NZ205142A

NZ205142A - Casting terminal onto battery interelectrode strap

Info

Publication number: NZ205142A
Application number: NZ205142A
Authority: NZ
Inventors: D Orlando; A H Wolf; M Rechkin
Original assignee: Gnb Batteries Inc
Priority date: 1982-08-23
Filing date: 1983-08-04
Publication date: 1987-05-29
Also published as: KR840005935A; JPS5954173A; BE897579A; JPH0360153B2; AU567297B2; DE3329709A1; GB8321330D0; FR2532119B1; AU1785083A; GB2128518A; FR2532119A1; MX153034A; IT1170443B; IT8348859A0

Description

<div class="application article clearfix" id="description"> 2 0 51 o1 Priority D8te(s): J?; £-2 Complete Specification Filed: Class: tf&.ttjQ/tA- Motfiijll Publication Date: g,9 MAY.1987 P.O. Journal, No: ..-4 AUG 1983 ■ I* *// N.Z.No. NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION "Method and Apparatus for Providing a Cast-on Battery Terminal Structure." We, GNB BATTERIES INC., a corporation of the State of Delaware of 1110 Highway ]J0, Mendota Heights, Minnesota 55118, United states of America do hereby declare the invention, for which we pray that a Patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by th following statement : - - 1- - 'Followed by ta.) 2 0 51 4 -i/H Description "Method and Apparatus for Providing A Cast-on Battery Terminal Structure" 5 Technical Field This invention relates to battery manufacture and in particular to method and apparatus for casting on a terminal structure to a plate connecting strap provided on a battery cell element. 10 Background Art In typical battery construction, a plurality of plates of alternating polarity are arranged in spaced relationship. Alternating plates of one polarity are interconnected by a first conductive strap and alter-15 nating plates of the opposite polarity are connected by a second conductive strap. The respective positive and negative straps may be disposed at an upper end of the plate assembly or cell element and extend in generally parallel side-by-side spaced relation-20 ship. The cell elements provided for use as the terminal cell elements of a battery further require the provision of some means for connecting one set of the plates thereof to the external terminal connections 25 of the battery. The present invention is concerned with the provision of terminal structure on one of the element connecting straps for use in effecting such connection to the external battery terminals. The plate connecting straps typically are made 30 by a casting process of a suitable castable material, 205142 2 such as lead. Thus, the present method and apparatus for providing the terminal structures are arranged for connecting the terminal structures to the fusible material of the cast connecting straps. Disclosure of Invention The present invention comprehends an improved method and apparatus for providing a terminal on a battery cell element. The invention is directed to the provision of a terminal of a desired configuration, such as a terminal post configuration or a side terminal configuration, in association with a conductive metal strap electrically connecting plates of like polarity in the battery cell element. In the illustrated embodiment, a typical terminal post configuration is shown with a connection means provided on the element or plate connecting strap and the terminal post structure electrically connected thereto. In the illustrated embodiment, the terminal structure is cast onto the connection means of the plate connecting strap. It will be apparent, however, that a terminal of the side terminal configuration may likewise be cast onto the connection means and it is intended that this invention include such side terminal and any other terminal configuration falling within the appended claims. For illustrative purposes, a mold is provided having an upwardly opening mold cavity defining a terminal post portion and a connection portion. Molten metal is provided in the mold cavity and the 2 0 r 1 connection means, in the form of a projection of the plate connecting strap is inserted into the molten metal to cause surface fusion of the connection projection. Upon cooling of the fused portion of the 5 connection projection and the molten metal in the mold cavity, the connected terminal post structure is separated or released from the mold and the battery cell element having the terminal posts provided thereon is transferred to a conveyor, or the like, 10 for further use. The battery cell element is disposed with the plate connecting strap lowermost in carrying out the terminal cast-on operation. In the illustrated embodiment, the connection 15 means defines an elongated rib or projection which extends along the conductive strap and projects downwardly from the strap during the terminal forming operation. The rib is firstly subjected to a brushing oper-20 ation by moving the rib lengthwise against a rotating brush. Flux is applied to the brushed rib and the fluxed rib is then lowered into the body of molten casting metal previously provided in the mold cavity. 25 The surface portion of the connection projection rib becomes fused in the molten metal, and upon cooling thereof, an effectively autogenous bond is provided between the cast terminal post structure and the connection projection rib. 30 Upon cooling of the fused material to solidified form, the cooled material is separated or released from the mold as by use of suitable knockout means. 4 2 0 51 4 The released cast structure is then transferred from the mold as desired. In the illustrated embodiment, the battery cell element with the terminal post structure cast thereon is reverted to bring the terminal post uppermost and the battery cell element is then placed on a suitable conveyor for delivery as desired. The battery cell element is transported to the various stations of the apparatus by a delivery clamp carrier and is transported from the mold by a transfer clamp carrier. The clamp carriers are arranged to gently, but effectively, clamp the battery cell elements therebetween. Upon completion of the casting operation, the transfer clamped carrier engages the battery cell element, while the delivery clamp carrier is released therefrom. In the illustrated embodiment, the clamp carriers include movable clamp plates on opposite sides of the battery cell element, which are concurrently moved toward and away from the battery cell element so as to provide a gentle engagement and release without sliding action between the battery cell element and clamp plates. As shown, the second plate connecting strap is disposed outwardly of the mold during the casting on of the terminal post structure to the connection projection rib of the first plate connecting strap. Means are provided for providing a clearance relief in the connecting portion of the terminal post structure so as to maintain suitable spacing between the terminal post structure and the second strap of the battery cell element. The post 20 51 portion of the terminal post structure extends upwardly from substantially midway between the two connecting straps of the battery cell element