WO2009142621A1

WO2009142621A1 - Battery parts and associated methods of manufacture and use

Info

Publication number: WO2009142621A1
Application number: PCT/US2008/064161
Authority: WO
Inventors: Paolo Ferrari; Giuseppe Segreto; Orazio Bino; Michael Garin
Original assignee: Aquila Piombo S.R.L.
Priority date: 2008-05-19
Filing date: 2008-05-19
Publication date: 2009-11-26
Also published as: EP2286479A4; EP2286479A1

Abstract

Battery parts and methods of manufacturing parts are disclosed. A base portion includes a flange spaced apart from a second flange, and resists torsion of the base with respect to the container when at least partially embedded in a wall of the battery container. The base portion may optionally further include one or more sealing rings positioned between the flanges to prevent or inhibit leakage of fluid from the battery.

Description

BATTERY PARTS AND ASSOCIATED METHODS OF MANUFACTURE AND USE

TECHNICAL FIELD

[0001] The following disclosure relates generally to battery parts and, more particularly, to battery terminals, battery terminal bushings, and the like.

BACKGROUND

[0002] Battery terminals are typically cold formed or die cast from lead or lead alloys. In a conventional battery, the terminals protrude from a casing or container which carries electrolyte. The container is typically formed from a moldable thermoplastic resin, such as polypropylene. During manufacture of the container, the resin flows around the base of the terminals so that the resin will secure the terminals in place once it hardens. After a terminal has been secured, a lead anode can be inserted into a central hole in the terminal and melted to fill the hole and form a mechanical and electrical connection to a battery grid positioned within the container.

[0003] Battery terminals can include annular acid rings that extend around the base of the terminal to provide an extended interface between the base of the terminal and the adjacent container material. This interface can provide a torturous path or "labyrinth seal" that inhibits or prevents electrolyte from escaping the battery container. Various types of terminal seals, and methods for making such seals are disclosed in US Patent No. 7,338,539, and US Patent Application No. 11/011 ,362, both of which are incorporated into the present application in their entireties by reference.

[0004] Conventional battery terminals may become loose in the container wall if subjected to repeated or excessive twisting or torsional loads. Additionally, shrinkage of the battery container may also contribute to loosening of conventional terminals over time. Accordingly, it would be advantageous to provide battery terminals and/or other battery parts that address these shortcomings. SUMMARY

[0005] Aspects of the present disclosure are directed generally toward battery parts, such as lead or lead alloy battery terminals and the like. A battery part configured in accordance with one embodiment includes a base portion configured to be at least partially embedded in battery container material. The base portion can include a first torque-resisting feature spaced apart from a second torque-resisting feature. In some embodiments, the first and second torque-resisting features can include flanges or other projections having one or more flat or generally flat side portions. In other embodiments, the base portion can include a sealing portion positioned between the first and second torque-resisting features. The sealing portion can include, for example, at least one annular sealing ring.

[0006] A battery terminal configured in accordance with another embodiment of the disclosure can include a lug portion extending from a base portion. The base portion can include a first flange spaced apart from a second flange, and at least one acid sealing feature positioned between the first and second flanges. In one embodiment, the first and second flanges can have non-circular peripheries. In another embodiment, at least one of the first and second flange portions can have a polygonal shape.

[0007] A battery assembly configured in accordance with a further embodiment of the disclosure can include at least one battery part secured to a battery container. The container can be formed from moldable material and can have an inner surface portion spaced apart from an outer surface portion. The battery part can include first and second spaced apart flange portions configured to resist torsion of the battery part relative to the container. In one aspect of this embodiment, the first flange portion is at least partially embedded in the moldable container material adjacent to the outer surface portion of the container, and the second flange portion is at least partially embedded in the moldable container material adjacent to the inner surface portion of the container. The battery part can further include a sealing portion embedded in the moldable container material between the first and second flange portions.

[0008] A method of manufacturing a battery part in accordance with another embodiment of the disclosure includes forming a first flange portion toward a first end of the battery part, and forming a second flange portion between the first flange portion and a second end of the battery part. In one embodiment, forming the first flange portion includes forming at least one flat side portion, and forming the second flange portion includes forming at least one flat side portion. The method can further include forming a sealing portion between the first and second flange portions. In one embodiment, forming a sealing portion can include forming at least one annular acid sealing ring.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an isometric view of a battery part configured in accordance with an embodiment of the invention.

