Abstract: A leak-proof package for at least one defective battery containing corrosive liquid. The inventive package has at least three layers and includes an inner container configured to accept the battery therewithin, a fluid-impermeable intermediate container sealing the inner container therewithin, and an outer container enclosing the intermediate container such that the liquid-containing defective battery is protectively packaged for leak-free transportation. Another aspect of the present invention is a method for packaging at least one battery containing corrosive liquid by loading the battery into the inner container which is sealed within the intermediate container inside the locked outer container such that the liquid-containing defective battery is protectively packaged for leak-free transportation.

Abstract: A leak-proof package for at least one defective battery containing corrosive liquid. The inventive package has at least three layers and includes an inner container configured to accept the battery therewithin, a fluid-impermeable intermediate container sealing the inner container therewithin, and an outer container enclosing the intermediate container such that the liquid-containing defective battery is protectively packaged for leak-free transportation. Another aspect of the present invention is a method for packaging at least one battery containing corrosive liquid by loading the battery into the inner container which is sealed within the intermediate container inside the locked outer container such that the liquid-containing defective battery is protectively packaged for leak-free transportation.

Abstract: A heater unit for dispensing metered portions of molten lead includes a cavity capable of selectively receiving a metered portion of molten lead from the lead reservoir. The heater unit is moveable between a first position for receiving lead into the lead reservoir and a second position for dispensing molten lead from the cavity.

Abstract: A method of dispensing metered portions of molten lead comprises the steps of providing a heater body with a lead reservoir that produces sufficient heat to form molten lead and providing a lead dispensing shuttle plate with at least two lead metered cavities that are filled with molten lead in a fill position. The heater body is movable between a dispense position and a feed position. At least one of the metered cavities releases the molten lead when the heater body is moved to the dispense position. In one aspect, the method comprises supplying a strip of lead so that when the heater body moves to the feed position, it receives a portion of the strip of lead. In another aspect, the method comprises injecting inert gas over the lead reservoir and into the dispensing metered cavity to prevent air from entering the metered cavity.

Abstract: A battery terminal connection assembly for connecting a terminal to a cable is disclosed. The assembly preferably includes a conductive cable fitting for connection to a cable, a conductive terminal connector having an arm adapted to engage the terminal, a cold-flow-resistant sleeve positioned in and bonded to the connector, the sleeve defining a bore for receiving the cable fitting, and a tensioning member adapted to connect to and urge the cable fitting into contact with the bore. When assembled, the tensioning member ensures electrical contact between the cable and the terminal. The invention also includes a battery terminal and cable connection arrangement utilizing such a connection assembly.

Abstract: A telescopically adjustable holddown (10) is disclosed including first and second brackets (16,18) and drawing elements (12) adapted to extend between a battery tray (14) and the brackets for drawing the brackets toward the battery tray to hold a battery (2). The brackets each include a generally L-shaped clamp (20) having top (22) and side members (24) for abutting the top (3) and sides (4) of the battery. An ear (26) extends from each side member and includes an aperture (36) for receiving a bolt (12) extending from the battery tray. Each bracket includes a cross rod (17,19) with second cross rod (19) having a cavity (46) for slidably receiving the first cross rod (17). The cavity requires that relative movement of the first and second brackets be substantially along the cavity axis (50) to allow telescopic assembly of the first and second brackets. The brackets are drawn toward the battery tray by tightening nuts (13) on the bolts to prevent relative movement of the brackets.

Abstract: A battery container with battery plates contained therein is retained by a container positioner. A battery cover is retained by a cover positioner. Molten lead is retained within a lead dispenser/heater unit. The exposed areas of the lead dispenser/heater unit are preferably flooded with an inert gas to prevent drossing of the molten lead. A container heating platen is disposed on a top of the lead dispenser/heater unit and a cover heating platen on a bottom thereof. The container positioner brings the battery container in contact with the container heating platen and the cover positioner brings the battery cover in contact with the cover heating platen. Molten lead is dispensed into the battery cover; the lead dispenser/heater unit is withdrawn; and the battery container is sealed against the battery cover while the lugs of the battery plates are inserted into molten lead in the battery cover.