and the connecting portion of the terminal post structure 5 abuts the plate connecting strap adjacent the connection projection rib for further improved connection of the terminal post structure to the plate connecting strap. The invention comprehends that the casting of 10 the terminals of the two end or terminal cell elements of the battery be accomplished concurrently by casting the terminal post structures thereof concurrently in adjacent molds. In the illustrated embodiment, the terminal post 15 structures are provided in left and righthand forms suitable for use as terminal structures, generally at opposite ends of the battery. The transfer clamp carrier is effectively rotated 180° about a horizontal axis during the transfer 20 operation so as to dispose the battery cell elements with the terminal post structures thereof uppermost, permitting the battery cell elements to be set upon the delivery conveyor for further operation. In the illustrated embodiment, the mold includes 25 a lowermost knockout pin defining the distal end of the post portion of the terminal post structure. Upon completion of the cooling operation, the mold is lowered about the knockout pin which holds the terminal post structure against downward movement and, 30 thus, frees or releases the terminal post structure from the mold cavity walls. 2 0 51 v The transfer clamp carrier further lifts the battery cell element with the battery post structure cast thereon away from the mold prior to horizontal translation thereof from the mold to the transfer 5 conveyor. In the illustrated embodiment, the mold is cooled subsequent to the insertion of the connection means into the top surface of the molten metal therein so as to expedite the setting of the molten metal 10 in casting the terminal post structure. The connection means may comprise any desired configuration; however, the configuration as shown herein is in the form of a projection rib. In the illustrated embodiment, the cooling of the mold is effected by conduct-15 ing a heat transfer fluid, such as cooling air, in direct contact with the mold. The clearance relief in the connecting portion of the terminal post structure is effected by the inherent design of a retractable dam located in the, 20 upper portion of the molten metal in the mold cavity during the casting operation. Upon completion of the cooling of the metal and downward movement of the mold, the dam is retracted, permitting the release and removal of the cast terminal post structure from 25 the mold cavity without hindrance from the dam. The molten metal is provided from a reservoir movably carried adjacent the mold. Delivery of the molten metal to the mold is effected for a preselected period of time at a prese-30 lected rate of flow to provide the controlled quantity of molten metal in the mold cavity. 7 2n f M v y ^ i *-v £i- The molten metal is quickly delivered from the reservoir through a lowermost outlet controlled by a dump valve, with the reservoir disposed adjacently above the mold cavity. 5 The casting of the cast-on terminal post struc ture is automatically effected by a suitable associated control whereby the provision of the terminal post structures may be rapidly and accurately effected as a step in the overall manufacturing of second-10 ary battery structures incorporating such structures. The method and apparatus of the present invention are extremely simple and economical while yet providing the highly desirable features and functioning discussed above. 15 Brief Description of the Drawing Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein: FIGURE 1 is a perspective view of a battery hav-20 ing a terminal post structure manufactured by a method and apparatus embodying the invention, with a portion of the battery case broken away to illustrate the arrangement of the battery cell element therein; FIGURE 2 is a perspective view showing the bat-25 tery cell element provided with a .plate connecting strap having a connection projection rib for use in connecting the terminal post structure thereto; FIGURE 3 is a fragmentary perspective view illustrating the battery cell element of Figure 1 hav-30 ing the battery post structure provided thereon; 2051 4 B FIGURE 4 is a fragmentary vertical section illustrating the arrangement of the battery post structure in the battery structure of Figure 1;, FIGURE 5 is a fragmentary schematic plan view of the battery post structure casting apparatus of the invention; FIGURE 6 is a fragmentary side elevation thereof; FIGURE 7 is a top plan view illustrating the apparatus in greater detail; FIGURE 8 is a fragmentary plan view of the mold and associated apparatus; FIGURE 9 is a fragmentary enlarged front view of the pickup carrier means; FIGURE 10 is a top plan view thereof; FIGURE 11 is a fragmentary side elevation thereof; FIGURE 12 is a fragmentary side elevation of the mold structure; FIGURE 13 is a fragmentary side elevation thereof as arranged upon lowering of the mold to effect the release of the cast terminal post structure therefrom; FIGURE 14 is a fragmentary elevation illustrating the mold in greater detail; FIGURE 15 is a plan view of the plate connecting strap with the terminal post structure cast in association therewith; FIGURE 16 is a side elevation thereof; FIGURE 17 is an end elevation illustrating the formation of the pair of terminal post structures in 9 2051 4 side-by-side relationship in the apparatus of the invention; FIGURE 18 is a perspective view illustrating the arrangement of the pair of concurrently cast terminal 5 post structures on the associated pair of battery cell elements to be subsequently used as terminal cell elements of the battery; FIGURE 19 is a top plan view with portions broken away of the unload carrier; 10 FIGURE 20 is a side elevation thereof with por tions broken away; FIGURE 21 is a fragmentary end elevation thereof; FIGURE 22 is a fragmentary side elevation of the 15 unload clamp carrier and associated apparatus; FIGURE 23 is a fragmentary end elevation thereof illustrating the clamp carrier in the arrangement as upon picking up of the battery cell element from the mold cavity; 20 FIGURE 24 is a fragmentary end elevation illus trating the arrangement thereof as upon inversion of the unload clamp carrier to invert the picked-up battery cell element; FIGURE 25 is a schematic side elevation illus-25 trating the brushing of the connection projection rib in full lines and the application of flux to the brushed rib in broken lines; FIGURE 26 is a schematic side elevation illustrating the arrangement of the battery cell element 30 in overlying relationship to the mold cavity; FIGURE 27 is a schematic side elevation illustrating the step of delivering molten metal to the 2051 4 10 mold cavity immediately prior to the insertion of the connection rib thereinto; FIGURE 28 is a schematic side elevation illustrating the movement of the battery cell element downwardly to insert the connection projection rib into the top portion of the molten metal in the mold cavity; FIGURE 29 is a schematic side elevation