Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: An apparatus and method for fusing intercell connectors to battery cell terminal posts. The apparatus includes inexpensive, non-metallic molds, each having a mold opening and being positionable onto a connector with the mold opening in aligned relation to a terminal post positioned in a connector opening for defining a mold cavity adjacent an end of the terminal post and the connector opening. A selectively positionable induction heating head is provided for locating an induction heating coil in predetermined spaced relation to a terminal post and connector to be fused such that generation of a high frequency, oscillating current in the coil causes melting and fusion of the terminal post and connector with the mold retaining and forming the molten lead. The induction heating head may be manually positionable for use with batteries with different post locations and orientations and includes safety and position locating features.