CA1047104A - Thermoplastic casings for batteries, with sidewalls having a sinusoidal cross section - Google Patents

Thermoplastic casings for batteries, with sidewalls having a sinusoidal cross section

Info

Publication number
CA1047104A
CA1047104A CA238,052A CA238052A CA1047104A CA 1047104 A CA1047104 A CA 1047104A CA 238052 A CA238052 A CA 238052A CA 1047104 A CA1047104 A CA 1047104A
Authority
CA
Canada
Prior art keywords
base
casing
side walls
enclosure
sinusoidal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA238,052A
Other languages
French (fr)
Other versions
CA238052S (en
Inventor
Camillo M. Vecchiotti
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Amerace Corp
Original Assignee
Amerace Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Amerace Corp filed Critical Amerace Corp
Application granted granted Critical
Publication of CA1047104A publication Critical patent/CA1047104A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/102Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/103Primary casings; Jackets or wrappings characterised by their shape or physical structure prismatic or rectangular
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/14Primary casings; Jackets or wrappings for protecting against damage caused by external factors
    • H01M50/145Primary casings; Jackets or wrappings for protecting against damage caused by external factors for protecting against corrosion
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S206/00Special receptacle or package
    • Y10S206/819Material

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Sealing Battery Cases Or Jackets (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

A THERMOPLASTIC CASING AND METHOD OF MANUFACTURING SAME

Abstract of the Disclosure A casing formed by a hollow enclosure molded integral from a polycarbonate material, with at least a portion of the enclosure having a sinusoidal, cross-sectional configuration.
A method of manufacturing a casing of the above type.

Description

1047~4 Background of the Invention This invention relates to a hollow casing formed of plastic material and a method for manufacturing such a casing.
More particularly, the present invention relates to such a casing and method in which the casing is molded from a poly-carbonate material with its wall having a continuous, sinu-soidal, cross-sectional configuration.
Traditionally, casings manufactured for use in indus-trial applications such as, for example, containers for large storage batteries, have been formed o~ a the~moset or vulcanized material, such as hard rubber. While such composi-tion normally has the desired chemical and load resistant properties required, it is quite heavy, is not flame resis-tant, and has poor impact resistance. Also, the costs of hard rubber have been gradually increasing until the use of plastics has lately become a possible alternativeO
However, the use of plastics in forming casings or other similar structures is not without problems. For example, in the manufacture of relatively large casings, the use of polyethylenes has been proven unsatisfactory since they lack the proper strength properties to accommodate the high mechanical stresses that are often placed on the casing.
Also, thermoplastic polyesters, while having adequate mechan-ical strength, are often susceptible to attack by chemicals and, in addition, are often too costly to be economically feasible.
Of course, it is possible to produce a laminated struc-ture of two plastic materials, one for supplying the re-quired mechanical strength and the other having a proper resistivity to attack by chemicals. However, it can be ~.~

47~

appreciated that the requirement for two plastic materials increases the costs of materials and labor, often to unac-ceptable levels.

Summary of the Invention It is,therefore, an object of the present inven-tion to provide a casing that can be produced from a single thermoplastic material, yet retain the proper strength and chemical resistive characteristics required for industrial use.
It is a further object of the present invention to provide a casing of the above type which is relatively low in cost and relatively easy to manufacture.
It is a further object of -the present invention to provide a method for manufacturing a plastic casing of the above type.
According to the present invention there is pro-vided a battery casing comprising a hollow, acid resistant enclosure molded integral from a polycarbonate material, said enclosure including a base, a plurality of side walls extending from said base and an access opening disposed remotely from said base, said side walls extending substan-tially perpendicular to each other and to said base re-spectively, at least a portion of each of said side walls having a sinusoidal cross-sectional configuration as de-fined by the intersection of said portion with a plane pas-sing through said portion substantially parallel to said base, said sinusoidal cross-sectional configuration forming a plurality of corrugations in said side walls extending between said base and said access opening substantially ~ _3_ ,~

~047~4 perpendicular to said base, the wall thic~ness of said side wall portions being sufficient to prevent lateral flexural displace-ment of said wall portions when said casing is filled with an electrolyte.

Brief Description of the Drawings Fig. 1 is a partial frontelevational, partial sec-tional view of the battery casing of the present invention;
Fig. 2 is a cross-sectional view taken along the line 2-2 of Fig. l;
Fig. 3 is a partial side elevational, partial sec-tional view of the casing of Fig. l; and -3a-,~

47~4 \
Fig. 4 is a cross-sectional view taken along the line 4-4 of Fig. 3.

