Method and apparatus for forming battery straps and intercell connections

• US 4,341,256 A
• Filed: 07/30/1980
• Issued: 07/27/1982
• Est. Priority Date: 12/20/1976
• Status: Expired due to Term

• Current Assignee: General Battery Corporation
• Original Assignee: General Battery Corporation
• Inventors: Eberle, William J.
• Primary Examiner(s): Hampilos, Gus T.
• Application Number:
  US06/173,481
• Time in Patent Office: 727 Days
• Field of Search: 164/108-112, 164/135, 164/136, 164/332-335, 164/337, 164/342, 164/DIG. 1, 222/162, 222/170, 222/166, 222/167, 222/269, 222/270, 222/271, 222/274, 222/275, 222/282, 222/385, 222/367, 222/370, 222/478, 222/564, 222/252, 222/330, 222/604, 222/629
• US Class Current: 164/109
• 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: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10S 164/01 Battery

Abstract

Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

Claims

1. A method for automatically casting the commoning straps and intercell connections of a storage battery, said method comprising the steps of:

(a) providing a work surface for receiving a battery case, each cell of said battery case containing stacked positive and negative plates;

(b) providing a battery case having at least two cells defined therein and separated by a cellular partition each cell of said battery case containing stacked positive and negative plates, each of said plates having protruding lugs thereon;

(c) forming mold means around the protruding lugs of said positive and negative plates within said battery case, said mold means comprising respective molding channels for said positive and said negative protruding lugs;

(d) providing molten lead from a reservoir having an outlet means for dispensing molten lead and a return means for receiving molten metal;

(e) providing casting means operatively connected to said outlet means and said return means for circulating said lead through said casting means;

(f) measuring aliquot portions of lead in said casting means;

(g) pouring said aliquot portions simultaneously into respective molding channels to cast said straps and intercell connectors.

2. In a method for automatically casting the commoning straps and intercell connections of a lead acid storage battery, said battery comprising a case, said case having a plurality of partitions defining a plurality of cells therein, each of said partitions having at least one aperture defined therein through which said intercell connections are formed, each of said cells containing a stack of interleaved insulating positive and negative plates, with each plate having an upstanding protruding lug on a top edge thereof, said plates being arranged so that all of the positive lugs within a stack lie along one side of the case and all of the negative plate lugs lie along a second, opposite side thereof, all of said lugs extending generally towards the top of said battery case, wherein said casting method comprises the steps of providing at least one open-topped battery case, placing a plate stack in each of said cells, forming an open mold around at least a portion of said positive and negative lugs in each stack and pouring molten lead into said mold to cast a strap and intercell connection, the improvement comprising:

(a) providing molten lead from a reservoir having an outlet means for dispensing molten lead and a return means for receiving molten lead;

(b) providing casting means operatively connected to said outlet means and said return means for circulating said lead through said casting means;

(c) circulating lead through said casting means;

(d) forming a plurality of premeasured aliquot portions of molten lead in said casting means, the number of said portions being equal to the number of straps being cast, each portion being equal to the volume of lead required to cast a strap and intercell connection in one of said molds; and

(e) simultaneously pouring all of said aliquot portions of molten lead, one into each of said molds to cast straps and intercell connections of said battery.

3. The method of claim 2 wherein each of said molds is tapered uniformly towards said portions.

4. The method of claim 2 wherein the step of pouring said plurality of aliquot portions of molten lead into said molds comprises:

(a) introducing molten lead from an external reservoir into a lead circulation system comprising a ladle having an elongated, inner chamber, said ladle being movable between standby and pouring positions and further comprising a plurality of delivery orifices, one for each mold to be supplied, said orifices having pouring spouts affixed thereto to conduct said molten lead to said molds;

(b) isolating the individual aliquot portions of molten lead within said inner chamber; and

(c) delivering said individual aliquot portions into said molds through said delivery orifices and pouring spouts after said ladle chamber has been moved from the standby to the pouring position.

5. The method of claim 4 further including the step of circulating molten lead to establish an equilibrium temperature thereof when said chamber is in the standby position, wherein said step comprises:

(a) continuously draining a portion of molten lead from said ladle from an outlet orifice in one end of said elongated chamber;

(b) returning said portion of drained lead to a reservoir for reheating; and

(c) pumping a portion of reheated lead equal to said drained portion from said reservoir back into said ladle through an inlet orifice located in the opposite end of said elongated chamber said inlet and outlet being at a level so that sufficient lead for all of said aliquot portions is pumped into said ladle, said pumping causing said lead to circulate through said inner chamber when said ladle is in the stand-by position.

6. The method of claim 4 wherein said ladle is a horizontally disposed cylinder and said movement between said standby and pouring positions comprises rotating said cylinder around its transverse axis.

7. The method of claim 4 wherein the lead circulation system is divided into a first ladle along one side and a second ladle along the other side of said case, said ladles being disposed over said lug arrays and adapted to cooperate so as to move into said pouring positions substantially simultaneously to form all of said straps and intercell connectors at one time.

8. The method of claim 4 wherein said isolated aliquot portions are formed by:

(a) dividing said inner chamber by a plurality of transverse internal, partial partitions which act to form a set of compartments, each adapted to premeasure and hold one of said aliquot portions, said internal partitions being disposed within said elongated cylinder so that they are above the level of the circulating lead when said ladle is in the standby position so that said lead circulation is unimpeded; and

(b) positioning said delivery orifice within each compartment at a point so that when said ladle is in the pouring position, said delivery orifice will be located in its bottommost portion so that said molten lead will drain out completely.