Abstract: A telescopically adjustable holddown (10) is disclosed including first and second brackets (16,18) and drawing elements (12) adapted to extend between a battery tray (14) and the brackets for drawing the brackets toward the battery tray to hold a battery (2). The brackets each include a generally L-shaped clamp (20) having top (22) and side members (24) for abutting the top (3) and sides (4) of the battery. An ear (26) extends from each side member and includes an aperture (36) for receiving a bolt (12) extending from the battery tray. Each bracket includes a cross rod (17,19) with second cross rod (19) having a cavity (46) for slidably receiving the first cross rod (17). The cavity requires that relative movement of the first and second brackets be substantially along the cavity axis (50) to allow telescopic assembly of the first and second brackets. The brackets are drawn toward the battery tray by tightening nuts (13) on the bolts to prevent relative movement of the brackets.

Abstract: A battery assembling method includes a lead dispenser/heater unit, cover positioner, container positioner, and lead feeder. A battery container with battery plates contained therein is retained by the container positioner. A battery cover is retained by the cover positioner. Molten lead is retained within the lead dispenser/heater unit. The exposed areas of the lead dispenser/heater unit are preferably flooded with an inert gas to prevent drossing of the molten lead. A container heating platen is disposed on a top of the lead dispenser/heater unit and a cover heating platen on a bottom thereof. The container positioner brings the battery container in contact with the container heating platen and the cover positioner brings the battery cover in contact with the cover heating platen.

Abstract: The invention involves a battery connector electrically connecting a multi-strand automotive-type cable to an automotive-type battery terminal where the battery connector is comprised of a connecting portion for engagement with an automotive-type battery terminal and a rigid cable-attachment portion that includes a non-deformable neck that extends from the connecting portion and defines a cavity having a depth, a closed inner end, an open outer end and a cross-sectional area that is substantially equal along the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable. Solder is secured within the cavity, and flux is secured within the cavity in contact with the solder. The solder and flux are both of amounts suitable for soldering engagement of the cable to the cable-attachment portion, thereby facilitating soldering of the automotive-type cable to the battery connector.

Abstract: An improved battery design which utilizes the cover of the container as a mold to simultaneously create a plurality of solid cast electrical circuits, including external terminals, all without welded connections. The battery cover includes a plurality of plate strap mold wells or mold wells which receive molten lead. Adjacent plate strap mold wells are separated by a partition wall. An aperture is formed in the partition wall which allows molten lead to flow between adjacent plate strap mold wells and connect thereof. Terminal mold wells have terminal apertures through which molten lead flows to form an external terminal with the aid of a external terminal mold. A meltable sealant material is pre-applied to the plurality of mold wells and which becomes fluid upon introduction of molten lead. Upon cooling, the sealant material prevents migration of electrolyte between mold wells.

Abstract: A battery connection apparatus for gang-connecting batteries together includes a terminal on a battery and a connector coupled to the terminal. The connector and terminal are resiliently snap-fitted to one another. The apparatus employs what may be termed a "ball-and-socket" arrangement in which a male portion (whether on the battery or on the connector) snap-fits into a female portion. Resiliency is provided by "springy" split finger pieces or by a compressed resilient core-like component. Using the new apparatus, batteries may be gang-connected horizontally or vertically and, essentially, without the use of tools.

Abstract: Method and apparatus for manufacturing storage batteries. The method is directed toward manufacture of a storage battery with a single weld between intercell connectors, positive and negative plates and external terminals. The apparatus comprises a frame, holding and positioning components, a lead dispensing assembly and an edge-heater assembly for sealing the battery case. The apparatus and inventive method permit dispensing of molten lead into selective segments of the battery case substantially simultaneously with sealing of the battery case.