illustrating the step of cooling of the molten metal to form the autogenously bonded terminal post structure on the connection projection rib; FIGURE 30 is a schematic side elevation illustrating the step of engaging the transfer clamp carrier with the battery cell element; FIGURE 31 is a schematic side elevation illustrating the step of releasing and withdrawing the pickup clamp carrier from the battery cell element, with the battery cell element being held by the unload clamp carrier, and supported on the knockout pin with the mold being moved downwardly away from the terminal post structure to release it therefrom; FIGURE 32 is a schematic side elevation illustrating the step of raising of the battery cell element to disengage the terminal post structure from the supporting knockout pin; FIGURE 33 is a schematic side elevation illustrating the movement of the battery cell element away from the mold apparatus; FIGURE 34 is a schematic side elevation illustrating the step of inverting the battery cell element so as to dispose the terminal post structure uppermost; w' 1 11 FIGURE 35 is a schematic side elevation illustrating the step of placing the battery cell element on the transfer conveyor; FIGURE 36 is a schematic timing chart illustra-5 ting the relationship and sequence of the various steps in the method of manufacture of the terminal post structure. FIGURE 37 is a side elevation illustrating an alternative embodiment of a cast-on terminal device 10 in the form of a side terminal configuration; FIGURE 38 is an end elevation of the terminal configuration shown in Figure 37; and FIGURES 39,39A are fragmentary side elevations of the mold and dam structures. 15 Best Mode for Carrying Out the Invention In the illustrative embodiment of the invention as disclosed in the drawing, a method and apparatus generally designated 10 for providing a terminal, structure generally designated 11 in a battery cell 20 element generally designated 12 are disclosed. As seen in Figure 1, the battery 20 may comprise a terminal post upstanding from the end or battery terminal cell element 12 to have electrical connection with an exposed connection post 13 of the battery. 25 As further illustrated in Figure 1, a pair of such posts is provided at opposite ends of the battery for providing opposite polarity connections to the battery. The invention comprehends the applicability of 30 the method and apparatus also for providing terminal 205142 12 post structures (as shown in Figs. 37 and 38) suitable for use in sidewall terminal connection batteries, as well as in the top wall battery illustrated in Figure 1. As further illustrated in Figure 1, the battery cell element 12 is defined by a plurality of plates 14 and 15 of opposite polarity arranged in an alternating sequence and separated by a serpentine divider or separator sheet 16. As illustrated in greater detail in Figure 2, one set of plates is provided with a first plate connecting strap 17 electrically interconnecting plates 15, and a second plate connecting strap 18 electrically connecting plates 14. Strap 17 is provided with a plurality of inter-cell connecting lugs 19 for use in connecting the battery cell element 12 to the battery cell element in the next adjacent cell space (not shown) in the battery 20. The present invention is concerned with the provision of the terminal post structure 11 on the plate connecting strap 18 of the battery cell elements 12 at the opposite ends of battery 20. As illustrated in Figure 2, plate connecting strap 18 is provided with a connection means in the form of a projection 21. In the illustrated embodiment, the connection means comprises a projecting rib extending longitudinally of the strap 18 approximately one-half the length thereof. As shown in Figure 3, terminal post structure 11 is connected to strap 18 by means of the connection projection rib 21. Terminal post structure 11 is formed as a casting 2051 4 13 onto the rib, as will be brought out in greater detail herefollowing. Straps 17 and 18 are provided in the battery cell elements by a strap casting apparatus generally 5 designated 22, as illustrated in Figure 5. Apparatus 22 forms no part of the present invention, it being understood that the apparatus 22 provides the straps in the form illustrated in Figure 2, as discussed above. 10 As further generally indicated in Figure 5, ap paratus 10 includes a pickup apparatus generally designated 23, which picks up a pair of the end cell elements 12 and 12', which are identical except for the opposite disposition of the straps 17 and 18 15 thereon. As shown in Figure 5, the pair of end or terminal cell elements is processed concurrently in apparatus 10 to provide a pair of terminal cell elements having terminal post structures 11 provided on the strap 18 thereof. 20 As shown, apparatus 10 includes, in addition to the pickup apparatus 23, a brushing apparatus 24, a flux applying apparatus 25., a mold apparatus 26, a molten metal delivery apparatus 27, and an unload apparatus 28 for transferring the completed battery 25 cell element structures to a transfer conveyor 29. Apparatus 10 is illustrated in greater detail in elevation in Figure 6, and in top plan view in Figure 7. As illustrated therein, apparatus 10 defines a pair of individual apparatuses arranged in side-by-30 side relationship for effecting the concurrent casting on of the terminal post structures 11 on the side-by-side spaced battery cell elements 12 and 12'. 14 As shown in Figure 6, the pickup apparatus 23 and the unload apparatus 28 are carried on a pair of common rails 30 overlying the brushing apparatus 24, flux applying apparatus 25, mold 26, and reservoir 27. As further illustrated in Figure 7, the molten metal reservoir 27 is selectively positionable transversely thereto on slide rails 31. As seen in Figure 6, the slide rails are disposed below the level of mold 26 so that when the reservoir structure 27 is disposed in a retracted disposition, unload apparatus 28 has free access to the mold 26 for unloading the battery cell elements with the terminal post structures 11 provided thereon. Selective disposition of the molten metal delivery apparatus 27 in the laterally retracted disposition shown in Figure 7 and the operative position thereof in alignment with the molds 82 and 83, as shown in Figure 8, is effected by suitable control of piston cylinder device 38 as by controller 40. As further illustrated in Figure 8, the molten metal reservoir 27 defines a housing 32 having a pair of delivery chutes 33 and 34 extending outwardly from a bottom opening therein selectively controlled by plunger valves 35 and 36, respectively. The valves are carried on a pivot arm structure 37 operated by a actuator device 39 under the control of an overall control 40 of the apparatus for effecting the delivery of a controlled quantity of the hot molten metal to the mold 2 6 at proper time in the operation of the apparatus. Control 40 is further connected to each of the other elements of the apparatus for effecting 15 2 03142 coordinated control. As shown, apparatus 10 may be provided on a base 41. As seen in Figure 7, the piston cylinder device 38 is carried on a support plate 163. Rails 31 are 5 mounted to the support plate, which further carries a platform 164, in turn carrying the reservoir housing 132 of the molten metal supply apparatus 27. As further shown in Figure 8, actuator 39 is mounted to the support plate 164. 