Abstract: A novel battery dumping apparatus is described which is uniquely suited for dumping corrosive substances, such as battery acid, simultaneously from a number of batteries. The novel apparatus generally comprises a sealed tube adapted for rotation through an arc of less than 360 degrees for inverting batteries contained therein. Novel sealing and pouring means disposed at opposite ends of the tubular member provide for safe collection of the dumped corrosive liquids. Four inflatable members of novel construction are appropriately positioned within the tube for the purpose of selectively gripping groups of batteries to be inverted. The inflatable members are pressurized for engaging the batteries and are vented to an evacuated tank to release them. A novel hydraulic piston is utilized as a safety interlock to prevent batteries in the inverted position from being released by the inflated gripping members.

Abstract: A novel high rate battery testing apparatus and method are disclosed. The high rate terminal blocks are adjustably mounted to service batteries with various terminal posts spacings. After indexing and alignment, each battery to be processed is located and clamped by a high rate test head, to create high quality electrical contact with the terminal blocks of the apparatus, after which a load is connected across the battery terminals to effect the testing operation. The terminal blocks are preferably of the same configuration as the molding templates used to mold the battery terminals, thereby ensuring precise alignment and excellent contact between the battery terminals and the water cooled terminal blocks.

Abstract: A novel tidal and wave-power collection apparatus is disclosed which is well suited for oceanic installations. In the preferred embodiment, a matrix of power collection units is easily assembled at sea, each being bridged and reinforced by catwalks extending therebetween which form trilateral power collection modules having such units at each of the corners thereof. Each power collection unit comprises a central tubular pilaster embedded in the ocean floor around which is disposed a toroidal float which moves up and down with the waves and tide and which acts to drive an air compressor while rising and falling. The output of the air compressor, i.e. compressed air, is stored in the float's chamber and is transmitted through conduits in the bridging structure to a remote power consumption site. The apparatus is efficient, economical and capable of capturing and storing large quantities of power which may be utilized to satisfy peak load power demands.

Abstract: A novel battery dumping apparatus is described which is uniquely suited for dumping corrosive substances, such as battery acid, simultaneously from a number of automotive batteries. The novel apparatus generally comprises a sealed tube adapted for rotation through an arc of less than 360 degrees. Within the tube are disposed two parallel spaced apart baffles which together form a sealed battery processing channel. This battery processing channel is pierced by a plurality of rods disposed in a plane which bisects the aforementioned baffles. These rods are ultimately caused to rotate in opposite directions by a gear drive disposed outside of said battery processing channel but within said tubular member. These gears are, in turn, caused to drive said rods by a pneumatic motor which is mounted outside of said tubular member.

Abstract: A novel burnishing apparatus and method for burnishing the terminal posts of lead-acid batteries is disclosed. The burnishing brushes are adjustably mounted to service batteries with various terminal posts spacings. After indexing and alignment, each battery to be processed is located and clamped by a battery processing head, after which the burnishing carriage which is slidably mounted thereon is moved relatively towards and away from the battery terminals to bring the burnishing brushes into contact with the battery terminals to effect the burnishing operation. The direction of rotation of the burnishing brushes is reversed when the burnishing brush carriage begins to withdraw from the battery terminals.

Abstract: A novel "cast-on" method and apparatus are disclosed wherein in the preferred embodiment only one major moving part is provided which is indexed through various positions to cast a group or element from a battery plate stack engaged thereby. In the preferred embodiment, a mold carriage block having a plurality of mold voids formed therethrough slidingly reciprocates along a base plate on which are defined fluxing (loading), casting and part-release positions. In the casting position, lead gravitationally siphons into the mold voids defined in the mold carriage through molten lead supply orifices defined in the base plate along which the carriage slides. Once the casting operation is completed, sliding the carriage out of the casting position effectively seals the molten lead supply orifices. The apparatus and method are particularly suited for use by a single operator who manually loads stacks into the apparatus and subsequently unloads completed groups or elements from the apparatus.

Abstract: Battery plate elements and separator elements are maintained in racks along opposite sides of a conveyor. Pivotally swingable vacuum pickup heads serve to withdraw plates and separators from their racks and deposit them onto the conveyor. A plurality of plates or separators are withdrawn simultaneously, and the conveyor is indexed from withdrawal station to withdrawal station for stacking the plates and separators one upon the other, alternately, whereby at any given time a plurality of plate and separator sandwiches are being formed, in different progressive stages. Capability is provided for adjustments for handling different sized plates and separators as well as the number of elements in a given stack. Synchronous drive means and adjustable vacuum means are disclosed.

Abstract: The present invention provides a novel electrode construction for use in extrusion-fusion type battery intercell welders, which alters the current carrying characteristics of the electrodes and produces a homogeneous weld exhibiting a superior grain structure, higher strength, and superior durability.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertial stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.