[0010] Figure 2 is an end view of the battery part of Figure 1.

[0011] Figure 3 is a side cross-sectional view of the battery part illustrated in Figures 1 and 2, taken substantially along line 3-3 in Figure 2.

[0012] Figure 4 is a side cross-sectional view of a battery part configured in accordance with another embodiment of the invention.

[0013] Figure 5 is a side cross-sectional view of a portion of a battery assembly having a battery part configured in accordance with an embodiment of the invention.

[0014] Figures 6A-6D are a series of isometric views of battery parts configured in accordance with further embodiments of the invention.

DETAILED DESCRIPTION

[0015] The following disclosure describes various embodiments of battery parts, such as battery terminals and the like, and associated methods of manufacture and use. In one embodiment, a battery terminal configured in accordance with the present disclosure includes one or more annular sealing rings positioned between two spaced apart flanges. The spaced apart flanges of this embodiment can be embedded in battery container material when the corresponding battery container is formed. The flanges can have shapes that enable the battery container material to grip the flanges and resist loosening of the terminal when the terminal is subjected to, for example, torsional or twist loads. In one embodiment, for example, each of the flanges can have a polygonal shape, such as a hexagonal shape. In other embodiments, battery terminals configured in accordance with the present disclosure can include flanges, lips, and/or other projections having different shapes. Such shapes can include, for example, rectangular shapes, non-circular shapes, partially-circular shapes, symmetrical shapes, non-symmetrical shapes, irregular shapes, flat surface portions, concave surface portions, convex surface portions, etc.

[0016] Certain details are set forth in the following description and in Figures 1- 6D to provide a thorough understanding of various embodiments of the invention. Other details describing well-known structures and systems often associated with battery parts (e.g., lead and/or lead alloy battery parts, moldable battery containers, etc.), and methods for forming such parts (e.g., forming, casting, injection molding, etc.), as well as other battery parts and assemblies, are not set forth in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the invention.

[0017] Many of the details, dimensions, angles and/or other portions shown in the Figures are merely illustrative of particular embodiments of the invention. Accordingly, other embodiments can have other details, dimensions, angles and/or portions without departing from the spirit or scope of the present invention. In addition, further embodiments of the invention may be practiced without several of the details described below, while still other embodiments of the invention may be practiced with additional details and/or portions.

[0018] In the Figures, identical reference numbers identify identical or at least generally similar elements. To facilitate the discussion of any particular element, the most significant digit or digits of any reference number refers to the Figure in which that element is first introduced. For example, element 110 is first introduced and discussed with reference to Figure 1.

[0019] Figure 1 is an isometric view of a battery part 100 configured in accordance with an embodiment of the invention. In the illustrated embodiment, the battery part 100 comprises a battery terminal (or "terminal bushing"). The battery part 100 can be formed from lead, lead alloy, and/or other suitable materials by forming (e.g., cold-forming, cold-forming with a segmented mold, hot-forming, roll- forming, stamping, etc.), casting (e.g., die casting), forging, machining, and/or other suitable methods known in the art. In one aspect of this embodiment, the battery part 100 includes a projecting portion or lug portion 104 that extends from a base portion 103. The battery part 100 can also include a passage or through-hole 106 extending through the battery part 100 from a first end portion 101 to a second end portion 102.

[0020] In another aspect of this embodiment, the base portion 103 includes a first torque-resisting feature 105 spaced apart from a second torque-resisting feature 107. In the illustrated embodiment, the first torque-resisting feature 105 includes a first flange 112 and the second torque-resisting feature 107 includes a second flange 114. Each of the first and second flanges 112 and 114 projects from the base portion 103 and extends around the battery part 100. In other embodiments, however, battery parts configured in accordance with the present disclosure can include one or more flanges that extend only partially around the base portion of the battery part.