10 As best seen in Figure 6, the actuator 39 in cludes a solenoid 165 and linkage 166 connected to the valve shafts 167 associated with the valves 35 and 36 (Fig. 8) for vertically reciprocably positioning the valves as a function of the energization of 15 the solenoid 165. Pickup 23 is illustrated in greater detail in Figures 9, 10 and 11. As shown in Figure 9, a delivery clamp carrier generally designated 42 is suspended from a plate 43 provided with slide blocks 44. 20 longitudinally slidable on rails 30 carried on overlying supports 45. Movement of the support plate 4 3 longitudinally of the slide rails is effected by a rodless positioning cylinder device 46 affixed to an overlying support 47. Such devices are well-known 25 and, briefly, comprise a cylinder barrel 48 having a longitudinal slit with a lug 49 extending outwardly therethrough and carried by the piston of the device. As shown in Figure 9, the lug engages an upstanding connector 50 on an extension 51 of support plate 43, 30 whereby the support plate is moved longitudinally on the slide rails 30 as a function of the positioning of the piston lug 49 of the positioning device 46 16 2051 4 and position of cylinder rod X2 on cylinder XI, as shown in Figure 6. As further illustrated in Figure 9, delivery clamp carrier 42 includes a vertical mounting plate 5 52 secured to the front end of support 43 by suitable bolts 53. A pair of opposite side plates 54 and 55 are mounted to the edges of vertical plate 52 by suitable bolts 56. The side plates carry at their lower end a pair of cylinders or pistons 57 and 58, 10 the plungers 59 of which carry, at the distal ends thereof, a pair of clamp plates 60 and 61. The plungers 59 are normally biased inwardly to urge the clamp plates 60 and 61 into seated relationship with the inner surface of the support plates 54 and 55. 15 Upon energization of the cylinders or pistons, however, the clamp plates are moved outwardly as to the dotted line showing thereof in Figure 9, for engaging the outer surface of the battery cell element in the strap cast-on apparatus 22. 20 The inner surface of the battery cell elements is engaged by a pair of clamp plates 62 and 63 which are movable between a retracted position shown in full lines in Figure 9, and an outward clamping position shown in broken lines therein, by a cam 64 ro-25 tatable within a housing 65 by a shaft 66. The shaft is rotated by a cylinder or piston 67 through linkage 68. The shaft rotating mechanism is carried on a support plate 69, in turn carried on the plate 43 by a pair of posts 70 extending through suitable 30 openings 71 in the plate 43. Plate 43, in turn, is moved vertically by a piston device 72 mounted to the plate 43 and having the 20514 2 17 piston rod thereof 73 secured to the plate 43 by a suitable bolt 74. Downward movement of plate 69 relative to plate 4 3 is limited by abutment of an adjustable stop 75 5 with the cylinder 72. As best seen in Figure 11, a pair of cam devices 64 is provided in the pickup clamp carrier. The cam devices are interconnected by a link chain 76 driven by a sprocket 77 on the lower end of shaft 66 so as 10 to effect concurrent rotation of the cam devices as a result of rotation of the shaft 66 by the solenoid 67. Thus, when the pickup clamp carrier is brought into straddling relationship to a pair of end cell 15 elements in the apparatus 22, as shown in Figure 5, the clamp plates 60 and 61 are urged inwardly against the outer surfaces of the pair of elements and the inner clamp plates 62 and 63 are urged outwardly concurrently against the inner surfaces thereof to gent-20 ly and effectively clamp the battery cell elements therebetween for pickup and delivery successively to the other stations in the apparatus 10. The mounting of the plate 69 to the plate 43 effects a vertical movement of the shaft rotating means 25 with the shaft 66 and the delivery clamp carrier 42. The picked-up elements 12 and 12' are moved along the rails 30 from the guide rails 78 of the strap cast-on apparatus 22, as seen in Figure 6. The depending ribs 21 and lower surfaces of the straps 18 30 are engaged with rotary brushes 79 of brush device 24 to clean the surfaces for improved fusion bonding in the mold 26. As shown in Figure 6, the apparatus 24 U I 18 may be provided with a suction duct 80 for removing particulate material brushed off by the brushes 79. From the brush device 24, the elements 12 and 12' are brought to the flux applying apparatus 25, wherein the depending projecting ribs are engaged with a suitable applicator sponge 81 for applying flux thereto as a result of engagement of the ribs with the sponge 81 as the carrier 42 moves to the left, as seen in Figure 6, through the flux applying apparatus station. Mold apparatus 26 is shown in greater detail in Figures 12-14 and 39. As shown in Figure 12, mold apparatus 26 includes a pair of molds 82 and 83 for concurrently casting the terminal post structures 11 to the pair of terminal cell elements 12 and 12'. As shown in Figure 14, the molds are carried on a support plate 84 secured to a bottom support plate 85 by a plurality of bolts 86. The molds are moved vertically on the support plates by a piston cylinder de- . vice 87. Support plate 85 is guided by an upright guide 88 mounted to the plate 85. A pair of knockout pins 89 and 90 are mounted to the base to upstand adjustably therefrom into a depending tubular lower portion 91 of the molds 82 and 83. The upper distal end 92 of the knockout pin is provided with a rounded recess 93 for defining a rounded distal end 106 of the terminal post structures 11. As best seen in Figures 12 and 14, each of the molds defines an upwardly opening mold cavity 94 defining a connection portion 95 and a terminal post portion 96 opening downwardly into the tubular mold 20514 2 19 extension 91 receiving the upper end of the knockout pins 89 and 90, as discussed above. As further illustrated in Figure 39, a dam 97 is removably positioned within the mold cavity 94 by a shaft 98 and a counterweight 99 connected to the dam for selectively retracting the dam therefrom to permit removal of the molded terminal post structure upon completion of the casting operation. Cooling air is supplied to the mold through a supply conduit 101 opening to air flow passages 102 in the plate 84 underlying the mold, as illustrated in Figure 14. It is intended that the mold remain substantially at constant temperature during operation of the apparatus. The cooling air is supplied to remove excess heat transferred from the molten metal delivered thereto. Suitable heater means, such as electric heating cartridges, 103 is associated with each of the molds for maintaining the