Description of the Preferred Embodiments The present invention is a result of applicant's dis-covery that a casing produced from a polycarbonate that is rotationally molded into a particular configuration possesses adequate strength characteristics and resistance to attack by chemicals, yet is relatively simple and inexpensive to manufac-ture.
An example of this type casing is shown in Figs. 1-4 in the form of a casing for a relatively large storage battery, and includes an open-ended enclosure, shown in general by the reference numeral 10. The enclosure 10 is formed by front and rear walls 12 and 14, respectively, and side walls 16 and 18 all molded integral with, and extending perpendicular to, a base 20. The base 20 is reinforced with a central circular rib 22 and four diagonal ribs 24 as better shown in Figs. 2 and 4.
Each wall 12, 14, 16 and 18 has a stepped, or shoulder, portion 26 near the open end of the enclosure 10 to form an enlarged mouth portion 28 for the purpose of increasing the volume of the enclosure, and to enable the casing to be suppor-ted or lifted by engaging the shoulder portions. Although not shown in the drawings, it is understood that, in normal use, a cover would be provided over the open end of the enclosure 10 .
According to a feature of the present invention, the cross-section of each of the walls 12, 14, 16 and 18 in a hori-zontal plane as viewed in Figs. 1 and 3, and as shown in Figs.
2 and 4, lS of a sinusoidal shape extending for substantially the entire width of each wall. For the purposes of this appli-47~
cation, it is understood that the term sinusoidal refers to acontinuous curve having equal amplitudes of variation in alternating directions from a center line, thus forming a configuration identical in shape to a sine wave, as is well-known in electronic terminology.
As noted from Figs. 1 and 3, the sinusoidal cross-sectional configuration extends for a substantial por~io`n of the length of each wall 12, 14, 16 a~d 18, from a point adja-cent the base 20 to the enlarged mouth portion 28.
The reference numerals 30 and 32 refer to a pair of reinforcing bands which axe attached to the walls 12 and 14, respectively, and which are shown in dot-dashed lines since they form an optional feature of the present invention. The specific details of the bands 30 and 32 will be described later.
The casing of the present invention is manufactured by rotationally molding a polycarbonate material. According to the method of manufacture, the polycarbonate material, in powder form, is placed in an open mold, the walls of which have a configuration corresponding to the sinusoidal shape discussed above in connection with the walls 12, 14, 16 and 1~ of the casing. The polycarbonate material is heated to a temperature above its melting temperature and the mold is rotated about two axes to deposit a layer of the melted polycarbonate material on the wall surfaces and the bottom of the mold. The mold and material are allowed to cool while rotating, and the material is then stripped from the mold in the basic form of the casing shown in Figs. 1-4. Since the basic rotational molding technique is conventional, it will not be described in any fur$her detail.

9173L~
It has been discovered that, with polycarbonate being used as the material and the walls 12, 14, 16 and 18 configured in the sinusoidal form shown, the resulting casing has strength characteristics and resistance to acidity compatible with use as a relatively large lead-storage battery casing or other similar uses, while eliminating the disadvantages set forth above with respect to the use of hard rubber or other plastic materials.

