Abstract: An apparatus and method for fusing the ends of battery cell terminal posts and the ends of hollow bushings fixed in the plastic cover of a battery being assembled and within which the terminal posts are concentrically disposed. The apparatus includes a pair of induction heating coils which each concentrically support a mold cavity insert adapted to receive the ends of the terminal posts and bushings to be fused and a ferrite insert adapted to concentrate induced current in the ends of the terminal post and bushings upon energization of the coils. An electrical control is provided for selectively generating a radio-frequency oscillating current in the coils to effect heating, melting, and fusion of the ends of the terminal posts and bushings to consistent fusion depths while the plastic battery case remains substantially uneffected.

Abstract: An apparatus and method for supplying electrode plates in the assembly of battery cell elements. The apparatus includes a shuttle feed device for containing a plurality of stacks of electrode plates of common polarity and successively dispensing a single plate from each stack, a walking beam transfer device for successively receiving plates from said shuttle device and moving the plates into a row with the plates commonly oriented and in predetermined spaced relation, and a plate loader for simultaneously engaging and removing from said walking beam transfer device the number of plates of common polarity required in the assembly of a battery cell element. The feeding device is adapted for easy plate loading, and in conjunction with the transfer device, is adapted to provide a reliable supply of electrode plates for use in the automated assembly of cell elements.

Abstract: A method and apparatus for controlling a work function, such as, for example, welding, requiring the control of at least one parameter according to a predetermined sequence, the apparatus including at least one work station where the work function is carried out, a slave controller associated with the work station for controlling the work function, at least one interface operably connected to the slave controller capable of receiving and storing information for a first parameter of the work function and preventing transmission of the parameter information to the slave controller until being probed by the slave controller, and a master controller operably connected to the interface to transmit thereto the parameter information, and the master controller being further operably connected to the slave controller to cause the slave controller to probe the interface to allow transmission of the parameter information to the slave controller.

Abstract: An apparatus for welding through-the-partition intercell connections in a lead-acid battery container wherein each partition has at least two spaced apertures therein for making such intercell connections includes in the exemplary embodiment three weld stations and a crimping station through which the containers are sequentially conveyed, and the containers are aligned and retained at dual positions in each station so that the welding or crimping operation can be carried out. A microprocessor based programmable controller serves as a master control to operate the apparatus, and a slave control is associated with each welding station.

Abstract: A method and apparatus for reliably assembling battery cell elements having relatively large numbers of electrode plates separated by a single interleaved spacer.

Abstract: The present invention relates to a titanium wire reinforced lead composite electrode support structure for use in lead-acid batteries comprising a titanium wire reinforced cast lead composite having titanium wires embedded in a cast lead matrix. The composite support structure may be made in the form of a lead grid for use in Faure type batteries, as a support structure for tubular type batteries, or as plates for use in Plante type batteries.

Abstract: A lead-based alloy containing, based upon the total weight of the alloy, 0.8-1.6% antimony, 0.08-0.16% arsenic, 0.006-0.012% silver and, optionally, 0.2-0.5% tin, is disclosed for making lead-acid battery grids using a continuous casting process.

Abstract: An improved battery charger apparatus having a control circuit providing different charging periods which are automatically correlated with the type of battery connected to the charge for charging the connected battery to a preselected full charge state. The apparatus has a charging circuit for charging the battery, a sensing circuit for sensing the state of the battery during charging thereof by the charging circuit and a circuit for determining first and second predetermined reference voltage/current states.The apparatus causes the charging of the battery at a preselected initial charging level for an initial time period and establishes a first finish time period.

Abstract: A timing circuit for charging motive power batteries (B). The timing control circuit (25) provides different times of charge in accordance with the time at which a predetermined voltage/current state of the battery is achieved. Control circuit (25) cooperates with a controller (18) in causing termination of the charging operation immediately upon reaching of the voltage/current state if this occurs in a first time slot of an initial control time period. The timing circuit (25) provides an automatic finish time period of charge if the battery (B) reaches the predetermined voltage/current state at some time during the initial control time period. The control includes a switch (23) permitting the user to cause an automatic additional amount of charging upon completion of the normal charging cycle effected by the control, such as for effecting a weekend charge.

Abstract: A process for metal-enrichment of lead bullion, wherein an alkali metal-desired metal intermetallic, such as sodium-antimony intermetallic, is added as a refining dross to the bullion and the desired metal is stripped from the dross and recovered as an enriched bullion. The process includes the steps of heating the lead bullion, in which the desired metal is to be recovered, to a temperature between 650.degree. F. and 900.degree. F.; agitating the molten bullion; adding said alkali metal-desired metal intermetallic to said bullion; mixing said intermetallic into said bullion; adding a stripping reagent for stripping said desired metal from said intermetallic; forming a desired metal-enriched lead bullion and a residue dross substantially void of said desired metal; and separating said enriched bullion from said residue dross. The process may also require a cleansing step to cleanse said enriched lead bullion of any said alkali metal in solution.