operating temperature as between molding operations, as is well-known in the art. Upon completion of the forming of the terminal post structure 11 in the mold, the molds are lowered, as illustrated in Figure 13, while the knockout pins 89 and 90 are maintained fixed on the base 41 so as to separate or release the formed terminal post structures from the mold. The lowering of the molds is effected by the retraction of the piston cylinder device 87, as illustrated in Figure 13, moving the support plate 85 downwardly toward base 41. As indicated above, the guide 88 further serves to guide the downward movement of the plate 85 by the piston 20 51^2 20 cylinder device 87 until the terminal post structure 11 is clear of the molds, as shown in Figure 13. The cast terminal post structures are illustrated in Figures 15-18 in greater detail. Thus, as 5 shown therein, the terminal post structure 11 includes a connecting portion 104 autogenously welded to the depending connection projection rib 21 and a post portion 105 projecting from the connecting portion 104. As discussed above, the upper end of the 10 knockouts is provided with a rounded recess so as to define a rounded distal end 106 of the post portion 105, as seen in Figure 16. The dam 97 defines a clearance recess 107 in the connecting portion 104 of the terminal post structure 15 as illustrated in Figure 17. The recess assures desired clearance between the terminal post structure and the adjacent strap 17 of the end cell element. As seen in Figure 16, the height of the connecting portion 104 increases from the opposite ends 20 thereof to the post portion 105. As best seen in Figure IB, the upper end of the post portion 105 is connected to the side of the connecting portion 104 by a connector portion 108 to provide a positive, rigid connection of the cantilevered post to the 25 strap 18. As illustrated in Figures 17 and 18, the pair of terminal post structures concurrently produced in the molds 82 and 83 are effectively mirror images of each other so as to be properly arranged for use as terminals, generally located at the oppo-30 site ends of the battery 20, as discussed above. Referring now more specifically to Figures 19 21 205142 through 24, unload apparatus 28 is arranged to pick up the battery cell element from the mold and transfer it to the conveyor 29. The battery cell element with the terminal post structure 11 cast integrally 5 thereon generally designated 109, as illustrated in Figure 3, is engaged by an unload head portion generally designated 110 of apparatus 28. As illustrated in Figure 19, the unload head defines a pair of clamps generally designated 111 and 112 for engaging 10 the two concurrently formed subassemblies 109 in side-by-side relationship from the molds 82 and 83. Clamps 111 and 112 are engaged with the elements 109 while they are supported on the knockout pins during the downward movement of the mold apparatus. As 15 illustrated, clamp 111 includes a first clamp plate 113 and a second clamp plate 114. Clamp 112 includes a first clamp plate 115 and a second clamp plate 116. Clamp plate 113 is moved inwardly by cylinders or pistons 117 from the retracted position shown in full 20 lines in Figure 19 to the clamping position shown in broken lines therein. The cylinder or piston is spring-biased to the retracted position. Clamp plate 115 is moved inwardly from the retracted position shown in full lines in Figure 19 to 25 the clamping position shown in broken lines therein by spring-biased cylinders or pistons 118. Clamp plates 114 and 116 are moved outwardly from a retracted position shown in full lines in Figure 19 to a clamping position shown in broken lines therein by 30 spring-biased actuators generally designated 119. Actuators 119, as shown in Figure 20, include cylinders or pistons 120 each provided with an elongated / 22 2 0 514 2 rod or shaft 121 which is spring-biased by suitable spring means 122 to urge the shaft to the left, as seen in Figure 20. A pair of cam pins 123 and 124 are fixed for 5 movement with shaft 121 so as to be urged to the right, as seen in Figure 19, upon actuation of the cylinder or piston 120. As shown in Figure 19, the pins are received in tapered recesses 125 and 126 cooperatively formed in 10 the clamp plates 116 and 114 so that upon rightward movement of the cam pins, clamp plates 116 and 114 are urged apart from the retracted position to the dotted line clamping position. As shown, the clamping movement is relative small while yet effectively 15 providing clearance between the clamp plates and the side face of the battery cell element upon release of the clamps. Clamp 113 and cylinder or piston 117 are mounted to a support plate 127, in turn mounted to a carrier. 20 plate 128. Clamp 115 and cylinder or piston 118 are mounted to a support plate 129 similarly mounted to the clamp plate 128 by similar screws 130. The carrier plate is rotatable about a horizontal axis 131 by a rotating device 132 mounted to a 25 depending support plate 133 of a lift head 134. The lift head further is provided with a cantilevered stop support 135 provided with an adjustable stop 136 at its distal end. As seen in Figure 24, the lift head is further 30 provided with a second arm 137 provided with an adjustable stop 138. The carrier plate includes an end portion 139 selectively engageable with stops 136 and 23 2 G ^ i 4- 138 to define limits of rotational movement of the carrier plate 128. As shown in Figures 22 and 24, carrier plate 128 is rotated 180° from the initial position thereof, in which the pickup head is 5 arranged to pick up the battery cell elements 109, to an inverted position wherein the terminal post structures of the battery cell elements 109 extend upwardly, as schematically illustrated in Figures 33 and 34. Thus, as seen in Figure 23, carrier plate 10 portion 139 is brought from engagement with stop 136 into engagement with stop 138 in the element-inverting disposition and is then retracted back to the element-clamping position wherein the carrier portion 139 is returned into engagement with stop 136, as 15 shown in Figure 24. As further illustrated in Figures 22 and 24, the lift head 134 is vertically positionable by a piston cylinder device 140 having one end secured to a support plate 141 and the piston rod 142 thereof connec-20 ted to a top plate 143 of the lift head 134. Support plate 141, in turn, is mounted to a plate 144 carried on the slide rails 30 by slide blocks 145 for horizontal movement along the slide rails. Such horizontal movement is effected by a rodless positioning de-25 vice 146 similar to device 46 and having a horizontally positionable lug 147 engaged with upstanding connector 148 on the support plate 144. Upward movement of the head 134 relative to the support plate 144 is limited by abutment of a first 30 pair of cooperating stops 149 and 150 and a second pair of cooperating stops 151 and 152 mounted respectively to the support plate 144 and head 134, as 20 5 24 shown in Figure 24. Downward movement of the lift head is controlled by a pair of stops 