# US 12,109,647 B2 · Method for producing hollow container

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- Number: US 12,109,647 B2
- Document ID: US12109647B2
- Status: Granted
- Kind: B2
- Application number: 17/611,864
- Filed: 2020-02-07
- Published: 2022-07-21
- Granted: 2024-10-08
- Earliest claimed: 2019-05-17
- Assignees: Nippon Light Metal Company, Ltd.
- Applicants: Nippon Light Metal Company, Ltd.
- Inventors: Nobushiro Seo; Keita Oikawa; Ryo Yoshida
- Web page: https://patentgrep.com/patent/US12109647B2

## CPC

- B23K 20/1225: {Particular aspects of welding with a non-consumable tool}
- B23K 20/128: {making use of additional material}
- B23K 20/12: the heat being generated by friction; Friction welding
- B23K 20/122: {using a non-consumable tool, e.g. friction stir welding}
- B23K 20/125: {Rotary tool drive mechanism}
- B23K 20/1255: {Tools therefor, e.g. characterised by the shape of the probe}
- B23K 20/127: {Friction stir welding involving a mechanical connection}
- B23K 20/16: with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas
- B23K 20/22: taking account of the properties of the materials to be welded
- B23K 20/233: without ferrous layer
- B23K 20/2336: {both layers being aluminium}
- B23K 2101/12: Vessels
- B23K 2103/10: Aluminium or alloys thereof
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM

## Abstract

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin, including: preparing a first metal member, a second metal member, and an auxiliary member; butting the first metal member and the second metal member to face with each other, the auxiliary member is interposed between the first metal member and the second metal member; and joining the first metal member with the second metal member via the auxiliary member. The first and second metal members, and the auxiliary member are made of aluminum or an aluminum alloy, and the first and second metal members have higher hardness than the auxiliary member. At least one of the first and second metal members has an inclined surface inclined outward, and the auxiliary member has an inclined surface, tapered from the external surface toward an internal surface, on at least one of the side surfaces.

## Claims

### Claim 1

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and an end surface of the peripheral wall of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the end surface of the peripheral wall of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surfaces, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the end surface of the peripheral wall of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
the end surface of the peripheral wall of at least one of the first metal member and the second metal member has an inclined surface to face outward, and the auxiliary member has an inclined surface, which is tapered from the external surface toward an internal surface, on at least one of the side surfaces.

### Claim 2 (depends on 1)

The method for manufacturing a hollow container as claimed in claim 1, wherein, in the joining step, the rotary tool is moved over an entire outer peripheral surfaces of the first metal member and the second metal member.

### Claim 3 (depends on 1)

The method for manufacturing a hollow container as claimed in claim 1, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 4

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and an end surface of the peripheral wall of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the end surface of the peripheral wall of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surfaces, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the end surface of the peripheral wall of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
the end surfaces of the peripheral walls of the first metal member and the second metal member have inclined surfaces to face outward, and the auxiliary member has inclined surfaces, which are tapered from the external surface toward an internal surface, on both of the side surfaces.

### Claim 5 (depends on 4)

The method for manufacturing a hollow container as claimed in claim 4, wherein, in the joining step, the rotary tool is moved over an entire outer peripheral surfaces of the first metal member and the second metal member.

### Claim 6 (depends on 4)

The method for manufacturing a hollow container as claimed in claim 4, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 7

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and an end surface of the peripheral wall of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the end surface of the peripheral wall of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surfaces, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the end surface of the peripheral wall of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member,
the end surface of the peripheral wall of at least one of the first metal member and the second metal member has an inclined surface to face outward, and
the auxiliary member has an inclined surface, which is tapered from the external surface toward an internal surface, on at least one of the side surfaces, and has a protrusion, which extends on at least one of the side surfaces side, on the internal surface.

### Claim 8

The method for manufacturing a hollow container as claimed in 7, wherein, in the joining step, the rotary tool is moved over an entire outer peripheral surfaces of the first metal member and the second metal member.

### Claim 9 (depends on 7)

The method for manufacturing a hollow container as claimed in claim 7, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 10

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and an end surface of the peripheral wall of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the end surface of the peripheral wall of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surfaces, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the end surface of the peripheral wall of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member,
the end surfaces of the peripheral walls of the first metal member and the second metal member have inclined surfaces to face outward, and
the auxiliary member has inclined surfaces, which are tapered from the external surface toward an internal surface, on both of the side surfaces, and has a protrusion, which extends on at least one of the side surfaces side, on the internal surface.