Abstract: An improved process for refining lead bullion containing antimony, in which the bullion is initially heated in a refining vessel to about 25.degree. F. (14.degree. C.) above the bullion melting point, and is thereafter kept molten primarily by exothermic process reactions. The process includes the steps of melting the lead-antimony bullion, agitating the bullion, adding caustic soda and metallic sodium to form an antimony-rich skimmable refining dross comprising a sodium-antimony intermetallic and separating the dross from the refined bullion. Along with antimony, other elements, such as arsenic, cadmium, copper, nickel, silver, sulfur, selenium, tellurium and zinc, if present in the bullion, are also removed in the dross by the sodium. The antimony-rich dross is accumulated for subsequent use. The process further comprises a cleansing operation wherein sodium present in solution in the refined bullion is removed using cleansing agents. This refining process is performed at a temperature between 600.degree.

Abstract: A batch process for desilverizing and refining lead bullion containing antimony and a low silver content, including the steps of melting the lead bullion, adding calcium to form a floating silver-rich dross containing a silver-antimony-calcium compound and separating the dross from the desilverized, molten lead bullion. The process further comprises a plurality of successive batch operations wherein silver-rich dross is separated and accumulated in each batch operation for subsequent processing. The successive batch operations are maintained at about 400.degree. C. in order to effect significant savings in energy, time and labor over processes previously used.

Abstract: An element stack and a method of making same is provided in which assembling a relatively large number of relatively small electrode plates into an element stack is facilitated by positioning a first set of electrode plates onto a strip of separator material in pre-selected locations and then affixing such plates to the strip. The resulting product may then be readily processed into the element stack by insertion of a second set of electrode plates of opposite polarity to the first set and then folding the separator in accordion fashion. The assembly method is amenable to automation and the resulting cell element stack may be handled as a unit thereby facilitating battery assembly.

Abstract: A maintenance-free, lead-acid cell that is capable of achieving long cycle life in deep discharge rapid recharge applications is sealed, has positive grids formed from antimony-lead alloys containing no more than about 2 wt. % of antimony, has negative grids formed from alloys that are essentially antimony-free, has highly porous, easily wetted separator material interposed between the plates which is capable of wicking the electrolyte, and provides a sufficient void volume to facilitate gaseous oxygen transport, and has the electrolyte required for operation of the cell substantially completely absorbed in the plates and separators, with the separators not being completely saturated.

Abstract: Metal/oxygen cells such as zinc/oxygen cells using air as the source of oxygen are provided with a cathode comprising a unitary member which, in a preferred embodiment, satisfies all of the diverse requirements for a cathode in this type of cell, the unitary member consisting of a hydrophobic portion and a hydrophilic portion comprising an ion exchange material which carries the desired amounts of an oxygen reduction catalyst. In a preferred embodiment, the oxygen reduction catalyst likewise serves as the current collector.

Abstract: A lead oxide for use in making an active material for pasted lead-acid battery plates comprises a doped lead oxide, the dopant preferably being copper in an amount of about 0.01 to about 0.07 percent based upon the total weight of the lead oxide. The use of such a doped oxide imparts to the resulting battery improvement in various of the electrical performance characteristics such as, for example, internal resistance, capacity, cycle life and the like.

Abstract: A battery vent plug providing repeated relief of a pressure condition within a battery at relatively low internal pressures. The vent plug is arranged to prevent dropping of the internal pressure to zero upon venting while yet having a small relief-reseal pressure range. The vent plug includes a relief valve within a housing defined by a rubber cylinder releasably engaging an annular seat on the housing about an inlet to a vent chamber within the housing. The rubber cylinder is maintained under a preselected compression assuring sealing thereof to the seat at pressures below a preselected venting pressure. Upon removal of the sealing portion of the cylinder from the seat, the pressurized gas escapes around the cylinder and through a hole in the housing to atmosphere.

Abstract: A battery termination structure wherein a connector post is mounted to the battery case in such a manner as to permit clamping of an electrical connector element, such as a ring tongue connector, to the post without substantial clamping strain transmission to the battery case. The connector post is retained in a recess provided in the case by an inturned retainer at the outer end of the recess which serves to prevent withdrawal of the assembly from the recess. The connector post is associated with the case so as to prevent rotation thereof as during connection of the electrical connector element to the post.

Abstract: This invention is directed to a lead-acid battery utilizing a novel electrolyte which includes a silica component. The silica component includes silica particles, means for repelling the particles from each other and for catalyzing the formation of siloxane cross-linkages and a sulfuric acid component. The lead-acid battery includes a container, a plurality of electrodes substantially enclosed by the container, and an electrolyte in substantial physical contact with the plurality of electrodes.A novel separator material having a silicate component for use in a lead-acid battery is also included in this invention. The separator material includes a silicate component integrally mixed with an oxygen compound of boron forming a microfiber mat. The mat has a pore size between about 0.5 to 10 microns in diameter and an electrical resistance of about 0.01 ohms per square inch for a 0.05 inch thickness.

Abstract: A vent plug for use in batteries, such as lead acid batteries. The vent plug is provided with a flame arresting vent passage portion defined by a plurality of elongated small cross section flow passages. The vent plug is adapted for low cost manufacture as by injection molding of separate parts thereof in accurate dimensional coordination. The flame arrestor passages, in the illustrated embodiment, are formed by projecting portions on one of the plug elements extending into fitted engagement with the other of the elements.