153 and 154 on a pair of vertical guides 155 and 156 slidable through the support plate 144 and having their lower ends secured to the lift head plate 143. The guides may be provided with a second set of stops 157 and 158 engageable with depending stops 159 and 160 on the support plate 144. It is desirable to raise the unload head clamps 110 a small amount, such as V, to separate the terminal post structures 11 from the upper end of the knockout pins. To effect an initial small upward movement, stops 149 and 151 are raised approximately V by cylinders or pistons 161 and 162 mounted 'to the support plate 144, as shown in Figure 22. Such upward displacement of the stops 149 and 151 permits the further upward retraction of the piston cylinder device 140 until stops 157 and 158 engage the stops 159 and 160 on the support plate. Having cleared the knockout pin tips, the battery cell element 109 may then be moved horizontally by leftward movement of the unload apparatus 28 on the rails 30 to bring the battery cell elements into overlying relationship with the conveyor 29. As discussed above, the battery cell element is rotated during the transfer so as to dispose the terminal post structure 11 thereof uppermost. The pickup head is then lowered by suitable operation of the piston cylinder device 140 to place the thusly turned battery cell element on the conveyor 29 for further disposition. As indicated above, each of the clamp 20bi4 2 25 plates 113,114,115,116 is movable away from the battery cell element so as to permit facilitated transfer thereof onto the conveyor without frictional damage to the sides of the battery cell element as by 5 sliding of the element thereagainst. Industrial Applicability The overall operation of apparatus 10 is illustrated schematically in Figures 25-35. Thus, as seen in Figure 25, the battery cell elements are initially 10 picked up by the pickup head clamp carriers 42 and brought to the brushing apparatus 24 wherein the depending connection means, or projection ribs, 21 are brushed by the rotating brushes 79 to remove foreign contaminant material from the surface thereof. 15 Movement of the carrier 42 is continued to the left, as seen in Figure 25, to then bring the battery cell element to the flux application apparatus 25, wherein the downwardly projecting ribs 21 are engaged with the sponge 81 of the flux applicator to apply 20 suitable bonding flux thereto. As shown in Figure 26, the carrier 4 2 is moved further to the left so as to bring the battery cell elements into overlying relationship with the mold apparatus 26. At this time, the molten metal in res-25 ervoir 27 is retained therein by the closed valves 35 and 36. As shown in Figure 27, valves 35 and 36 are then energized to deliver molten metal from the reservoir for a preselected period of time through the chutes 33 33 and 34 to the molds 82,83. 20 5 t 26 As shown in Figure 28, the valves are now de-energized to terminate delivery of the controlled quantity of metal to the mold and the carrier 42 is lowered to move the battery cell element downwardly so as to bring the depending rib 21 into the upper portion of the molten metal in the mold. As shown in Figure 29, the apparatus is maintained in this disposition for a sufficient time to permit cooling and solidification of the molten metal in the molds to form the terminal post structures 11 on the depending ribs. As shown in Figure 30, the unload apparatus 28 is moved to the right so as to engage the clamps 110 with the battery cell elements 109 having the terminal post structures 11 cast thereonto. Pickup apparatus 2 3 is then undamped from the battery cell elements 109 and moved upwardly and to the right into a holding position defined by cylinder XI and extended cylinder rod X2, as illustrated in Figure 6. The pickup apparatus remains in this holding position until apparatus 22, as seen in Figure 5, moves a pair of battery elements 12 and 12' into position in alignment with the pickup apparatus. Subsequently, cylinder rod X2 retracts, allowing the pickup apparatus to move to the right out of the holding position for pickup of a succeeding pair of battery cell elements 12 and 12'. At the same time, the mold apparatus 26 is lowered while retaining the knockout pins 89,90 against movement so as to free or release the cast terminal post structures 11 from the molds 82,83. Downward movement of mold 82,83 205'; • 27 simultaneously forces dam 97 into the open position for release of post bevel 107, as illustrated in Figure 17. Actuation of the cylinders or pistons 161 and 5 162 is then effected, as seen in Figure 32, to raise the stops 149 and 151 and thereby permit the lift piston device 140 to raise the lift head 134 and battery cell elements 109 carried thereby approximately V to provide clearance of the cast terminal 10 post structures 11 from the upper ends of the knockout pins. The released battery cell elements are then moved to the left, as seen in Figure 33, by leftward translation of the lift head 134 carried on the rails 15 30, while, as further shown in Figure 34, the carrier plate 128 is rotated by rotator 132 to position the battery cell elements with the cast-on terminal post structures 11 uppermost in the clamp device 110. As further illustrated in Figure 34, the leftward move-20 ment of the lift head 134 is continued until the battery cell elements 109 are disposed above the transfer conveyor 29. The battery cell elements 109 are then deposited on the conveyor 29 by a downward movement of the lift 25 head 134 by operation of the piston cylinder device 140, whereupon the clamping device 110 is released and then raised away from the cell elements to transfer the cell elements to the conveyor for further processing as desired. 30 A time sequence chart is provided in Figure 36 illustrating the relationship of the different operations discussed above relative to Figures 25-35 to 28 2051- each other in the overall operation of the apparatus 10. The operation may be coordinated by the control 40 to provide the desired timing sequences. Alternatively, the operation of the drive elements of the 5 apparatus may be controlled manually to provide the sequence of operations as discussed above. As seen in Figures 37 and 38, a side terminal 168 may selectively be formed on the depending ribs 16 by suitable configuration of the mold. Thus, the 10 side terminal includes a connecting portion 169 cast onto the rib, and a side terminal portion 170 at one end of the connecting portions. The dam 97 is not needed in forming the side terminal as the terminal portion 170 is at the end of the strap 18 and no 15 clearance bevel is required. Apparatus 10, as discussed above, is extremely simple and economical of construction while yet providing an improved coordinated functioning of the elements thereof in providing an improved terminal 20 post structure 11 on the battery cell element connecting ribs for use in the end cell structures of the battery. The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts com-25 prehended by the invention. </div>

