MOLD ASSEMBLIES INCLUDING REMOVABLE INSERTS AND ASSOCIATED METHODS OF USE AND MANUFACTURE
Mold assemblies and associated methods and components for forming battery grids for lead acid batteries are disclosed herein. In one embodiment, a battery grid mold assembly includes a first die block that is movable relative to a second die block between an assembled position and an unassembled position spaced apart from the second die block. The mold assembly also includes a first insert plate having a first side that is removably coupled to the first die block and a second side opposite the first side. The second side of the first insert plate includes a first recess. The mold assembly further includes a second insert plate having a third side removably coupled to the second die block and a fourth side opposite the third side. The fourth side includes a second recess. When the first and second die blocks are in the assembled positions, the first and second recesses at least partially define a grid cavity that is configured to receive a flowable material for forming a battery grid.
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The present application claims priority under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/296,447, filed Jan. 19, 2010, and U.S. Provisional Application Ser. No. 61/348,671, filed May 26, 2010, the disclosures of which are incorporated herein by reference in their entireties.
TECHNICAL FIELDThe following disclosure relates generally to mold assemblies for producing lead components and, more specifically, to mold assemblies and associated removable inserts for producing battery grids for lead acid batteries.
The following disclosure describes mold assemblies and associated mold components for producing lead parts, such as battery grids for use in lead acid batteries. As described in greater detail below, a mold assembly configured in accordance with one aspect of the disclosure includes removable insert plates that are releasably secured to corresponding die blocks. The removable insert plates, rather than the die blocks, form a cavity for casting (e.g., gravity casting) a battery grid. Certain details are set forth in the following description and in
Many of the details, dimensions, angles, and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles, and features without departing from the spirit or scope of the present disclosure. In addition, those of ordinary skill in the art will appreciate that further embodiments of the disclosure can be practiced without several of the details described below.
In the Figures, identical reference numbers identify identical or at least generally similar elements. To facilitate the discussion of any particular element, the most significant digit or digits of any reference number refers to the Figure in which that element is first introduced. For example, element 110 is first introduced and discussed with reference to
As will be understood by one of ordinary skill in the art, the assembly 100 shown in
In one aspect of the embodiment illustrated in
In the illustrated embodiment, the assembly 100 also includes multiple ejectors 180 extending through the die block 110 and corresponding portions of the insert plate 150 and fill plate 130. The ejectors are movable relative to these components to eject a finished casting from the assembly 100 following a casting process. For example, the ejectors 180 can be spring-loaded plungers, hydraulic plungers, etc. that are actuated or otherwise moved to push a part (e.g., a lead grid) out of the insert plate 150 after casting.
According to yet another aspect of the illustrated embodiment, the assembly 100 includes multiple biasing members 178 (e.g., coil springs) positioned between the die block 110 and the insert plate 150. The biasing members 178 are configured to push or bias the insert plate 150 away from the die block 110 to facilitate the separation of the insert plate 150 from the die block 110. To further aid removal, the insert plate 150 includes one or more recesses 151 at a peripheral edge portion to at least partially receive a leverage member, such as a pry bar, to separate the insert plate 150 from the die block 110. In the illustrated embodiment, and as described in detail below, the fill plate 130 also includes fluid couplings 131. The fluid couplings 131 are configured to attach to a fluid source to allow a fluid (e.g., coolant) to flow through the fill plate 130 during operation.
Further details of several components of the assembly 100 are described below with reference to
In another aspect of the illustrated embodiment, the fill plate 130 includes an inclined face 335 extending from a top surface 333 to an interior side surface 337. The side surface 337 includes multiple protrusions or teeth 340 extending laterally away therefrom. The teeth 340 are configured to direct or otherwise promote the flow of the casting material into the assembly 100.
Referring next to the insert plate 150,
According to another aspect of the illustrated embodiment, the insert plate 150 includes the cavity 152 for forming a battery grid. More specifically, when the insert plate 150 is mated against a corresponding insert plate, the cavity 152 becomes enclosed and at least partially defines a closed grid cavity or recess that can be used to cast two battery grids that can be separated after casting. For example, the cavity 152 includes a peripheral frame portion 454, a web or grid portion 456 extending inwardly from the frame portion 152, and a current connector or lug portion 458 extending away from the frame portion 152. One of ordinary skill in the art will appreciate that the shape of the cavity 152 illustrated in the Figures is merely representative of one type of battery grid configuration. In other embodiments, the cavity 152 can be configured to include various battery grid shapes and/or configurations. Moreover, in still further embodiments, the cavity 152 can be configured to form other battery components or other types of components.