[0021] Each of the first and second flanges 112 and 114 is configured to resist torsional or twist loads that are applied to the battery part 100 after it has been joined to a battery container (as described in more detail below). More particularly, in the illustrated embodiment the first flange 112 has a polygonal shape (e.g., a hexagonal shape) with a plurality of flat, or at least generally flat, side portions 113a- f. Similarly, the second flange 114 also has a polygonal shape (e.g., a hexagonal shape) with a plurality of flat, or at least generally flat, side portions 115a-f. Accordingly, the first and second flange portions 112 and 114 of the illustrated embodiment have non-circular peripheries which are different than annular flanges having circular peripheries, and the cross-sections of the first and second flange portions 112 and 114 vary around periphery of the battery part 100. The shapes of the first and second flange portions 112 and 114 can enhance the ability of the battery part 100 to resist torsional loads in use. As discussed in greater detail below, however, in other embodiments battery parts configured in accordance with the present disclosure can include more or fewer flanges (e.g., torque flanges) or flange portions having other shapes. These flange or flange portion shapes can include, for example, polygons (e.g., octagons, hexagons, pentagons, squares, rectangles, triangles, etc.), rectilinear shapes, curvilinear shapes, non-circular shapes, circular or partially-circular shapes, symmetrical shapes, non-symmetrical shapes, irregular shapes, saw-tooth shapes, sun-burst shapes, star patterns, cross- shapes, peripheral teeth, serrations, flat surface portions, angular surface portions, concave surface portions, convex surface portions, etc. Battery parts configured in accordance with the present disclosure can also include other torque-resisting features such as other types of flanges, portions of flanges, lips, protrusions, and/or other projections that extend around, or at least partially around, the battery part 100 with non-circular peripheries. Such torque-resisting features can also include recessed portions or indentations in the battery part 100. In addition, in various embodiments the first flange 112 can have a different shape than the second flange 114. Accordingly, the present invention is not limited to hexagonal-shaped or polygonal-shaped torque-flanges, but extends to other flanges, flange portions and other torque-resisting features having other shapes. Additionally, other embodiments of the invention can include battery terminals, terminal bushings, and other battery parts having configurations that may differ from that illustrated in Figure 1. For example, battery terminals and other battery parts having lugs and/or other features that may differ from that shown in Figure 1 can also include aspects of the present invention disclosed herein.

[0022] In a further aspect of this embodiment, the base portion 103 includes a sealing portion 109 positioned between the first flange 112 and the second flange 114. In the illustrated embodiment, the sealing portion 109 includes a first sealing ring 108 and a second sealing ring 110. The sealing rings 108 and 110 can be annular in shape and extend around the base portion 103. As described in greater detail below, the annular rings can interface with the battery container material which is molded around them to form a torturous path-type seal to inhibit or prevent electrolyte or acid from escaping the battery container. In other embodiments, battery parts configured in accordance with the present disclosure can include other types of sealing portions, sealing rings, and/or other sealing features that extend around, or at least partially around the base portion 103.

[0023] Figure 2 is an end view of the battery part 100. As this view illustrates, in this embodiment the first flange 112 has a hexagonal shape with a first non-circular periphery 221, and the second flange 114 has a hexagonal shape with a second non-circular periphery 222. In this embodiment, the first non-circular periphery 221 has a first maximum outer dimension 206, and the second non-circular periphery 222 has a second maximum outer dimension 208 that is greater than the first maximum outer dimension 206. Accordingly, in this embodiment, the second flange 114 has a greater overall width than the first flange 112. In other embodiments, however, the first flange 112 can have a greater width than the second flange 114. In still further embodiments, the first and second flanges 112 and 114 can be the same size or at least approximately the same size.

[0024] Figure 3 is a side cross-sectional view of the battery part 100 taken along line 3-3 in Figure 2. In the illustrated embodiment, the battery part 100 can have an overall length 320 of from about .75 inch to about 2 inches. For example, the overall length 320 can be from about 1 inch to about 1.5 inches, or about 1.2 inches. In other embodiments, the battery part 100 can have other lengths. In another aspect of this embodiment, the lug portion 104 can have a length 332 of from about .25 inch to about 1.25 inches. For example, the lug portion length 332 can be from about .5 inch to about .88 inch, or about .7 inch. In other embodiments, the lug portion 104 can have other lengths. In a further aspect of this embodiment, the lug portion 104 can have a base diameter 322 of from about .4 inch to about 1.5 inches. For example, the lug portion base diameter 322 can be from about .5 inch to about 1 inch, or about .7 inches. In other embodiments, the lug portion 104 can have other base diameters. In a further aspect of this embodiment, the first flange 112 can have a first across-the-flats dimension 334, and the second flange 114 can have a second across-the-flats dimension 336. In the illustrated embodiment, the first across-the-flats dimension 334 can be from about .5 inch to about 1 inch, such as about .7 inch, and the second across-the-flats dimension 336 can be from about .5 inches to about 1.2 inches, such as about .8 inches. In other embodiments, the first and second flanges 112 and 114 can have other across-the-flats dimensions. As those of ordinary skill in the art will appreciate, the various dimensions discussed above are merely representative of some embodiments of the present disclosure. Accordingly, the present disclosure is not limited to these dimensions and other embodiments can have dimensions greater than, less than, and/or otherwise different than those described above without departing from the spirit or scope of the present disclosure.

