Forming of battery components

• US 10,639,708 B2
• Filed: 03/11/2016
• Issued: 05/05/2020
• Est. Priority Date: 03/13/2015
• Status: Active Grant

• Current Assignee: TBS Engineering Limited (Berkshire Hathaway Incorporated)
• Original Assignee: TBS Engineering Limited (Berkshire Hathaway Incorporated)
• Inventors: Ormerod, Mark
• Primary Examiner(s): Kerns, Kevin P
• Application Number:
  US15/557,738
• Publication Number:
  US 20180065174A1
• Time in Patent Office: 1,516 Days
• Field of Search: 164129, 164130, 164322, 164108, 164109, 164110, 164332, 164333, 164334, 164133, 164337, 249 82, 249 83
• CPC Class Codes: B22C 9/06 Permanent moulds for shaped castings moulds for ingots B22D7/06
• CPC Class Codes: B22D 25/04 Casting metal electric battery plates or the like manufacture thereof by multi-step processes H01M4/82
• CPC Class Codes: B22D 35/02 into beds
• CPC Class Codes: B22D 35/04 into moulds, e.g. base plates, runners
• CPC Class Codes: B22D 39/02 having means for controlling the amount of molten metal by volume
• CPC Class Codes: H01M 10/0404 Machines for assembling batteries
• CPC Class Codes: H01M 10/12 Construction or manufacture
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A mould for forming battery components includes a first mould body having a first plurality of mould cavities and a second mould body having a second plurality of mould cavities. The first mould body and the second mould body are configured to be moveable between a moulding position in which the first plurality and second plurality of mould cavities are aligned, and a fill position in which the first plurality and second plurality of mould cavities are displaced from the aligned position and are proximal to a molten metal feed.

Claims

1. A cast on strap machine for moulding battery components, the machine comprising:

a molten metal delivery apparatus;

a battery plate positioning device; and

a mould comprising a first mould body comprising a first plurality of mould cavities and a second mould body comprising a second plurality of mould cavities; and

wherein the machine further comprises

a mould positioner configured to move the first mould body and the second mould body between;

a moulding position in which the first plurality and second plurality of mould cavities are in an aligned position, and are aligned relative to the battery plate positioning device; and

a fill position in which the first plurality and second plurality of mould cavities are displaced from the aligned position, and are proximal to an outlet of the metal delivery apparatus.

2. A cast on strap machine as claimed in claim 1, wherein the molten metal delivery apparatus comprises first and second molten metal delivery apparatuses associated respectively with the first and second mould bodies.

3. A cast on strap machine as claimed in claim 2, wherein the first and second molten metal delivery apparatuses are fed from a common lead supply.

4. A cast on strap machine as claimed in claim 2, wherein the first and second molten metal delivery apparatuses each comprise a plurality of outlets with one outlet associated with each of the mould cavities.

5. A cast on strap machine as claimed in claim 4, wherein each of the plurality of outlets is associated with a local molten metal reservoir.

6. A cast on strap machine as claimed in claim 1, wherein the outlet comprises a through cavity formed in a slidably mounted block and arranged to receive lead into the upper end of the through cavity when the block is in a first position and to release lead from the lower end of the through cavity when the block is in a second position.

7. A cast on strap machine as claimed in claim 1, wherein the outlet is arranged to dispense lead directly into a mould cavity when the mould bodies are in the fill position.

8. A cast on strap machine as claimed in claim 1, wherein the mould positioner is arranged to slide the first mould body and the second mould body linearly outwardly away from a nominal longitudinal centre line of the mould when moving from the moulding position to the fill position.

9. A cast on strap machine as claimed in claim 8, wherein the mould position includes a crank mechanism connected to the first and second mould bodies.

10. A cast on strap machine as claimed in claim 9, wherein the molten metal delivery apparatus is configured such that when the first and second mould bodies are in the fill position, the mould bodies are heated by radiant heat transfer from the delivery apparatus.

11. A cast on strap machine as claimed in claim 1, further comprising a mould loading apparatus.

12. A method of moulding battery components comprising the steps of:

providing a cast on strap machine as claimed in claim 1;

separating the first mould body and the second mould body; and

,

providing a supply of molten metal to each of the plurality of mould cavities with the first mould body and the second mould body at spaced apart locations; and

, when filled,

moving the filled first mould body and the second mould body to an aligned position to form the battery components.

13. A method of moulding battery components as claimed in claim 12, further comprising the steps of:

providing a plurality of aligned battery plates; and

,

after the step of moving the filled mould parts into the aligned position, positioning the plurality of battery plates relative to the mould such that a portion of the plurality of battery plates lie within the mould cavities; and

,

allowing the molten metal to solidify so as to form a connection between the plurality of battery plates.

14. A method of moulding battery components as claimed in claim 13, wherein the method further comprises moving the plurality of battery plates away from the mould to eject the moulded battery components from the mould.

15. A method of moulding battery components as claimed in claim 14, wherein, after ejection of the moulded battery components, the step of separating the mould parts is repeated to start a further moulding cycle.