9. The method of claim 8 wherein the steps of isolating and pouring said aliquot portions further comprise:

(a) moving said ladle toward said pouring position from said standby position, said movement acting to disconnect said ladle from said reservoir and to cause said partial partitions to fall below the level of the lead within said ladle, said movement further acting to trap and isolate a premeasured aliquot portion of lead within each of said internal compartments; and

(b) continuing movement of said ladle into said pouring position whereby said pouring spouts are disposed directly over the molds being filled so that said lead will completely drain out of said compartment into said molds to form said straps and intercell connectors.

10. The method of claim 9 further including the step of reversing the movement of said ladle after said aliquot portions have drained out, said reversal causing said laddle to return to said standby position and re-establish contact with said reservoir so that an additional quantity of lead may be introduced and circulated therethrough.

11. The method of claim 10 further including the steps of disassembling said molds and removing them from said battery so that said battery may proceed to further processing.

12. A method of automatically casting the straps and intercell connections of a lead acid electric storage battery, said battery comprising a case, said case having a plurality of partitions defining a plurality of cells therein, each of said partitions having at least one aperture defined therein through which said intercell connections are formed, each cell containing a stack of interleaved positive and negative plates, each plate being insulated from each other and having an upstanding protruding lug on the top edge thereof, said plates being arranged so that all of the positive lugs within a stack lie along one side of the case and all of the negative plate lugs lie along a second, opposite side thereof, all of said lugs extending generally towards the top of said battery case, wherein said casting method comprises the steps of:

(a) providing at least one open-topped battery case;

(b) placing a plate stack in each of said cells;

(c) aligning the plates of each stack to position each of said lugs so as to be substantially coaxial with said apertures;

(d) forming an open mold around at least a portion of said positive and negative rows in each stack so that in each of said cells said mold communicates through one of said apertures with an adjacent one of said molds, said molds being formed by mold means which selectively define said mold, said mold means comprising a plurality of dams for forming the surfaces of said mold with at least one dam being movable in relation to the remaining dams to align said lugs;

(e) providing molten lead from a reservoir having an outlet means for dispensing molten lead and a return means for receiving molten lead;

(f) providing casting means operatively connected to said outlet means and return means for circulating said lead through said casting means;

(g) circulating lead through said casting means;

(h) forming a plurality of premeasured aliquot portions of molten lead in said casting means, said plurality being equal to the number of straps being cast, said aliquot portions being equal to the volume of lead required to cast said strap and intercell connection in one of said molds; and

(i) simultaneously pouring said aliquot portions molten lead, one into each of said mold to cast the straps and intercell connections of said battery.

13. A method of automatically casting the straps and intercell connections of a multi-celled electric storage battery, said battery comprising a case having a plurality of cellular partitions defining said cells disposed therein, each of said cellular partitions having at least one aperture defined therein through which said intercell connections are formed, each cell containing a stack of interleaved, positive and negative plates, each plate being insulated from those on either side and having an upstanding protruding lug on the top edge thereof, said plates being arranged so that all of the positive lugs within a stack lie along one side of the case and all of the negative plate lugs lie along a second, opposite side thereof, all of said lugs extending generally towards the top of said battery case, wherein said casting method comprises the steps of:

(a) providing at least one open-topped battery case;

(b) placing a plate stack in each of said cells;

(c) aligning the plates of each stack to position each of said lugs substantially coaxially within said apertures;

(d) forming an open mold around at least a portion of said positive and negative rows in each stack so that in each of said cells said mold communicates through one of said apertures with an adjacent one of said molds;

(e) providing molding lead from a reservoir having an outlet means for dispensing molten lead and a return means for receiving molten lead;

(f) providing casting means operatively connected to said outlet means and return means for circulating said lead through said casting means;

(g) circulating lead through said casting means;

(h) forming a plurality of premeasured aliquot portions of molten lead in said casting means, said plurality being equal to the number of straps being cast, each portion being equal to the volume of lead required to cast said strap and intercell connection in one of said molds; and

(i) simultaneously pouring all of said aliquot portions of molten lead, one into each of said molds to cast the straps and intercell connections of said battery.

14. A method of automatically casting the straps and intercell connections of a lead storage battery having a plurality of cells, said cells being defined by at least one partition within an open topped battery case, said method comprising the steps of:

(a) providing at least one open-topped case for forming said battery;

(b) placing a stack of interleaved battery plates into each of said cells, each of said plates having an upstanding lug;

(c) aligning the plates of each stack to position said lugs into an array having end portions which are substantially coaxial with an aperture defined in at least one partition;

(d) forming an open mold having a plurality of mold cavities around at least a portion of said lug arrays in each stack, each of said mold cavities being adapted to communicate through said aperture with an adjacent one of said mold cavities;

(e) providing molten lead from a reservoir having an outlet means for dispensing molten lead and a return means for receiving molten lead;

(f) providing casting means operatively connected to said outlet means and return means for circulating said lead through said casting means;

(g) circulating lead through said casting means;

(h) forming a plurality of premeasured aliquot portions of molten lead in said casting means; and

(i) simultaneously pouring said aliquot portions of molten lead, one into each of said molding channels to cast the battery straps and intercell connections of said battery.

15. The method of claim 14 wherein said plate stack is formed by interleaving a plurality of positive and negative battery plates, said plates being insulated from each other.

16. The method of claim 14 wherein said step of forming said open mold comprises providing a mold means having a plurality of dams forming the sides and bottom of said open mold with at least one dam being movable in relation to the remaining dams said movable dam acting to align said lugs within said mold.

17. The method of claim 16 wherein said intercell connector is formed by adapting said mold means in one cell to fit over said aperture so that said communication is with a mold cavity on the other side of said partition and when said aliquot portions of molten lead are introduced, said lead will flow through said aperture so that the molded straps on either side of said aperture are interconnected.