[0025] In the illustrated embodiment, the first and second sealing rings 108 and 110 have generally round outer edges 310 and 312, respectively. In addition, each of the sealing rings 108 and 110 tapers slightly in cross-section as it projects outwardly from the base portion 103 of the battery part 100. Although the illustrated embodiment discloses two sealing rings 108 and 110 having generally round outer edges 310 and 312, respectively, in other embodiments, battery parts configured in accordance with the present disclosure can include more (e.g., 3, 4, 5, etc.) or fewer (e.g., 1 or 0) sealing rings and/or other sealing features having other configurations. For example, in other embodiments, battery parts configured in accordance with the present disclosure can include acid rings, sealing rings, and other sealing features having generally flat outer edges, pointed outer edges, angled outer edges, etc. In further embodiments, battery parts configured in accordance with the present disclosure can include acid rings, sealing rings and/or other acid sealing features at least generally similar in structure and function to those described in US Patent Application No. 11/011 ,362 and US Patent No. 7,338,539, both of which are incorporated herein in their entireties by reference. Accordingly, the present disclosure is not limited to the particular types of sealing portion and/or features illustrated in Figure 3, but extends to other types of acid rings, sealing rings, sealants, sealing compounds, and/or other sealing features known in the art. Furthermore, in other embodiments a suitable sealant may be used in conjunction with the one or more of the sealing rings 108 and 110. In addition or alternatively, in further embodiments one or both of the sealing rings 108 and 110 may be omitted, or they may be replaced by annular grooves, indentations, and/or other features in the base portion 103. In such embodiments, sealing may be facilitated with a suitable sealant or other compound.

[0026] The passage or through-hole 106 has a first opening 330 proximate the base portion 103 and a second opening 326 proximate the lug portion 104. In the illustrated embodiment, the first opening 330 can have a first diameter of from about .3 inch to about .8 inch, or about .55 inch, and the second opening 326 can have a second diameter of from about .3 inch to about .5 inch, or about .4 inch. In one aspect of this embodiment, flaring the through-hole 106 toward the distal end of the base portion 103 as shown in Figure 3 may advantageously reduce the amount of lead required to make the battery part 100. As those of ordinary skill in the art will appreciate, however, in other embodiments the through-hole 106 can have other dimensions and/or other shapes without departing from the spirit or scope of the present disclosure. Furthermore, in yet other embodiments, the through-hole 106 can be omitted.

[0027] Figure 4 is a side cross-sectional view of a battery part 400 that is generally similar in structure and function to the battery part 100 described above with reference to Figures 1-3. For example, the battery part 400 includes a base portion 403 having a plurality of sealing features (e.g., a first sealing ring 408 and a second sealing ring 410) positioned between a first flange 412 and a second flange 414. In the embodiment of Figure 4, however, the battery part 400 includes a through-hole 406 that tapers inwardly slightly from a first opening 430 proximate the distal end of the base portion 403, to a slightly smaller second opening 426 proximate the distal end of a lug portion 404.

[0028] Figure 5 is a side cross-sectional view of a portion of a battery assembly 540 configured in accordance with an embodiment of the invention. In one aspect of this embodiment, the battery part 100 is fixedly attached to a battery casing or container 542 so that the lug portion 104 is exposed and accessible. The battery container 542 can be formed from a moldable material 548, such as polypropylene, polyethylene, other plastics, thermoplastic resins, and/or other suitable materials known in the art. During manufacture of the battery assembly 540, molten container material 548 can be flowed around the base portion 103 of the battery part 100 so that the first flange 112 is embedded in the container material 548 adjacent to an inner surface portion 546 of the battery container 542, and the second flange 114 is embedded in the container material 548 adjacent to an outer surface portion 544. The container material 548 also forms around the first and second sealing rings 108 and 110 to create a seal that can prevent or at least inhibit liquid, e.g., electrolyte, acid, water, etc. from escaping the battery container 542. After the battery part 100 has been secured to the battery container 542 as illustrated in Figure 5, the through- hole 106 can be filled with molten lead or other suitable material to form a mechanical and electrical connection to a battery grid (not shown) within the battery container 542.

