Patent ID: 8012615

Claim:
A method of manufacturing a current interrupt device, comprising the steps of a) forming a first conductive plate composed, at least in part, of aluminum, including: i) a frustum having a first end and a second end having a diameter less than that of the first end; ii) a base extending radially from a perimeter of the first end of the frustum; and iii) an essentially planar cap sealing the second end of the frustum; b) forming a second conductive plate composed, at least in part, of aluminum, and wherein the second conductive plate includes at least one through-hole, whereby equalization of pressure between opposite sides of the second conductive plate is maintained without interference by the first conductive plate, and whereby higher pressure on a first surface of the first conductive plate facing the second conductive plate relative to a second surface of the first conductive plate will cause separation of the first conductive plate from the second conductive plate to thereby disrupt electrical communication at the electrical contact; and c) welding the second conductive plate onto the essentially planar cap of the first conductive plate while a temperature of the first conductive plate is controlled so as not to exceed the melting point of a surface of the first conductive plate opposite the weld.