Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-03-15
2001-10-30
Maples, John S. (Department: 1745)
Metal working
Method of mechanical manufacture
Electrical device making
C219S633000, C219S635000, C029S623200
Reexamination Certificate
active
06309429
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to batteries, and more particularly, to an improved method for bonding battery cell terminal posts to respective bushings in the battery casing to form terminals of the completed battery.
BACKGROUND OF THE INVENTION
In the manufacture of lead acid industrial and automotive storage batteries, it is customary to mold lead bushings in the plastic cover of the battery and to thereafter fuse the bushings to posts of the battery cell assemblies. Typically both the posts and bushings must be heated to temperatures above their melting points such that there is a fusion of the materials of the two components.
It has long been the practice to melt the ends of the posts and bushings by means of manually operated acetylene torches. Not only does such manual acetylene torch burning of the posts and bushings fail to lend itself to use in fully automated battery production lines, the quality and depth of the fused areas cannot be uniformly controlled. Moreover, particular care must be taken in not melting or otherwise damaging the portion of the plastic cover immediately adjacent the bushing, which can render the battery defective or sufficiently weaken the seal and support between the plastic cover and bushings as to create a potentially dangerous condition during use of the battery. Such acetylene torch burning, furthermore, is tedious and potentially harmful to the working environment, and it is difficult to control the flow of melted lead, resulting in unsightly irregularities in the surfaces of the finished battery terminals.
While various proposals have been made for automatically fusing battery terminal posts and cover bushings by means of acetylene torch heating, tungsten inert gas welding, electrical resistance heating, and electrical induction heating, such proposals all have faced various drawbacks, including the inability to obtain reliable fusion depths within the requisite processing time, undesirable melting of the cover about the bushings, unacceptable appearance of the finished terminals, or the necessity for utilizing auxiliary molds to control melted lead and achieve acceptable terminal appearance.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of bonding battery cell posts and casing bushings in forming battery terminals which can be carried out at lower heating temperatures than heretofore possible, and hence, reduces the possibility for melting of the plastic cover or damaging the seals between the bushings and the plastic cover.
Another object is to provide a method as characterized above that can be carried out without heating the battery cell posts above their melting temperature. A related object is to provide such a method that can be optimally controlled to more reliably prevent melting and damage of the plastic cover.
A further object is to provide a lead acid storage battery in which posts and cover bushings are bonded to form the battery terminals without the necessity for fusing and intermixing materials of the two components typical of the prior art.
Yet another object is to provide a lead acid storage battery of the above kind in which the cover bushings are formed of a solder material having a substantially lower melting temperature than the lead alloy of the battery cell posts to which they are bonded.
Another object is to provide a lead acid storage battery in which the cover has integrally formed mold sections completely surrounding the posts and bushings to form dams for the melted bushings during bonding and which mold the terminals in finished form.
A further object is to provide a battery of the foregoing type in which the integral mold sections of the cover aesthetically and protectively contain the battery terminals for the life of the battery.
Still another object is to provide such a lead acid storage battery in which the integral mold sections of the cover provide an alignment reference for positioning induction heating coils during bonding of the terminal posts and bushings for enhancing uniformity of the resulting bonds in automated battery production lines.
Yet another object is to provide a battery of the foregoing type in which the integral mold sections are bonded to a final outer cover of the battery to form a redundant seal between the cover and bushings for long term reliable usage.
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:
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Kump William H.
Lund David L.
Willing Rodger
GMB Technologies, Inc.
Leydig , Voit & Mayer, Ltd.
Maples John S.
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