Abstract: A system for assembling, processing and transferring battery cell elements including a plurality of element assemblers and an exit conveyor having a plurality of element conveying lanes. Each element assembler includes element transfer and processing apparatus comprising an endless chain conveyor having a plurality of longitudinally spaced element carriers adapted to successively engage an element at a loading station, carry the engaged element through a plurality of process stations, and release the element at a discharge station. In the illustrated apparatus, the carriers each engage a loosely assembled element at the loading station, compress the element to final size, and carry the element through an inspection and manual unload station, a plate alignment station, a plate lug brushing station, a plate alignment after brushing station, and a series of tape applicator stations which bind the element in assembled and processed condition.

Abstract: A method of casting metal straps on lugs of battery cell elements utilizes an electrically heatable mold having a strap cavity section and comprises introducing strap metal into the cavity section, conducting electrical current through the mold for heating the mold to a predetermined temperature in excess of the melting temperature of the strap metal, immersing the element lugs into the cavity, cooling the mold to a temperature below the solidification temperature of the strap metal and removing the element lugs from the cavity with straps cast thereon.

Abstract: An improved battery structure permitting facilitated replacement of an air supply tube through an air lift pump. The air lift pump includes, as guide means, a funnel portion receiving the inserted distal end of the replacement air supply tube for automatically guiding the distal end downwardly therethrough and into the passage of a depending barrel in which percolation of the electrolyte of the battery is effected by the bubbling of air downwardly through the air supply tube into the barrel. The upper end of the barrel is provided with an outlet tube extending downwardly into the electrolyte, thereby avoiding splashing of the electrolyte, such as against the flash arrester vent of the battery, thereby reducing maintenance and permitting long, troublefree life of the battery. The air supply tube and outlet tube may be formed of a transparent synthetic resin, permitting observation of the air flow during operation.

Abstract: A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold.

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: A method and apparatus for providing a compound (22) in each of the cell spaces of a multicell battery case (10). The compound comprises a bituminous material delivered to a plurality of the cell spaces concurrently through a plurality of nozzles (25) of a dispensing head (24). The battery case (10) is accurately positioned against a back stop (45) and a forward stop (36). A sensor (49) determines the accurate alignment of the battery case (10) in the fill position and cooperates with a controller (81) for controlling operation of the automatic dispenser (23). In the dispensing operation, the nozzles (25) are moved along a first plurality of cells. The nozzles are then retracted and moved lengthwise of the case to be aligned with a second group of cells. The nozzles are then moved along the case cells while dispensing compound to the second group of cells.

Abstract: An apparatus and method for assembling battery cell elements having a plurality of electrode plates of alternating polarity separated by a continuous interleaved insulating sheet.

Abstract: A method and apparatus for assembling battery components including a battery case (10) having a plurality of divider walls (32) defining a plurality of side-by-side cell spaces (26,27,28,29,30,31) opening through a top portion of the case. A plurality of intermediate cell elements (34,35,36,37) are provided in the cell spaces intermediate the end cell spaces (26,31) and end cell elements (38,39) having terminal post portions (101) are inserted in the end cell spaces (26,31). The apparatus effects an automatic pickup of the cell elements at one or more insert stations from delivery conveyors (19,20) suitably positions the picked-up cell elements for proper polarity relationship in the inserted disposition within the battery case, and after moving the picked-up cell elements to overlying relationship with the battery case, inserts the cell elements automatically into the proper cell spaces.

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: 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: 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: 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 battery terminal post seal manufacture wherein a battery terminal post (14) is sealed to a battery case wall portion (12) by a body of sealing material (17) fixedly sealed to the terminal post and movably sealed to the portion of the battery case defining the opening (13) through which the terminal post extends. In one form, the sealing space (16) receiving the flowable sealing material is defined by inner and outer peripheral encircling ribs (18,19) on the terminal post. In another form, the outer closure (122) of the sealing space is defined by a cap (122) removably mounted to the terminal post end (123) by a threaded element (126). In another form, the terminal post is provided with a peripheral recess (227) within the battery case opening (213), with the post (214) having snug fit with the battery case in the opening so as to define the lowermost sealant dam.

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.