In certain embodiments, the insert plate 150 can be made from steel, such as P-20 steel. In other embodiments, however, the insert plate 150 can be made from other materials suitable for mold casting. Moreover, in one embodiment, the insert plate 150 is configured to weigh approximately 8 to 12 pounds, or 10 pounds, and the fill plate 130 is configured to weigh approximately 10 to 14 pounds, or 12 pounds. Accordingly, two insert plates 150 along with two fill plates 130 have a combined weight of approximately 44 pounds. In other embodiments, however, each of these components can have a weight that is greater than or lesser than the values stated above.
Referring to
The embodiments described herein, including the insert plate 150 that is removably secured to the die block 110, provide several advantages. More specifically, the relatively small size and weight of the insert plate 150 allows operators to easily remove the insert plate 150 to clean, coat, and/or otherwise treat the cavity 152. As noted above, in an embodiment configured to produce battery grids, the combined weight of two insert plates 150 and two fill plates 130 can be approximately 44 pounds, which is significantly lighter than the weight of a single die block 110. This reduction of weight can provide significant savings when shipping the insert plate 150 and/or fill plate 130 to be cleaned, coated, or otherwise treated. Moreover, in embodiments where the insert plate 150 is a separate component from the fill plate 130, these components can be shipped separately, or otherwise switched out at different intervals. This may be advantages in certain applications, for example, where a coating on each of these components deteriorates at different rates. For instance, the inventors have found that a coating on the cavity 152 in the insert plate 150 may deteriorate or otherwise become unusable more quickly than the same coating on the filler plate 130.
According to one feature of the embodiment illustrated in
From the foregoing, it will be appreciated that specific embodiments of the disclosure have been described herein in detail for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the disclosure. Further, while various advantages associated with certain embodiments of the disclosure have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the disclosure. Accordingly, the disclosure is note limited, except as by the appended claims.
Claims
1. A mold assembly for forming a battery grid for a lead acid battery, the mold assembly comprising:
- a first subassembly comprising— a first die block; and a first insert plate removably coupled to the first die block adjacent to the first fill plate, wherein the first insert plate includes a first recess; and
- a second subassembly configured to be removably coupled to the first subassembly, the second subassembly comprising— a second die block; and a second insert plate removably coupled to the second die block adjacent to the second fill plate, wherein the second insert plate includes a second recess, and wherein the first insert plate contacts the second insert plate and the first and second recesses at least partially define a grid cavity configured to receive a flowable material for forming a battery grid when the first subassembly is coupled to the second subassembly.
2. The assembly of claim 1, further comprising:
- a first fill plate removably coupled to the first die block; and
- a second fill plate removably coupled to the second die block, wherein the first fill plate contacts the second fill plate when the first subassembly is coupled to the second subassembly.
3. The assembly of claim 1 wherein:
- the first die block includes a first ejector opening;
- the first insert plate includes a second ejector opening that is aligned with the first ejector opening when the first insert plate is coupled to the first die block; and
- the assembly further comprises an ejector that is movable through the first and second ejector openings to eject a finished battery grid from the first recess.
4. The assembly of claim 1, further comprising at least one biasing member positioned between the first die block and the first insert plate when the first insert plate is coupled to the first die block, wherein the biasing member urges the first insert plate away from the first die block to facilitate separation thereof.
5. The assembly of claim 1 wherein:
- the first recess includes a peripheral frame portion and multiple grid channels extending within the peripheral frame portion; and
- the first insert plate includes multiple grid features positioned between adjacent grid channels.
6. The assembly of claim 5 wherein the first insert plate includes multiple vent holes passing through corresponding grid features, and wherein the individual vent holes are configured to allow gas to escape from the cavity as the flowable material fills the cavity.
7. The assembly of claim 6 wherein the first insert plate includes a first surface that contacts the first die block and a second surface opposite the first surface that contacts the second insert plate in the assembled position, and wherein the first surface includes one or more vent channels extending at least partially therethrough, wherein the one or more vent channels are aligned with one or more corresponding vent holes.