Claims

<div class="application article clearfix printTableText" id="claims"> 29 I WHAT WE CLAIM IS: —

1. The method of providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity and a conductive metal strap electrically connecting the plates, said method comprising the steps of: providing on the strap a connection means; providing a mold having an upwardly opening mold cavity defining a terminal portion and a connection portion; providing molten metal in said mold cavity; inserting the strap connection means into the molten metal in said connection portion of the mold to cause surface fusion of the connection means; and causing the fused portion of the connection means and the molten metal in the mold cavity to cool thereby to form a terminal structure having a terminal portion and a connecting portion fused to said connection means of the conductive strap.

2. The method of providing a terminal structure of Claim 1 wherein said conductive strap defines a surface portion extending transversely away from said connection means and said connecting portion of the terminal is fused to said surface portion.

3. The method of providing a terminal structure of Claim 1 wherein said connection means defines a projection. 30 205 1

4. The method of providing a terminal structure of Claim 1 wherein said connection means defines an elongated rib projecting from and extending lengthwise of said conductive strap.

5. The method of providing a terminal structure of Claim 1 wherein said mold is provided with an insulative layer defining said mold cavity.

6. The method of providing a terminal structure of Claim 1 wherein the rate of delivery of said molten metal to said mold cavity is manually adjustable to provide a controlled quantity of molten metal therein during a preselected period of time.

7. The method of providing a terminal structure of Claim 1 wherein the time of delivery of said molten metal to said mold cavity is preselected to provide a controlled quantity of molten metal therein .

8. The method of providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity and a conductive metal strap electrically connecting the plates, said method comprising the steps of: providing on the strap a connection projection; brushing the connection projection; providing a flux to the projection; providing a mold having an upwardly opening mold cavity defining a terminal portion and a connection portion; 205142 31 providing molten metal in said mold cavity; inserting the projection into the molten metal in said connection portion of the mold to 15 cause surface fusion of the brushed and fluxed projection; and causing the fused portion of the projection and the molten metal in the mold cavity to cool thereby to form a terminal structure having 20 a terminal portion and a connecting portion fused to said connection projection of the conductive strap.

9. The method of providing a terminal structure of Claim 8 wherein said step of brushing the connection projection comprises a step of moving the connection projection past a rotating brush to a flux 5 providing station.

10. The method of providing a terminal structure of Claim 8 wherein said conductive strap defines a surface portion extending transversely away from said connection projection and said surface portion is 5 brushed concurrently with the brushing of the connection projection, said brushed surface portion being fused to said connecting portion of the terminal in said mold.

11. The method of providing a terminal structure of Claim 8 wherein said element is carried with said rib lowermost during said steps. 205142 32

12. The method of providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity and a conductive metal strap electrically connecting the plates, said method comprising the steps of: providing on the strap a projecting rib; providing a mold having an upwardly opening mold cavity defining a terminal portion and a connection portion; providing molten metal in said mold cavity; inserting said rib into the molten metal in said connection portion of the mold to cause surface fusion of the rib along substantially its entire length; and causing the fused portion of the rib and the molten metal in the mold cavity to cool thereby to form a terminal structure having a terminal post portion and a connecting portion fused to said rib of the conductive strap.

13. The method of providing a terminal structure of Claim 12 wherein said connecting portion includes a portion abutting the strap adjacent the rib.

14. The method of providing a terminal structure of Claim 12 wherein said connecting portion includes a first portion overlying the strap and a second portion projecting laterally therefrom, said terminal portion being connected to said second portion. 205142 33

15. Ti^e method of providing a terminal structure of Claim 12 wherein said connecting portion includes a first portion overlying the strap and a second portion projecting laterally therefrom, said terminal 5 portion being connected to said second portion, and a removable dam is disposed in said mold cavity during the forming of the terminal and connecting portions to provide a clearance space in said connecting portions opening away from said strap.

16. The method of providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity and a conductive metal strap electrically connecting the 5 plates, said method comprising the steps of: providing on the strap a connection projection; picking up the element with said strap lowermost; moving the picked-up element to engage the con-10 nection projection with a brush; moving the picked-up element to engage the connection projection with a flux applicator to provide a flux to the projection; providing a mold having an upwardly opening mold 15 cavity defining a terminal portion and a connection portion; moving the element to a position over the mold; providing molten metal in said mold cavity; moving the element downwardly to insert said 20 connection projection of the strap into the molten metal in said connection portion of the mold to cause surface fusion of the 20 514 2 34 projection; engaging the element with a pickup device; 25 causing the fused portion of the projection and the molten metal in the mold cavity to cool thereby to form a terminal structure having a terminal portion and a connecting portion fused to said connection projection 30 of the conductive strap; releasing the terminal structure from the mold; and transferring the battery cell element with the cast terminal structure from the mold.

17. The method of providing a terminal structure of Claim 16 wherein cooling fluid is directed against the mold for causing the molten metal in the mold cavity to cool rapidly.

18. The method of providing a terminal structure of Claim 16 wherein the strap adjacent the connection projection is caused to be concurrently engaged by said brush.

19. The method of providing a terminal structure of Claim 16 wherein said brush is caused to move rapidly while in engagement with said connection projection.

20. The method of providing a terminal structure of Claim 16 wherein a lower portion of the mold is defined by a knockout pin and said knockout pin is 2 0 5 142 caused to extend into the mold cavity to release said terminal structure from the mold.

21. The method of providing a terminal structure of Claim 16 including the step of inserting a self-release dam across a portion of the mold cavity during the molding operation to define a clearance space in the molded condition portion.

22. The method of providing a terminal structure of Claim 16 including the step of inserting a dam across a portion of the mold cavity during the molding operation to define a clearance space in the molded condition portion, said dam being retracted from the mold cavity upon completion of the cooling step to permit the release and transfer of the cast terminal structure from the mold.

23. The method of providing a terminal structure of Claim 16 wherein a reservoir of molten metal is provided adjacent the mold, said step of providing molten metal in the mold cavity comprising a step of transferring a controlled quantity of molten metal from the reservoir to the mold cavity.

24. The method of providing a terminal structure of Claim 16 wherein a reservoir of molten metal is provided adjacent the mold, said step of providing molten metal in the mold cavity comprising a step of transferring a controlled quantity of molten metal from the reservoir to the mold cavity at a preselected flow rate for a preselected time. 2051 4

25. The method of providing a terminal structure of Claim 16 wherein said mold cavity opens upwardly and is substantially filled with molten metal, said connection projection being substantially the sole portion of the battery cell element inserted into the molten metal.

26. The method of providing a terminal structure of Claim 16 wherein said battery cell element includes a second conductive metal strap connecting plate of polarity opposite to those connected by said first named strap, said second strap being disposed exteriorly of the mold during the forming of said terminal structure.

27. The method of providing a terminal structure of Claim 16 wherein said mold is moved downwardly while the cast terminal structure is held against downward movement to effect the releasing from the mold of the terminal structure.

28. The method of providing a terminal structure of Claim 16 wherein said battery cell element is held in a delivery clamp during the molding of the terminal structure.

29. The method of providing a terminal structure of Claim 16 wherein said battery cell element is held in a delivery clamp during the molding of the terminal structure and a pickup clamp is engaged with the battery cell element for transferring the battery 205143 37 cell element subsequent to the casting and releasing thereof from the mold.

