensile strength ranging from 100 MPa to 350 MPa.

20. The current interrupt device of claim 18, wherein each respective notch area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 350 MPa.

21. The current interrupt device of claim 18, wherein each respective notch area exhibits or is configured to exhibit an elongation from 0.5% to 15.0%.

22. The current interrupt device of claim 18, wherein each normal area exhibits or is configured to exhibit an ultimate tensile strength ranging from 150 MPa to 250 MPa.

23. The current interrupt device of claim 18, wherein each normal area exhibits or is configured to exhibit a yield strength ranging from 50 MPa to 250 MPa.

24. The current interrupt device of claim 18, wherein each normal area exhibits or is configured to exhibit an elongation from 2.0% to 18.0%.

25. The current interrupt device of claim 1, wherein the body has a thickness ranging from 0.1 mm to 2.0 mm.

26. A battery comprising the current interrupt device of any of claims 1- 25.

27. The battery of claim 26, further comprising: an electrode terminal; and an electrochemical cell including an electrode electrically coupled to the electrode terminal via the current interrupt device, wherein an internal pressure of the battery exceeding the predefined threshold is configured to deform the body of the current interrupt device and interrupt electrical communication between the electrode terminal and the electrode through the body.

28. A method of producing a current interrupt device, wherein the method comprises: processing a molten metal mixture comprising a 3xxx series aluminum alloy to create an aluminum alloy product, wherein the 3xxx series aluminum alloy has a recycled aluminum content of at least 70%; and forming the aluminum alloy product to generate the current interrupt device, the current interrupt device comprising: a body comprising the 3xxx series aluminum alloy, wherein the body includes one or more recesses configured to deform the body in response to an applied gas pressure exceeding a predefined threshold.

29. The method of claim 28, wherein forming the aluminum alloy product comprises: stamping the aluminum alloy product to form the one or more recesses in a first surface of the body.

30. The method of claim 29, wherein forming the aluminum alloy product further comprises: heat treating the stamped aluminum alloy product using a heat treatment temperature from 60° C to 400° C for up to 3 hours.

31. The method of claim 30, wherein the heat treatment step is configured to reduce a yield strength or ultimate tensile strength of the body.

32. A method of producing a battery, comprising: providing an electrochemical cell including a first electrode and a second electrode; providing a current interrupt device comprising a 3xxx series aluminum alloy body having a recycled aluminum content of at least 70 wt.%; and positioning the current interrupt device between the electrochemical cell and an electrode terminal in a battery casing such that the current interrupt device provides electrical communication between the first electrode and the electrode terminal, wherein the 3xxx series aluminum alloy body includes one or more recesses configured to deform the 3xxx series aluminum alloy body in response to an applied gas pressure within the battery exceeding a predefined threshold and interrupt electrical communication between the electrode terminal and the first electrode through the current interrupt device.

33. A battery formed using the method of claim 32.

34. The battery of claim 33, wherein the battery is an electric vehicle battery.