Method and apparatus for casting straps onto storage battery plates

• US 6,708,753 B1
• Filed: 11/14/2002
• Issued: 03/23/2004
• Est. Priority Date: 11/14/2002
• Status: Expired due to Fees

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Brantley, Randall F.
• Primary Examiner(s): Elve, M. Alexandra
• Application Number:
  US10/295,655
• Time in Patent Office: 495 Days
• Field of Search: 164/129, 164/130, 164/133, 164/134, 164/135, 164/136
• US Class Current: 164/136
• CPC Class Codes: B22D 25/04 Casting metal electric battery plates or the like manufacture thereof by multi-step processes H01M4/82

Abstract

A method and apparatus for preparing connecting straps and end terminals for lead batteries by filling selected cavities of the mold is disclosed. The mold has cavities for casting connecting straps and an end terminal. Molten lead is filled up to an amount of lead sufficient to fill the preselected cavities of the mold. The content of the mold is brought together with inverted plate lugs of grouped battery plates to fuse the plate lugs together with the content of the mold prior to solidification. The method and apparatus includes a first mold block having at least three mold cavities in an upper face thereof, whereby at least two preselected cavities of the at least three mold cavities are translationally aligned to be filled with lead.

Claims

1. A method for casting elements onto storage battery plates comprising;

providing a source of molten lead;

receiving a first mold block having five mold cavities linearly aligned in an upper face thereof in a first molding station, whereby at least two preselected cavities of the five mold cavities are filled with lead;

translating the mold block to align each of the at least two preselected cavities with the source of molten lead; and

translating the mold block toward a battery plate group to dip lugs of the group into the at least two preselected cavities.

2. The method of claim 1 wherein the five cavities comprise a first cavity configured to form one of a first strap and a first post terminal, a second strap cavity configured to form a second strap, a third strap cavity configured to form a third strap, a fourth strap cavity configured to form a fourth strap, and a fifth post terminal cavity configured to form a second post terminal.

3. The method of claim 2 wherein the first, second, third, and fourth straps are configured having an extension tab extending substantially perpendicular thereto, each extension tab extending from an opposite end of a respective contiguous strap of the first, second, third, and fourth straps.

4. The method of claim 3 wherein first, second, third and fourth straps are contiguous on the mold block.

5. The method of claim 4 further comprising a second mold block, wherein the second mold block includes five cavities, the five cavities further comprise a sixth strap cavity configured to form a sixth strap, a seventh strap cavity configured to form a seventh strap, an eighth strap cavity configured to form an eighth strap, a ninth strap cavity configured to form a ninth strap, and a tenth post terminal cavity configured to form a third post terminal, the sixth, seventh, eighth, and ninth straps are contiguous and each strap includes the extension tab in an opposite orientation of the first, second, third, and fourth straps, respectively.

6. The method of claim 5 wherein first mold having first cavity configured to form said first post terminal and first mold having first cavity configured to form first strap together with second mold provide four different configurations of strap and terminal connectors.

7. The method of claim 5 wherein twelve cell elements are manufactured in three cycles using first and second molds with two molding machines, first mold having said first cavity configured to form said first strap.

8. The method of claim 6 wherein six cell elements are manufactured in one of four and six cycles using first mold having said first cavity configured to form said first post terminal with a single molding machine.

9. The method of claim 8 further comprising:

selecting a first four contiguous cavities including said first cavity;

filling said first four contiguous cavities with molten lead;

joining a first two cells to respective cavities to form first and second molded cell elements;

selecting a second four contiguous cavities including said fifth cavity;

filling said second four contiguous cavities with molten lead;

joining a second two cells to respective cavities to form third and fourth molded cell elements;

selecting a first two contiguous strap cavities including said second strap cavity;

filling said first two contiguous strap cavities with molten lead;

joining a first single cell to said first two contiguous strap cavities to form a fifth molded cell element;

selecting a second two contiguous strap cavities including said fourth strap cavity;

filling said second two contiguous strap cavities with molten lead; and

joining a second single cell to said second two contiguous cavities to form a sixth molded cell element.

10. The method of claim 1 wherein the source of molten lead is a lead injection machine.

11. The method of claim 7 wherein the cell elements produced are disposed in a battery case wherein each extension tab is aligned with holes in cell partition walls within the battery case, each extension tab aligned with another extension tab in a contiguous cell for electrically joining tabs extending in contiguous cells together to provide a series connection between the cells of the battery.