Abstract: A method and apparatus for continuous, high-speed production of punched strip having an array of high-tolerance closely-spaced holes with positive ejection of waste punch-out material. A first pair of opposed rotary dies, one a female die and the other a male/female die, punches a first set of holes in a strip fed continuously between the dies, and a second pair of opposed rotary dies, one the male/female die and the other a male die, punches a second set of holes in the strip between the first set of holes, the strip being wrapped about the common male/female die during punching of the first and second sets of holes to continuously index the strip with the two opposed pairs of rotary dies to ensure production of the high-tolerance closely-spaced holes.

Abstract: A method and apparatus for continuous, high-speed production of strip having an array of high-tolerance closely-spaced holes forming a continuous grid structure having wires bent out of the plane of the grid. The strip can be produced by continuous casting, extruding or by rolling reduction methods and the holes can be formed such as by linear punching and rotary punching.

Abstract: A method and apparatus for continuous, high-speed production of punched strip having an array of high-tolerance closely-spaced holes with positive ejection of waste punch-out material. A first pair of opposed rotary dies, one a female die and the other a male/female die, punches a first set of holes in a strip fed continuously between the dies, and a second pair of opposed rotary dies, one the male/female die and the other a male die, punches a second set of holes in the strip between the first set of holes, the strip being wrapped about the common male/female die during punching of the first and second sets of holes to continuously index the strip with the two opposed pairs of rotary dies to ensure production of the high-tolerance closely-spaced holes.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A reduced weight lead-acid battery is produced incorporating light-weight negative battery plates each comprising an electrically-conductive open mesh grid formed from a strip of expanded, punched or cast metal, a pair of outer lower density support layers such as polymer or polymer-coated glass fibre or low density metal on each side of the central open grid, preferably arranged in a rectangular lattice, attached to each other through openings in the grid preferably by an acid-resistant adhesive, and an electrochemically-active paste saturating the void spaces thereof. An acid-resistant thermoplastic resin adhesive or ties or lugs may be used to attach the support layers together.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: An apparatus for gripping, guiding and transporting opposite longitudinal side edges of slit, deformable strip for forming expanded mesh sheet. One chain of each of two pairs of opposed endless chains has a longitudinal recess adjacent a longitudinal planar side edge of the strip for receiving the planar edge of the strip therein and the opposed chain of each of said pairs has a plurality of equispaced sharp projections for penetrating the longitudinal planar side edge of the strip whereby the said edge is effectively gripped between the opposed chains during expansion.

Abstract: The strip is cast on a chilled casting surface of a rotating drum from a pool of the molten metal contained in a tundish having a graphite lip insert seated therein cooperating with, the casting surface adjacent to the tundish to form and contain the pool of the molten metal. The tundish preferably contains a feed chamber, a return chamber, and a diverting chamber, the feed chamber and the diverting chamber effectively removing turbulence from the molten feed and the return chamber having a vertically adjustable weir dividing the return chamber from the diverting chamber for controlling the surface level of the pool of molten metal in the diverting chamber and the lip insert and for diverting a flow of molten metal to the return chamber. A preferred lead alloy is a low antimony-lead alloy which is cast into strip and is subjected to a heat treatment to permit expansion and shaping in subsequent production of expanded mesh battery grids.

Abstract: A method and an apparatus are disclosed for forming expanded mesh sheet from deformable strip by the steps of concurrently slitting and preforming the strip to provide transverse bands of slit and elongated wire segments projecting alternately from opposite sides of the plane of the strip separated by transverse bands of unslit strip, slitting the strip at alternate bands to extend slit segments in a staggered relation and laterally expanding the slit and preformed strip. Concurrent slitting and preforming and subsequent slitting can be effected by a cluster of three rolls or by a linear arrangement of pairs of opposed rolls.The invention has particular utility in forming expanded mesh sheet of exact final dimensions for use as battery grids from lead or lead alloy strip.

Abstract: A method of forming elongated slit segments in deformable strip includes concurrently slitting and preforming the strip by intermeshing substantially convexly shaped tool surfaces each having a linear leading portion and a linear trailing portion joined by a rounded apex portion. The linear leading and trailing portions are collinear with and generally define portions of the sides of a triangle which has a base with a length equal to the length of the strip being slit. The length of the side of the triangle corresponding to and collinear with the leading portion is less than the length of the side of the triangle corresponding to and collinear with the trailing portion, and the angle formed between the side of the triangle corresponding to the leading portion and the base is not greater than 90.degree..

Abstract: A method and an apparatus are disclosed for forming expanded mesh sheet from deformable strip by the steps of concurrently slitting and preforming the strip to provide transverse bands of slit and elongated wire segments projecting alternately from opposite sides of the plane of the strip separated by transverse bands of unslit strip, slitting the strip at alternate bands to extend slit segments in a staggered relation and laterally expanding the slit and preformed strip. Concurrent slitting and preforming and subsequent slitting can be effected by a cluster of three rolls or by a linear arrangement of pairs of opposed rolls.The invention has particular utility in forming expanded mesh sheet of exact final dimensions for use as battery grids from lead or lead alloy strip.