Abstract: Batteries are moved along a first roller type conveyor to a leak testing station, above which is located an assembly having a plurality of nozzles matable over battery cell inlets. A first set of alternate cells is supplied with air at a given pressure, and metering means notes pressure change. Thereupon, the remaining alternate cells receive the same treatment. If the cells do not leak, the battery advances from the testing station along the roller conveyor. If a leak is detected, a push bar connected to a cable system below the rollers ejects the battery transversely from the testing station along to a second conveyor, thereby isolating leaky batteries either for removal or further testing to locate more precisely the leak.

Abstract: Containers, such as batteries, battery cases and the like, are moved along a first conveyor to a leak testing station, above which is located an assembly having means matable over the openings in the top of the container. The container is supplied with air at a given pressure, and metering means notes pressure change. If the container does not leak, the container advances from the testing station along the conveyor. If a leak is detected, a reject means ejects the container transversely from the testing station along a second conveyor, thereby isolating leaky containers for further processing.

Abstract: A novel method of producing storage battery lead alloy parts is provided comprising the steps of (a) providing a grid mold having a mold substrate consisting essentially of aluminum, (b) hard surface anodizing at least a portion of said mold substrate to produce molding surface thereon, (c) introducing molten lead alloy into such mold against said molding surface and (d) allowing said lead alloy to cool to form said storage battery grid. Other steps which may be included as a novel method of the present invention including texturing the mold substrate prior to the hard surface anodizing step to form a discontinuous surface thereon, which texturing step may be accomplished by peening said substrate with shot, blasting said substrate with glass beads, or blasting said substrate with sand.

Abstract: A novel apparatus for forming lead-acid storage battery plate envelopes from a continuous roll of heat sealable separator material is described comprising material feed means for supplying material from the roll for use in the envelope, draw means for drawing preselected lengths of separated material into a processing position, cut-off means for severing predetermined lengths of material at the processing position into envelope forming lengths, means for folding said envelope forming lengths around a plate into a folded configuration wherein overlapping edges of separator material protrude beyond at least one side edge of said plate and sealing means for heating edges of said material under pressure to seal said overlapping edges to form said battery plate envelope.

Abstract: A novel battery dumping apparatus is described wherein a tubular member having openings at each of the opposing ends thereof for allowing the passage of storage batteries therethrough is externally supported and engaged for reciprocal rotation. The interior of the tubular member is defined into a plurality of longitudinally extending acid proof channels, at least one of which has a conveyor therein for selectively moving batteries therethrough. Unitary inflatable gripping members disposed within this battery processing channel grip and engage the batteries to be dumped as the tubular member is rotated to invert the batteries to dump acid therefrom.

Abstract: A system is provided whereby the vapors that are given off during wet-cell battery formation are drawn directly from the batteries through openings in the cells thereof, into conduits that are readily accessible to an operator, and with the vapors further being drawn into a duct through which they may be delivered for neutralizing, for eventual discharge to atmosphere. A novel nozzle is provided capable of introduction onto the tops of any of the three different standard sized batteries during forming, which nozzles in addition to collecting vapors that are given off during wet-cell battery formation further collect a pre-selected amount of atmospheric gas for combination with said vapors, which selection reduces the explosive potential of the collected fluids during subsequent environmentally acceptable processing.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. A novel molding means is described comprising a structural member composed of aluminum or other high heat transfer material, which is adapted to interchangeably engage an aluminum mold member which mates with a structural housing and which actually forms the voids in which the melting and casting processes take place. The mold members, which are also composed of aluminum or other high heat transfer material, are provided with a novel mold coating consisting essentially of aluminum oxide formed through a hard surface anodizing process.

Abstract: Batteries are moved along a first roller type conveyor to a leak testing station, above which is located an assembly having a plurality of nozzles matable over battery cell inlets. A first set of alternate cells is supplied with air at a given pressure, and metering means notes pressure change. Thereupon, the remaining alternate cells receive the same treatment. If the cells do not leak, the battery advances from the testing station along the roller conveyor. If a leak is detected, a push bar connected to a cable system below the rollers ejects the battery transversely from the testing station along to a second conveyor, thereby isolating leaky batteries either for removal or further testing to locate more precisely the leak.

Abstract: In a system for sequentially processing batteries with battery processing equipment an apparatus is described for retaining each of said batteries in at least one standby position, for advancing each of said batteries to at least one battery processing position, for aligning each of said batteries with respect to said battery processing equipment during the operation of said equipment, and for allowing the discharge of each of said batteries from said battery processing position. Said apparatus comprises a conveyor surface defined by a plurality of transverse rollers, at least two of which rollers which are spaced apart by a distance at least as great as the longitudinal dimension of said batteries to be processed, are adapted for movement with respect to said surface between first normal positions and second stop positions, whereby longitudinal movement of at least two of said batteries along said surface is halted at said standby and said battery positions by said rollers and said stop positions.

Abstract: Containers, such as batteries, battery cases and the like, are moved along a first conveyor to a leak testing station, above which is located an assembly having means matable over the openings in the top of the container. The container is supplied with air at a given pressure, and metering means notes pressure change. If the container does not leak, the container advances from the testing station along the conveyor. If a leak is detected, a reject means ejects the container transversely from the testing station along a second conveyor, thereby isolating leaky containers for further processing.