### Claim 11 (depends on 10)

The method for manufacturing a hollow container as claimed in claim 10, wherein, in the joining step, the rotary tool is moved over an entire outer peripheral surfaces of the first metal member and the second metal member.

### Claim 12 (depends on 10)

The method for manufacturing a hollow container as claimed in claim 10, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 13

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin, the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a plate shape, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and a peripheral edge on an internal surface of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surface and the peripheral edge, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the peripheral edge on the internal surface of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
at least one of the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member has an inclined surface to face outward, and the auxiliary member has an inclined surface, which is tapered from the external surface toward an internal surface, on at least one of the side surfaces.

### Claim 14 (depends on 13)

The method for manufacturing a hollow container as claimed in claim 13, wherein, in the joining step, the rotary tool is moved over around the first metal member and the second metal member.

### Claim 15 (depends on 13)

The method for manufacturing a hollow container as claimed in claim 13, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 16

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a plate shape, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall portion of the first metal member and a peripheral edge on an internal surface of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surface and the peripheral edge, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the peripheral edge on the internal surface of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member have inclined surfaces to face outward, and the auxiliary member has inclined surfaces, which are tapered from the external surface toward an internal surface, on both of the side surfaces.

### Claim 17

The method for manufacturing a hollow container as claimed in 16, wherein, in the joining step, the rotary tool is moved over around the first metal member and the second metal member.

### Claim 18 (depends on 16)

The method for manufacturing a hollow container as claimed in claim 16, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 19

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a plate shape, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and a peripheral edge on an internal surface of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surface and the peripheral edge, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the peripheral edge on the internal surface of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
at least one of the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member has an inclined surface to face outward, and the auxiliary member has an inclined surface, which is tapered from the external surface toward an internal surface, on at least one of the side surfaces, and has a protrusion, which extends on at least one of the side surfaces side, on the internal surface.

### Claim 20 (depends on 19)

The method for manufacturing a hollow container as claimed in claim 19, wherein, in the joining step, the rotary tool is moved over around the first metal member and the second metal member.

### Claim 21 (depends on 19)

The method for manufacturing a hollow container as claimed in claim 19, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.

### Claim 22

A method for manufacturing a hollow container with use of a rotary tool including a tapered stirring pin,
the method comprising:
preparing a first metal member having a concave portion which is formed by a bottom and a peripheral wall extending from a peripheral edge of the bottom, a second metal member having a plate shape, and an auxiliary member having a frame structure corresponding to an end surface of the peripheral wall of the first metal member and a peripheral edge on an internal surface of the second metal member;
butting, in which the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member are faced with each other, the auxiliary member is interposed in a gap between the end surface and the peripheral edge, the end surface of the peripheral wall of the first metal member is butted against one side surface of the auxiliary member to form a first butted portion, and the peripheral edge on the internal surface of the second metal member is butted against the other side surface of the auxiliary member to form a second butted portion; and
joining, in which the rotating rotary tool is inserted only through an external surface of the auxiliary member and is relatively moved along the first butted portion and the second butted portion, with only the stirring pin contacting the auxiliary member and an outer peripheral surface of the stirring pin contacting the first and second metal members, to join the first metal member to the second metal member via the auxiliary member with a contact margin between the outer peripheral surface of the stirring pin and the end surfaces set to be less than 1.0 mm,
wherein the first metal member, the second metal member, and the auxiliary member are made of aluminum or an aluminum alloy, and the first metal member and the second metal member have higher hardness than the auxiliary member, and
the end surface of the peripheral wall of the first metal member and the peripheral edge on the internal surface of the second metal member have inclined surfaces to face outward, and the auxiliary member has inclined surfaces, which are tapered from the external surface toward an internal surface, on both of the side surfaces, and has a protrusion, which extends on at least one of the side surfaces side, on the internal surface.

### Claim 23 (depends on 22)

The method for manufacturing a hollow container as claimed in claim 22, wherein, in the joining step, the rotary tool is moved over around the first metal member and the second metal member.

### Claim 24 (depends on 22)

The method for manufacturing a hollow container as claimed in claim 22, wherein the first metal member and the second metal member are made of a casting material, and the auxiliary member is made of an wrought aluminum alloy material.