Metal working – Bias cutting of tubular stock
Patent
1984-04-13
1985-10-22
Goldberg, Howard N.
Metal working
Bias cutting of tubular stock
29730, B23P 1300
Patent
active
045479399
DESCRIPTION:
BRIEF SUMMARY
This invention relates to a plate for a secondary battery and to a method of manufacturing same.
It has been proposed to construct a plate for a multi-cell secondary battery incorporating a perimeter frame of thermoplastic material with a metal mesh spanning the area of the frame to provide support for the active battery paste. It is convenient when manufacturing such a plate for the mesh to also act as a current collector for that particular plate. It has been proposed to produce the frame and mesh assembly by moulding the plastic material of the frame insitu around the perimeter of, or part of the perimeter of the mesh.
In producing such an assembly problems have arisen due to the thermal contraction of the frame after moulding. This contraction frequently results in a buckling or distortion of the metal mesh which produces subsequent problems in the applying of the paste to the mesh, and particularly in regard to the promoting of the flow of the paste material through the openings of the mesh.
It is therefore the object of the present invention to provide a method of manufacturing battery plates for the above general construction which overcomes the problem of buckling of the mesh.
With this object in view there is provided a method of manufacturing a battery plate having a metal mesh element disposed within a moulded plastic frame with at least a portion of the mesh element embedded in the frame including the step of, forming in the exposed portion of the mesh after the frame has been moulded an array of depressions and/or projections to stretch the mesh and increase the nominal thickness of the mesh element.
By the term `nominal thickness of the mesh element` it is meant the thickness measured across the peaks of the projections on opposite sides of the mesh. If the peaks are not of a uniform height then the nominal thickness is measured across the mean height of the peaks on the opposite sides of the mesh element.
Preferably the exposed portion of the mesh element is subjected to a rolling or pressing operation to form the depressions and/or projections therein. Conveniently the forming of the mesh element provides projections on one side of the element and complementary depressions on the opposite side.
In the preferred form the mesh element is subjected to a forming operation that imparts a corrugated shape to the exposed portion thereof thus forming a series of alternate valleys and ridges when viewed from either side. The corrugations may be conveniently formed by a rolling operation.
The stretching of the mesh element resulting from the formation of the depressions and/or projections removes any buckling of the mesh element that may have developed as a result of expansion and contraction during moulding of the frame about the mesh element. The forming of the projections and/or depressions may be controlled relative to the plane of the frame so that after the forming operation the mesh is accurately positioned relative to the plane of the frame, and may thus be readily pasted with active paste material.
In one preferred form there is provided a battery plate frame moulded from theremoplastic material having a plurality of division elements disposed parallel to two opposite sides of the frame to form within the frame a plurality of side by side paste receiving areas, each battery paste receiving area having a metal mesh element spanning the area and embedded during moulding of the frame into portions of the frame forming at least two opposite sides of the paste receiving area, each mesh element having an array of depressions and/or projections formed therein after moulding of the frame to stretch the mesh element and increase the nominal thickness thereof.
Preferably each mesh element is formed into a corrugated shape, conveniently by a rolling operation.
The corrugations may be applied to the mesh elements of a frame having a plurality of side by side paste areas as described above by passing the frames through a pair of rollers. The rollers have peripheral surfaces contoured to apply the require
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Maplesden Alan K.
McDowall William L.
Echols P. W.
Goldberg Howard N.
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