Example 65 pounds of finely divided LEXAN (Trade Mark) RP-701, a roto-molding grade of polycarbonate marketed by the General Electric Company, is pre-dried in an air circulating oven at 250F. for at least 2 hours in shallow trays not over 2 inches deep. The dried polycarbonate is then molded in the heating oven of a conventional three spindle roto-cast machine (McNeil) at a temperature of 650F. for 28 minutes. Rotation of the spindle of the machine is set at 5 rpm and 6 rpm, respectively, on the major and minor axes to produce a 5:1 ratio of the vertical to horizontal axis rotation. At the end of the oven cycle, the mold is indexed to the cooling chamber of the same machine while rotating on both axes. Cooling is accomplished by a sequence of forced air for 23 minutes, followed by 5 minutes of water fog spray, and again by 1 minute of forced air. After cooling, the mold is indexed to the unload posi-tion of the machine at which time the mold is opened and the molded part removed therefrom.
The resulting casing, with overall dimensions of about 19 3/4" x 17 7/16", x 52 1/8" high, and having an average wall thickness of 3/8" in all respects matches the industry speci-ficationsfor battery casings of this type, while other casings ~47~04 o the same wall thickness and constructed of other plastic materials or having different wall configurations, including those having ribs, or the lïke, projecting from one surface of the walls, lack the structural strength required for these specifications.
As stated above, the bands 30 and 32 may be affixed to the outer surfaces of the walls 12 and 14, respectively, to provide added strength to the casing. The bands 30 and 32 extend for substantially the entire width of their respective walls 12 and 14, and have a tapered, or beveled, cross-section.
A plurality of grooves are formed in the inner surfaces of the bands 30 and 32 to receive the projecting portions of the walls 12 and 14, respectively. The bands 30 and 32 are molded from a iberglass reinforced polyester material with very high flexural modulus p~operties and are affixed to the walls 12 and 14, respectively, by adhesive, or the like.
In addition to increasing the strength characteristics of the casing lO, as discussed above, the use of the bands 30 and 32 makes it possible to decrease the cost of the casing while maintaining its strength characteristics. For example, by including the bands 30 and 32, the casing described in ; connection with the above example can be manufactured with walls having an average thickness of 5/16", yet will match the industry specifications. As a result, the weight of the initial charge of finely divided polycarbonate can be re-duced to 55 pounds thereby reducing the materlal costs con-siderably.
It is understood that several variations may be made in the casing of the present invention without departing from the scope of the invention. For example, the particuiar shape of the casing and the location of the reinforcing bands may be varied. Still other variations of the specific con-L7~
struction and arrangement of the casing and method disclosed - above can be made by those skilled in the art without depart-ing from the invention as defined in the appended claims.

Claims (5)

The embodiments of the invention in which an exclusive property or privelege is defined are claimed as follows:
1. A battery casing comprising a hollow, acid resistant enclosure molded integral from a polycarbonate material, said enclosure including a base, a plurality of side walls extending from said base and an access opening disposed remotely from said base, said side walls extending substantially perpendicular to each other and to said base respectively, at least a portion of each of said side walls having a sinusoidal cross-sectional configuration as defined by the intersection of said portion with a plane passing through said portion substantially parallel to said base, said sinusoidal cross-sectional configuration forming a plurality of corrugations in said side walls extending between said base and said access opening substantially perpendicular to said base, the wall thickness of said side wall portions being sufficient to prevent lateral flexural displacement of said wall portions when said casing is filled with an electro-lyte .
2. A battery casing as claimed in claim 1, wherein said sinusoidal portion of the side walls is spaced from said base and extends toward said opening, wherein said enclosure further includes a reinforcing strip affixed to a surface of at least one of said side wall portions and including a plurality of grooves on the inner surface of said strip, said grooves being complementary to the sinusoidal configuration of said surface of at least one of said side wall portions whereby said rein-forcing strip enables the wall thickness of said portion to be less than it otherwise would be in order to substantially main-tain said side wall portion in its original configuration.
3. A battery casing as claimed in claim 2, wherein at least a pair of reinforcing strips are affixed to a surface of a pair of opposed side walls of said casing respectively, each of said reinforcing strips including a plurality of grooves in one side thereof, said grooves being complementary to said corrugations.
4. A battery casing as claimed in claim 1, wherin each of said plurality of corrugations in each said portion are of substantially constant size.
5. A battery casing as claimed in claim 1, wherein said side walls form an enlarged mouth portion adjacent the access opening of said enclosure, said enlarged mouth portion forming a shoulder extending outwardly beyond said corrugations in at least one of said side wall portions.
CA238,052A 1974-10-21 1975-10-21 Thermoplastic casings for batteries, with sidewalls having a sinusoidal cross section Expired CA1047104A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US05/516,420 US4125187A (en) 1974-10-21 1974-10-21 Thermoplastic casing and method of manufacturing same

Publications (1)

Publication Number Publication Date
CA1047104A true CA1047104A (en) 1979-01-23

Family

ID=24055504

Family Applications (1)

Application Number Title Priority Date Filing Date
CA238,052A Expired CA1047104A (en) 1974-10-21 1975-10-21 Thermoplastic casings for batteries, with sidewalls having a sinusoidal cross section

Country Status (3)

Country Link
US (1) US4125187A (en)
CA (1) CA1047104A (en)
IT (1) IT1048071B (en)

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Also Published As

Publication number Publication date
US4125187A (en) 1978-11-14
IT1048071B (en) 1980-11-20

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