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: 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: A battery side terminal assembly which includes a metal terminal insert keyed into the external portion of the battery side wall with a body portion which passes through an aperture in the side wall to the inner area of the battery container. The terminal insert is held in close contact with the battery side wall by a plastic ring which is force fit onto the body portion of the terminal insert. Subsequently a side terminal strap is resistance welded to the body portion of the insert to create a tightly sealed assembly. The plastic ring advantageously cooperates with the body portion of the insert and the strap to retain molten lead during the resistance welding operation.