[0029] One advantage of the embodiment illustrated in Figure 5 is that the two, spaced apart flanges 112 and 114 can increase the ability of the battery container 542 to hold the battery part 100 in place when a force, such as a torsional or twisting force, is applied to the lug portion 104 of the battery part 100. In addition, the offset flanges 112 and 114 can also enhance the sealing capability of the interface between the battery part 100 and the container 542.

[0030] Figures 6A-6D are a series of isometric views illustrating battery parts 600a-600d, respectively, configured in accordance with other embodiments of the invention. Many aspects and features of the battery parts 600a-600d can be at least generally similar in structure and function to corresponding aspects and features of the battery parts 100 and 400 described in detail above with reference to Figures 1- 5. The battery parts 600a-600d, however, include other flange and flange portion configurations encompassed by the present disclosure. In Figure 6A, for example, the battery part 600a includes first and second flanges 612a and 614a, respectively. Each of the first and second flanges 612a and 614a include a series of protrusions 613 and 615, respectively, extending outwardly from the battery part 600a in an undulating sunburst pattern. Referring next to Figure 6B, the battery part 600b includes first and second flanges 612b and 614b, respectively, which have rectangular or square shapes. Referring next to Figure 6C, the battery part 600c includes first and second flanges 612c and 614c, respectively, which include a plurality of flat-sided, rectilinear protrusions 613c and 615c, respectively, extending outwardly from the battery part 600c. Turning next to Figure 6D, the battery part 60Od includes first, second, and third flanges 612c, 613d, and 614d, respectively. In this embodiment, at least a first sealing ring 608 is positioned between the first and second flanges 612d and 613d, and at least a second sealing ring 610 is positioned between the second and third flanges 613d and 614d.

[0031] The various battery parts described above can be manufactured from lead, lead alloys, and/or other suitable materials known to those of ordinary skill in the art. In addition, these parts can be manufactured by any suitable manufacturing method such as die casting, cold forming, roll forming, stamping, forging, machining, etc. For example, in one embodiment, the battery parts described herein can be formed by cold-forming with a segmented mold, such as a segmented mold having two segments. In addition, various embodiments of the battery parts described herein can be formed in accordance with methods disclosed in, and can include features at least generally similar to, those disclosed in US Patent No. 5,349,840, which is incorporated herein in its entirety by reference. [0032] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the various embodiments of the invention. For example, although many of the Figures described above illustrate battery parts having cylindrical portions (e.g., cylindrical lug portions, base portions, sealing rings, through-holes, etc.), in other battery parts configured in accordance with the present disclosure these portions can have one or more flat sides and/or other non-cylindrical surfaces. Further, while various advantages associated with certain embodiments of the invention have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited, except as by the appended claims.

Claims

CLAIMSI/We claim:

1. A battery part comprising: a base portion configured to be at least partially embedded in battery container material, wherein the base portion includes: a first torque-resisting feature configured to resist torsion of the battery part; and a second torque-resisting feature spaced apart from the first torque- resisting feature, wherein the second torque-resisting feature is configured to resist torsion of the battery part.

2. The battery part of claim 1 , wherein the first torque-resisting feature includes a first projection extending outwardly from the base portion, and wherein the second torque-resisting feature includes a second projection extending outwardly from the base portion.

3. The battery part of claim 1 wherein the first torque-resisting feature includes a first flange portion that extends at least partially around the base portion, and wherein the second torque-resisting feature includes a second flange portion that extends at least partially around the base portion.

4. The battery part of claim 1 wherein the battery part includes a first end portion spaced apart from a second end portion, wherein the first torque-resisting feature is positioned toward the first end portion, and wherein the second torque- resisting feature is positioned between the first torque-resisting feature and the second end portion.

5. The battery part of claim 1 wherein each of the first and second torque- resisting features includes a plurality of flat side portions.

