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- Nachgewiesen in: USPTO Patent Grants
- Sprachen: English
- Patent Number: 5,126,528
- Publication Date: June 30, 1992
- Appl. No: 07/528,945
- Application Filed: May 25, 1990
- Assignees: CMW, Inc. (Indianapolis, IN)
- Claim: What is claimed is
- Claim: 1. A process for fabricating a resistance welding electrode, comprising
- Claim: mounting an electrically conductive metal blank having a front end and an opposite rear end in a holder, said blank having a base axis running centrally therethrough between said front end and said rear end, said holder having a major axis, wherein said blank is mounted in said holder so that said base axis and said major axis are oriented with respect to each other at a mounting angle less than 180.degree. so that said base axis and said major axis are nonparallel;
- Claim: engaging a cutting tool with said blank for cutting a nose portion from said front end of said blank; and
- Claim: spinning said blank and said cutting tool with respect to each other about said major axis to cut said front end of said blank to form said nose portion having a nose axis which coincides with said major axis, wherein said base axis and said nose axis are oriented with respect to each other at a nose angle less than 180.degree. so that said base axis and said nose axis are nonparallel, said nose portion being tapered down to a welding tip face, wherein said spinning step to cut said blank includes the step of cutting said nose portion into a concave profile taper.
- Claim: 2. The process of claim 1 and further comprising the preliminary step of cold forming said blank into a generally cylindrical shape with a longitudinal cooling recess formed in said rear end of said blank.
- Claim: 3. The process of claim 2 wherein said spinning step to cut said blank includes the step of spinning said holder about said major axis with said rear end of said blank revolving around said major axis.
- Claim: 4. The process of claim 3 and further comprising the step of forming said welding tip face to have a convex curvature defining a crown height of about 0.002 inches.
- Claim: 5. The process of claim 4 wherein said nose portion is made of dispersion strengthened copper having co-axial, anisotropic fibrous grain structure at said welding tip face which is oriented at an angular, non-normal angle with respect to said welding tip face to resist cracking.
- Claim: 6. The process of claim 4 wherein said nose portion is made of a copper material consisting of essentially pure copper or of copper combined with one or more metals selected from the group consisting of chromium, zirconium, cadmium, cobalt, nickel, beryllium, tungsten, aluminum, tungsten carbide, iron, and molybdenum.
- Claim: 7. The process of claim 2 wherein said welding tip face has a face diameter, and wherein said nose portion has an axial nose length along said nose axis, said face diameter being about equal to said nose length.
- Claim: 8. The process of claim 2 wherein said concave profile taper of said nose portion defines a frustum of a vortical surface, and wherein said concave profile taper has a concave curvature of an arc of a circle.
- Claim: 9. The process of claim 1 wherein said nose portion is made of dispersion strengthened copper having co-axial, anisotropic fibrous grain structure at said welding tip face which is oriented at an angular, non-normal angle with respect to said welding tip face to resist cracking.
- Claim: 10. The process of claim 1 wherein said spinning step to cut said blank includes the step of spinning said holder about said major axis with said rear end of said blank revolving around said major axis.
- Claim: 11. The process of claim 1 and further comprising the step of forming said welding tip face to have a convex curvature defining a crown height.
- Claim: 12. The process of claim 1 wherein said nose portion is made of a copper material consisting of essentially pure copper or of copper combined with one or more metals selected from the group consisting of chromium, zirconium, cadmium, cobalt, nickel, beryllium, tungsten, aluminum, tungsten carbide, iron, and molybdenum.
- Claim: 13. A resistance welding electrode, comprising
- Claim: an electrically conductive base portion defining a central base axis longitudinally therethrough; and
- Claim: an electrically conductive nose portion projecting from said base portion an axial nose length and terminating in a welding tip face, wherein said nose portion tapers inwardly between said base portion and said welding tip face with a concave profile taper, said nose portion defining a nose axis therethrough, said nose axis being generally normal to said welding tip face; and
- Claim: wherein said base axis and said nose axis are oriented with respect to each other at a nose angle less than 180.degree. so that said base axis and said nose axis are nonparallel.
- Claim: 14. The electrode of claim 13 wherein said welding tip face is fabricated to define a slight convex welding tip curvature.
- Claim: 15. The electrode of claim 14 wherein said welding tip face has a face diameter about equal to said nose length.
- Claim: 16. The electrode of claim 15 wherein said concave profile taper of said nose portion defines a frustum of a vortical surface, and wherein said concave profile taper has a concave curvature of an arc of a circle.
- Claim: 17. The electrode of claim 16 wherein said slight convex curvature defines a crown height of about 0.002 inches.
- Claim: 18. The electrode of claim 14 wherein said nose portion is made of dispersion strengthened copper having co-axial, anisotropic fibrous grain structure at said welding tip face which is oriented at an angular, non-normal angle with respect to said welding tip face to resist cracking.
- Claim: 19. The electrode of claim 14 wherein said slight convex curvature defines a crown height of about 0.002 inches.
- Claim: 20. The electrode of claim 13 wherein said welding tip face has a face diameter about equal to said nose length.
- Claim: 21. The electrode of claim 13 wherein said concave profile taper of said nose portion defines a frustum of a vortical surface, and wherein said concave profile taper has a concave curvature of an arc of a circle.
- Claim: 22. The electrode of claim 13 wherein said nose portion and said base define a shoulder therebetween, and wherein said welding tip face has a circular shape and said shoulder has an elliptical shape when viewed from a frontal perspective looking along said nose axis.
- Claim: 23. The electrode of claim 13 wherein said nose portion is made of a copper material consisting of essentially pure copper or of copper combined with one or more metals selected from the group consisting of chromium, zirconium, cadmium, cobalt, nickel, beryllium, tungsten, aluminum, tungsten carbide, iron, and molybdenum.
- Claim: 24. The electrode of claim 13 wherein said concave profile is defined by a plurality of incremental linear segments.
- Claim: 25. The electrode of claim 13 wherein said nose portion has co-axial, anisotropic fibrous grain structure at said welding tip face which is oriented at an angular, non-normal angle with respect to said welding tip face to resist cracking.
- Current U.S. Class: 219/119
- Current International Class: B23K 3502
- Patent References Cited: 4954687 September 1990 Bush et al.
- Primary Examiner: Shaw, Clifford C.
- Attorney, Agent or Firm: Woodard, Emhardt, Naughton, Moriarty & McNett
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