30. The method of providing a terminal structure of Claim 16 wherein said battery cell element is held in a delivery clamp during the molding of the terminal structure and a pickup clamp is engaged with the battery cell element for transferring the battery cell element subsequent to the casting and releasing thereof from the mold, said delivery clamp being disengaged from the battery cell element upon engagement thereof by the pickup clamp.

31. The method of providing a terminal structure of Claim 16 wherein said battery cell element is turned about a horizontal axis while being transferred so as to dispose the cast terminal structure uppermost.

32. The method of providing a terminal structure of Claim 16 wherein a lower portion of the mold is defined by a knockout pin and said knockout pin is caused to extend into the mold cavity to release said terminal structure from the mold, said knockout pin defining a distal rounded recess for causing the distal end of the cast terminal to be rounded.

33. The method of providing a terminal structure of Claim 16 wherein said mold is preheated prior to delivery of molten metal thereto.

34. The method of providing a terminal structure of Claim 16 wherein said mold is preheated prior to delivery of molten metal thereto and is cooled upon insertion of the connection projection into the molten metal in the mold cavity. 205143

35. Apparatus for providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity, said apparatus comprising: means which provides a conductive metal strap electrically connecting said plates and having a connection means defining a projection having fusible surface portion; a mold having an upwardly opening mold cavity defining a terminal portion and a connection portion; means which provides molten metal in said mold cavity at a temperature preselected to be above the fusion temperature of said connection means surface portion; means which inserts the connection means into the molten metal in said connection portion of the mold to cause fusion of said connection means surface portion; and means which causes the fused surface portion of the connection means and the molten metal in the mold cavity to cool thereby to define a terminal structure having a terminal post and a connecting portion defining with said connection means of the conductive strap an autogenous bond.

3 6. The apparatus of Claim 35 wherein a second strap is provided on the battery cell element, and said means which inserts the connection means causes the second strap to be disposed outwardly of the mold when the connection means is inserted thereinto.

37. The apparatus of Claim 35 further including means which brushes the connection means and means which applies flux to the ij'\f t'9-JULl98( 39 205142 brushed connection means for improved fusion bonding thereof to the terminal post.

38. The apparatus of Claim 35 further including means which conveys the battery cell element to the mold including a pickup clamp releasably engaging the battery cell element with the strap lowermost.

39. The apparatus of Claim 35 further including means which releases the cast terminal structure from the mold.

40. The apparatus of Claim 35 further including means which releases the cast terminal structure from the mold and means which transfers the battery cell element with the released cast terminal structure from the mold.

41. The apparatus of Claim 3 5 further including means which transfers the battery cell element with the cast terminal structure from the mold including an unload clamp releasably engaging the battery cell element.

42. The apparatus of Claim 35 further including means which conveys the battery cell element and the mold including a pickup clamp releasably engaging the battery cell element with the strap lowermost, means which transfers the battery cell element with the cast terminal structure from the mold including an unload clamp releasably engaging the battery cell element, and means which releases said pickup clamp upon engagement of the battery cell element by the unload clamp.

43. The apparatus of Claim 35 further including means which moves the mold relative to the battery cell element for effecting the release of the cast terminal fV 9JULI986 205148 v

44. Apparatus for providing a terminal structure on a battery cell element having a plurality of facially spaced plates of similar polarity, said apparatus comprising: means which provides a conductive metal strap electrically connecting the plates and having a connection projection; means which picks up the element with said strap lowermost; a brush; means which moves the picked-up element to engage the connection projection and the strap adjacent said projection with the brush; a flux applicator; means which moves the picked-up element to engage the connection projection and the strap adjacent said projection with the flux applicator to provide a welding flux to the projection and the strap adjacent said projection; a mold having an upwardly opening mold cavity defining a terminal portion and a connection portion; means which moves the element to a position over the mold; means which provides molten metal in said mold cavity; means which moves the element downwardly to insert said connection projection of the strap and the strap adjacent said projection into the molten metal in said connection portion of the mold to cause surface fusion of the projection and the strap adjacent said projection; ,£to A" '9JULI9&; 205143 a pickup device; .cooling means which causes the fused portion of the projection, the surface of the strap adjacent the projection, and the molten metal in the mold cavity to cool thereby to define a terminal structure having a terminal portion and a connecting portion fused to said connection projection of the conductive strap and the strap adjacent said projection; means which releases the terminal structure in the mold; and means which transfers the battery cell element with the cast terminal structure from the mold.

45. The apparatus of Claim 44 wherein a second strap is provided on the battery cell element and said means which inserts the connection projection and the strap adjacent said projection causes the second strap to be disposed outwardly of the mold when the connection projection and the strap adjacent said projection are inserted thereinto.

4 6. The apparatus of Claim 44 wherein said means which picks up the element comprises clamping means.

47. The apparatus of Claim 44 wherein said means which transfers the element comprises clamping means.

48. The apparatus of Claim 44 wherein said means which picks up the element comprises clamping means, and said means which transfers the element comprises clamping means engageable with said battery cell element upon release of said first named , . clamping means. //* - 42 - 205142

49. A battery cell element having a plurality of facially spaced plates and separator means between said plates comprising : a connecting strap interconnecting said plates, said strap being formed of cast fusible metal and defining a connection projection comprising an elongated rib thereon; and a terminal structure having a terminal portion, and a connecting portion formed of cast fusible metal having an autogenous bond with said srap connection projection, said connecting portion being formed in situ to abut said strap laterally of said connction projection and fully embed said rib. - 43 - 205142

50. The battery cell element of Claim 49 wherein said connecting portion includes a portion extending laterally away from said strap and said terminal portion is provided on said laterally extending

51. The battery cell element of Claim 49 wherein said connecting portion includes a portion extending laterally away from said strap and said terminal portion is provided on said laterally extending por- lying the rib greatest adjacent said terminal portion.

52. The battery cell element of Claim 49 wherein the autogenous bond between said connection projection and connecting portion of the terminal structure is free of connection projection surface 5 contaminants.

53. The battery cell element of Claim 49 wherein the autogenous bond between said connection projection and connecting portion of the terminal structure is free of connection projection surface 5 contaminants and includes at least traces of flux ma- 5 portion. 5 tion, and said connecting portion has a height over- GNB BATTERIES INC., By Their Attorneys H 'ED 1 </div>