Abstract: An improved battery grid for use in lead-acid batteries has been formed which has resistance to the detrimental effects of grid growth. The improved battery grid has been formed to relieve stress at predetermined locations. Specifically, stress is released by having an overdeveloped reticulum and/or flexible junctions including where the reticulum meets the frame and/or by having either no borders or borders which are released from the reticulum through use of the battery. This battery grid can be a positive grid formed on a continuous casting machine and has a growth relief mechanism to accommodate the condition of imperfect grain formation without interruption of the reticulum.

Abstract: A continuous casting machine is disclosed of the type having a rotary casting drum with a mold cavity machined thereon, and a shoe in close engagement with the mold cavity so as to disperse molten media therein. The casting drum is formed from a series of ring segments that are interconnectable to form a shell having any desired width. By adding or subtracting ring segments, the width of the shell can be adjusted to the desired production specifications. In addition, a pressure control system is provided which is placed in fluid communication with the mold cavity via flow pathways through the casting drum upon rotation thereof. The pressure control system is operable for evacuating the mold cavity just prior to dispersion of molten media therein, and for subsequently ejecting the cast product upon solidification thereof.

Abstract: The present invention is directed to a method of manufacturing battery grids. In particular, a method of simultaneously casting multiple battery grid strips on a continuous casting machine is provided. The mold includes a bipartite grid cavity having a pair of adjacent grid cavity segments which communicate with each other through a common groove such that the resultant dual grid strip formed thereon includes a corresponding pair of grid strip segments that are interconnected by a series of flexible or frangible nodes. A dual grid strip can be folded along the flexible or frangible nodes to form a layered grid strip. The layered grid strip is then pasted with an active material and cut into individual battery plates.