6. The battery part of claim 1 wherein the base portion further comprises at least one sealing portion positioned between the first and second torque-resisting features.

7. The battery part of claim 6 wherein the at least one sealing portion includes at least one ring that extends at least partially around the base portion.

8. The battery part of claim 6 wherein the at least one sealing portion is shaped differently than the first and second torque-resisting features.

9. The battery part of claim 6 wherein the first torque-resisting feature includes a first flange portion having a plurality of flat sides, wherein the second torque-resisting feature includes a second flange portion having a plurality of flat sides, and wherein the at least one sealing portion includes at least a portion of an annular ring.

10. The battery part of claim 6 wherein the first torque-resisting feature includes a first flange portion having a polygonal shape, wherein the second torque- resisting feature includes a second flange portion having a polygonal shape, and wherein the at least one sealing portion includes a plurality of annular acid sealing rings.

11. A battery terminal comprising: a base portion; a lug portion extending from the base portion; a first flange positioned on the base portion; a second flange positioned on the base portion and spaced apart from the first flange, wherein the first and second flanges have non- circular peripheries; and a sealing portion positioned on the base portion between the first and second flanges.

12. The battery terminal of claim 11 wherein at least one of the first and second flanges has a generally flat side portion.

13. The battery terminal of claim 11 wherein at least one of the first and second flanges has a hexagonal shape.

14. The battery terminal of claim 11 wherein the second flange is positioned between the first flange and the lug portion, and wherein the second flange is larger than the first flange.

15. The battery terminal of claim 11 , further comprising a passage having a first opening proximate the lug portion and a second opening proximate the base portion.

16. The battery terminal of claim 11, further comprising a passage having a first opening proximate the lug portion and a second opening proximate the base portion, wherein the second opening is larger than the first opening.

17. The battery terminal of claim 11 wherein the sealing portion includes at least one annular ring.

18. A battery assembly comprising: a container formed from moldable material, the container having an inner surface portion spaced apart from an outer surface portion; and at least one battery part, wherein the battery part includes: a first torque-resisting feature at least partially embedded in the moldable container material adjacent to the outer surface portion of the container; a second torque-resisting feature at least partially embedded in the moldable container material adjacent to the inner surface portion of the container; and at least one sealing portion embedded in the moldable container material between the first and second torque-resisting features.

19. The battery assembly of claim 18 wherein the first torque-resisting feature includes a first flange portion configured to resist torsion of the battery part, wherein the first flange portion is at least partially embedded in the moldable container material adjacent to the outer surface portion of the containers second flange portion configured to resist torsion of the battery part, wherein the second flange portion is at least partially embedded in the moldable container material adjacent to the inner surface portion of the container;

20. The battery assembly of claim 18 wherein the at least one sealing portion includes a plurality of acid sealing rings.

21. The battery assembly of claim 18 wherein at least one of the first and second flange portions includes at least one flat side portion.

22. The battery assembly of claim 18 wherein the first and second flange portions are non-circular.

23. A battery terminal comprising: a base portion configured to be at least partially embedded in battery container material, wherein the base portion includes: first means for torsionally securing the battery terminal to the container material; second means, spaced apart from the first means, for torsionally securing the battery terminal to the container material; and means for sealing an interface between the battery terminal and the container material.

24. The battery terminal of claim 23 wherein the means for sealing liquid an interface are positioned between the first means for torsionally securing and the second means for torsionally securing.

25. The battery terminal of claim 23 wherein at least one of the first and second means for torsionally securing has a flat side portion.

26. A method of manufacturing a battery part, the method comprising: forming a first flange portion toward a first end of the battery part, the first flange portion having a non-circular periphery; forming a second flange portion between the first flange portion and a second end of the battery part, the second flange portion having a non-circular periphery; and forming at least one sealing portion between the first and second flange portions.

27. The method of claim 26 wherein forming a first non-circular flange portion includes forming at least one flat side portion.

28. The method of claim 26 wherein forming at least one sealing portion includes forming at least one annular sealing ring.

29. The method of claim 26 wherein forming a first non-circular flange portion includes forming the first non-circular flange portion from at least one of lead and a lead alloy.

30. The method of claim 26 wherein forming a first non-circular flange portion includes cold forming the first non-circular flange portion from at least one of lead and a lead alloy.