Abstract: An improved battery grid for use in lead-acid batteries has been formed which has resistance to the detrimental effects of grid growth. The improved battery grid has been formed to relieve stress at predetermined locations. Specifically, stress is released by having an overdeveloped reticulum and/or flexible junctions including where the reticulum meets the frame and/or by having either no borders or borders which are released from the reticulum through use of the battery. This battery grid can be a positive grid formed on a continuous casting machine and has a growth relief mechanism to accommodate the condition of imperfect grain formation without interruption of the reticulum.

Abstract: A continuous casting machine is disclosed of the type having a rotary casting drum with a mold cavity machined thereon, and a shoe in close engagement with the mold cavity so as to disperse molten media therein. The casting drum is formed from a series of ring segments that are interconnectable to form a shell having any desired width. By adding or subtracting ring segments, the width of the shell can be adjusted to the desired production specifications. In addition, a pressure control system is provided which is placed in fluid communication with the mold cavity via flow pathways through the casting drum upon rotation thereof. The pressure control system is operable for evacuating the mold cavity just prior to dispersion of molten media therein, and for subsequently ejecting the cast product upon solidification thereof.

Abstract: The present invention is directed to a method of manufacturing battery grids. In particular, a method of simultaneously casting multiple battery grid strips on a continuous casting machine is provided. The mold includes a bipartite grid cavity having a pair of adjacent grid cavity segments which communicate with each other through a common groove such that the resultant dual grid strip formed thereon includes a corresponding pair of grid strip segments that are interconnected by a series of flexible or frangible nodes. A dual grid strip can be folded along the flexible or frangible nodes to form a layered grid strip. The layered grid strip is then pasted with an active material and cut into individual battery plates.

Abstract: A continuous casting machine is disclosed of the type having a rotary mold cavity movable relative to a shoe in fluid communication with a source of molten casting material. The shoe has a main body defining an internal passageway and a discharge slot leading from the internal passageway to an outer surface of the shoe. The shoe also has an inlet and an outlet connecting the internal passage to the source of molten casting material. A heating mechanism is positioned within the internal passageway and is controlled for heating the molten casting material flowing through the passageway prior to its discharge from the discharge slot.

Abstract: A machine for casting battery grids continuously includes a rotary, cylindrical drum in the outer peripheral surface of which the battery grid cavity is machined in the form of a plurality of intersecting axially and circumferentially extending grooves. A shoe is arranged in close fitting, mating engagement with an arcuate segment of the peripheral surface of the drum. The shoe has a molten lead passageway therein which communicates with the peripheral surface of the drum by means of an orifice slot extending lengthwise of the shoe and across the drum. Molten lead under superatmospheric pressure is directed into a tube extending lengthwise within the lead passageway in the shoe and provided with a plurality of openings spaced lengthwise of the tube. The lead is discharged through these openings into the lead passageway, through the orifice slot and against the surface of the drum.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it advanced beyond the opening of the orifice slot.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it advanced beyond the opening of the orifice slot.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it advanced beyond the opening of the orifice slot.

Abstract: A continuous casting machine for battery grids includes a rotary drum on the outer peripheral surface of which the battery grid pattern is formed by a series of grooves. The peripheral surface of the drum mates with a shoe through which molten lead is directed into the grooves as the drum rotates. The outer periphery of the drum is a shell that is connected to rotary side plates by means of roll pins that enable the shell as a whole to expand and contract independently of the side plates. The drum is maintained at a desired temperature to solidify the molten lead directed into the grooves of the battery grid pattern by circulating a heated liquid through the drum.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it is advanced beyond the opening of the orifice slot.

Abstract: A machine for casting battery grids has a rotary drum, the pattern of the battery grid cavity being recessed into the outer periphery thereof. An arcuate shoe is fixedly positioned against the rotating drum in sliding contact with the outer peripheral surface thereof. The shoe has an internal passageway connected to an orifice slot which extends to the periphery of the drum. The orifice slot is connected at one end to a source of molten lead under pressure and at its other end to a return line. The molten lead in the orifice slot is under superatmospheric pressure. The rate of flow of the molten lead through the orifice slot is in excess of that required to fill the grid cavity.

Abstract: A battery cover arrangement for a battery having symmetrically disposed posts of opposite polarity including abutments on at least some of the posts and opposing projections on the underside of the cover which prevent the posts from fully extending through apertures in the cover when the cover is mis-oriented with respect to the polarity of the posts and polarity indicia on the cover.

Abstract: An intercell connector assembly including a connector with an opening on an upstanding collar at each end, a bushing with radial and cylindrical flanges and a battery post projecting through the bushing and extending above the cylindrical flange and the collar to provide, when melted down, the metal to fill the cavity between the post and the collar.

Abstract: Methods for positive displacement casting and/or for positive displacement bonding and, more particularly, for automatically locating the bonding apparatus with respect to the workpieces, locking thereon, and, thereafter forming, on a continuous, reproducible basis, fusion bonds devoid of structural, electrical and cosmetic defects between two or more workpieces by moving a heated electrode into the area to be bonded so as to uniformly heat and melt the portions of the workpieces to be bonded while, at the same time, displacing substantially all of the molten material from the area to be bonded into a storage area or reservoir surrounding the heated electrode where such molten material is maintained in its uniformly heated molten state, and then retracting the electrode so as to permit the molten material to return to the cavity formed by the electrode in the workpieces where such molten material is allowed to cool and solidify, thus forming a flawless bond between the workpieces--thermal or fusion bonds are