Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: A battery part such as a battery terminal and method of making the same with the battery part having a sealing region or sealing bead located on a lateral face of the acid ring with the beveled sealing region increasing the resistance to leakage therepast as the container shrinks. Another embodiment of the invention comprises a battery part with a bifurcated acid ring end and a beveled end face. The invention further includes the method of forming a battery terminal with an end face of the acid ring having a bifurcated end lip and a beveled face that permits one to either use the battery terminal in an as is condition or in a flared condition wherein a lip on the acid ring is flared to form a beveled sealing region on the lateral face of the acid ring.

Abstract: Battery parts, such as battery terminals and bushings providing both top and front access for connection, and associated methods of manufacture and use are described herein. In one embodiment, a battery terminal can include one or more features for interlocking or engaging the adjacent battery container material to prevent or reduce separation between the battery part and the container material and prevent or reduce acid leakage. In one embodiment, the engagement feature can include raised, parallel lips, rims or flanges that extend upwardly along outer edges of a groove or channel formed in a surface of the battery part. The flanges can be deformed by a tool or otherwise so that they bend inwardly toward each other to at least partially close off the opening to the channel. When battery container material flows into the channel and hardens, it forms a bead or elongate bulb that interlocks and engages the battery part.

Abstract: A battery part such as a battery terminal and method of making the same with the battery part having a sealing region or sealing bead located on a lateral face of the acid ring with the beveled sealing region increasing the resistance to leakage therepast as the container shrinks. Another embodiment of the invention comprises a battery part with a bifurcated acid ring end and a beveled end face. The invention further includes the method of forming a battery terminal with an end face of the acid ring having a bifurcated end lip and a beveled face that permits one to either use the battery terminal in an as is condition or in a flared condition wherein a lip on the acid ring is flared to form a beveled sealing region on the lateral face of the acid ring.

Abstract: A battery part such as a battery terminal and method of making the same with the battery part having a sealing region or sealing bead located on a lateral face of the acid ring with the beveled sealing region increasing the resistance to leakage therepast as the container shrinks. Another embodiment of the invention comprises a battery part with a bifurcated acid ring end and a beveled end face. The invention further includes the method of forming a battery terminal with an end face of the acid ring having a bifurcated end lip and a beveled face that permits one to either use the battery terminal in an as is condition or in a flared condition wherein a lip on the acid ring is flared to form a beveled sealing region on the lateral face of the acid ring.

Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: A battery part such as a battery terminal and method of making the same with the battery part having a sealing region or sealing bead located on a lateral face of the acid ring with the beveled sealing region increasing the resistance to leakage therepast as the container shrinks. Another embodiment of the invention comprises a battery part with a bifurcated acid ring end and a beveled end face. The invention further includes the method of forming a battery terminal with an end face of the acid ring having a bifurcated end lip and a beveled face that permits one to either use the battery terminal in an as is condition or in a flared condition wherein a lip on the acid ring is flared to form a beveled sealing region on the lateral face of the acid ring.

Abstract: An apparatus and method for enhanced gravity casting wherein a portion of the mold is maintained in pressure contact with molten metal as it solidifies to allow the mold surface to follow the contraction of the solidifying metal. A further feature of the invention is the use of an air clearance between mold parts that is sufficient to allow air to escape but insufficient to allow molten metal to flow therepast.

Abstract: An apparatus and method for enhanced gravity casting wherein a portion of the mold is maintained in pressure contact with molten metal as it solidifies to allow the mold surface to follow the contraction of the solidifying metal. A further feature of the invention is the use of an air clearance between mold parts that is sufficient to allow air to escape but insufficient to allow molten metal to flow therepast.

Abstract: A mold and a method of casting a part wherein the casting surfaces of the mold including the nooks and crannies of the mold are bounded by pitted mold surfaces with the pitted mold surfaces having surface voids therein that are sufficiently small to prevent the molten metal to enter therein; however, when the molten metal is poured in the mold having the pitted surfaces the molten metal solidifies on top of the pitted surface without entering into the pits in the mold surface, yet at the same time the molten metal flows smoothly over all the mold surfaces including the structural nooks and crannies of the mold to form a cast product that is substantially free of voids and fissures.

Abstract: A method of cold forming a two-part battery terminal and a two-part cold formed battery terminal comprising a cold formed lead or lead alloy slug having a male fastener protruding from a one side of the cold formed slug with a head portion of the fastener rotationally retained and embedded in the battery terminal by cold formed lead or lead alloy.

Abstract: A mold and a method of casting a part wherein the casting surfaces of the mold including the nooks and crannies of the mold are bounded by pitted mold surfaces with the pitted mold surfaces having surface voids therein that are sufficiently small to prevent the molten metal to enter therein; however, when the molten metal is poured in the mold having the pitted surfaces the molten metal solidifies on top of the pitted surface without entering into the pits in the mold surface, yet at the same time the molten metal flows smoothly over all the mold surfaces including the structural nooks and crannies of the mold to form a cast product that is substantially free of voids and fissures.

Abstract: A cold-forming method of making a finished battery terminal with a necked down flange by first expanding the metal radially outward until the battery terminal die cavity is partially filled with metal and then upsetting the metal to complete the deformation filling of the battery, terminal die cavity and to simultaneously form a necked down region in the flange on the battery terminal.

Abstract: A battery terminal with high torque resistance utilizing three sided frusto-conical recesses and mating protrusions extending from the battery terminal and method of making the terminal by a cold forming process that forms a finished battery terminal from a preworked lead slug by driving one end of a punch through the slug to remove excess material and form an axial through hole, a second and third portion of the punch to close the die chamber and a fourth portion of the punch to radially expand the lead slug into a finished battery terminal. The dies for forming the battery terminal include a movable multiple-segmented die for collapsing radially inward around the slug and a frusto-conical die for forming the top portion of the battery terminal. An ejector sleeve removes the finished battery terminal after the cold forming process.

Abstract: A battery terminal with high torque resistance utilizing three sided frusto-conical recesses and mating protrusions extending from the battery terminal and method of making the terminal by a cold forming process that forms a finished battery terminal from a preworked lead slug by driving one end of a punch through the slug to remove excess material and form an axial through hole, a second and third portion of the punch to close the die chamber and a fourth portion of the punch to radially expand the lead slug into a finished battery terminal. The dies for forming the battery terminal include a movable multiple-segmented die for collapsing radially inward around the slug and a frusto-conical die for forming the top portion of the battery terminal. An ejector sleeve removes the finished battery terminal after the cold forming process.

Abstract: A theft alarm for an automotive hood ornament which utilizes simple components and can be installed without removing any factory installed parts. The switch is contained in a plastic and aluminum housing which is mounted to the automobile under the hood. A lever extends out from the housing and contains a slot for attaching a ball chain. The ball chain is connected at one end to the lever and at the other end to the retaining spring of the hood ornament. The switch is connected to the automobile's battery and horn. When a thief attempts to pull the hood ornament off the automobile the retaining spring compresses and pulls up on the ball chain and lever. The swtich closes and sounds the automobile's horn. Every attempt to remove the hood ornament is matched by the sound of the automobile's horn.