Abstract: An improved storage battery and method for manufacture. The battery includes a case with first and second walls, surrounding wall structure and partitions forming first, last and at least one middle cells, each containing a group of positive and negative plates and electrolyte. The first wall inner surface forms positive and negative lead-containing wells in alignment with the wells of adjacent cells, and an intercell connector across each partition and held in fluid-tight engagement with the case in position to electrically connect the lead in one well of a middle cell to the lead in a well of the adjacent cell.

Abstract: A method for manufacturing storage batteries including: molding plastic to integrally preform bottom and side walls and partitions to form first, last and at least two middle cells, the bottom wall having upwardly projecting ridges with upper edges below the electrolyte fill level forming positive and negative wells which extend to the partitions and are in alignment with the negative and positive wells, respectively, of the adjacent cells; placing an intercell connector across each partition below the fill level to be held by the case in position extending from one middle-cell well to a well in the adjacent cell; pouring molten lead into each well, the lead in each well of each middle cell engaging an intercell connector; inserting a cell group of plates into each cell, the plates having lower portions immersed in the molten lead in the wells before hardening; and closing the container by sealing a top wall to the side walls.

Abstract: A battery with a case with bottom, top and side walls and partitions forming first, last and at least one middle cells, each containing a group of positive and negative plates and electrolyte to a fill level, characterized by preformed unitary bottom and side walls and partitions having hermetically sealed surfaces and junctures, each cell floor forming positive and negative lead-containing wells in alignment with the wells of adjacent cells, and an intercell connector across each partition below the fill level and held in fluid-tight engagement with the case in position to electrically connect the lead in one well of a middle cell to the lead in a well of the adjacent cell. A method for manufacture of such battery.

Abstract: An improved adjustable crimping tool having jaws each with a die wheel, each jaw and die wheel having aligned non-round apertures therethrough, and for each jaw and die wheel an axle through the non-round apertures having axially aligned first and second portions selectively engageable with the non-round apertures, the jaw and die wheel non-rotatable on the first portion and rotatable on the second portion.

Abstract: Connectors which are essentially, by weight, 85% to 93% copper, with silicon in the amount of 1.5% to 2.5% is disclosed. The balance of the material is zinc, desirably in the range of 5% to 12%. Trace elements of tin, lead and aluminum can be tolerated but should be minimized to less than 0.05%. Ideally the material is 81% to 91% copper, 1.75% to 2.4% silicon and the balance zinc of 6% to 10%. The traces may be 0.05% tin, 0.01% lead, and 0.005% aluminum.

Abstract: A method and apparatus for presenting fasteners seriatim at a predetermined position in a predetermined orientation for subsequent transfer or fastening. The invention includes a container for jumbled similar fasteners, reciprocating or other lifting means having an arm extending to a distal end within the container, and passive pickup means on the distal end configured to receive a fastener from among the jumbled fasteners and hold it by cradling as the pickup element moves upwardly through the jumbled fasteners to a position thereabove. The method and apparatus can repetitively present one type of fastener to one position, an array of one type of fastener to several positions, or an array of plural types of fasteners to plural positions.

Abstract: Disclosed is a cable connector in which a body portion has an anchor and anchor connector. A cable clamp of flat material with threaded edges at one end is provided with an interior cable grip in the form of a hole. A cable clamp slot is provided in the body of the connector to receive the flat cable clamp. After the strand end of the cable is inserted into the cable grip hole, a cable clamp nut threadedly engages the nut threads of the cable clamp and moves the clamp into a tight gripping relationship with the cable. In assembling, the cable clamp is force-fitted into the cable clamp slot. To assure alignment, and deburring so that the strand end of the cable will enter the connector easily, a tool is employed to align the cable clamp hole with the cable tube portion of the body, while at the same time deburring the table clamp.