8. The assembly of claim 7 wherein individual vent channels have a width that is approximately the same as a cross-sectional dimension of the corresponding one or more vent holes.
9. The assembly of claim 1 wherein:
- the first die block includes an alignment features extending away therefrom; and
- the first insert plate includes an alignment opening that receives the alignment feature when the first insert plate is coupled to the first die block.
10. The assembly of claim 1 where in the first fill plate comprises:
- a body; and
- a fluid channel extending through at least a portion of the body and configured to receive a fluid different than the flowable material for transferring heat to or from the body.
11. A battery grid manufacturing assembly comprising:
- a first die block;
- a second die block movable relative to the first die block between a first position at least proximate to the first die block and a second position spaced apart from the first die block;
- a first insert plate having a first side removably coupled to the first die block and a second side opposite the first side, wherein the second side includes a first recess; and
- a second insert plate having a third side removably coupled to the second die block and a fourth side opposite the third side, wherein the fourth side includes a second recess, and wherein when the second die block is in the first position the first and second recesses define a grid cavity for forming a battery grid.
12. The assembly of claim 11, further comprising:
- a first fill plate removably coupled to the first die block adjacent to the first insert plate; and
- a second fill plate removably coupled to the second die block adjacent to the second insert plate, and wherein the second die block is in the first position the first and second fill plates are positioned to receive a flowable material and introduce the flowable material into the grid cavity.
13. The assembly of claim 11 wherein:
- each of the first and second recesses includes a plurality of grid channels; and
- each of the first and second insert plates includes a plurality of grid features extending between adjacent grid channels in the corresponding first and second recesses.
14. The assembly of claim 13 wherein at least one of the first and second insert plates includes a plurality of vent holes aligned with individual corresponding grid features.
15. The assembly of claim 14 wherein the at least one of the first and second insert plates includes a plurality of vent channels in the first side, and wherein individual vent channels are aligned with corresponding vent holes in the grid features of the first insert plate.
16. The assembly of claim 11, further comprising:
- a first alignment feature extending from the first die block and through at least a portion of the first insert plate when the first insert plate is coupled to the first die block; and
- a second alignment feature extending from the second die block and through at least a portion of the second insert plate when the second insert plate is coupled to the second die block.
17. The assembly of claim 11 wherein when the second die block is in the second position the second die block is spaced apart from the first die block by a distance that is approximately equal to a combined thickness of the first and second insert plates.
18. A method of making a battery grid, the method comprising:
- releasably securing a first insert plate to a first die block, the first insert plate having a first recess in a first surface opposite the first die block;
- releasably securing a second insert plate to a second die block, the second insert plate having a second recess in a second surface opposite the second die block;
- coupling the first die block at least proximate to the second die block in a molding position, wherein in the molding position the first surface of the first insert plate mates with the second surface of the second insert plate and the first and second recesses at least partially define a battery grid cavity;
- introducing a casting material into the battery grid cavity; and
- allowing the battery grid material to at least partially solidify in the battery grid cavity.
19. The method of claim 18, further comprising:
- removably securing a first fill plate to the first die block adjacent to the first insert plate;
- removably securing a second fill plate to the second die block adjacent to the second insert plate, wherein in the molding position the first fill plate mates with the second fill plate and the first and second fill plates at least partially define a fluid opening; and
- wherein introducing the casting material comprises introducing the casting material into the grid cavity via the fluid opening.
20. The method of claim 18 wherein after allowing the battery grid material to at least partially solidify, the method further comprises:
- removing the at least partially solidified battery grid material from the battery grid cavity; and
- removing at least one of the first and second insert plates from the corresponding first and second die blocks.
21. The method of claim 18, further comprising allowing the battery grid cavity to vent while introducing the casting material into the battery grid cavity.
22. The method of claim 18 wherein after allowing the battery grid material to at least partially solidify, the method further comprises ejecting the at least partially solidified battery material from at least one of the first and second recesses by contacting the at least partially solidified battery material with an ejector that moves through the corresponding first or second insert plates.
Type: Application
Filed: Jan 18, 2011
Publication Date: Jul 21, 2011
Applicant: Water Gremlin Company (White Bear Lake, MN)
Inventors: Michael A. Garin (Mahotmedi, MN), Tracy L. Cain (Forest Lake, MN)
Application Number: 13/008,673
International Classification: B22D 25/04 (20060101); B22C 9/00 (20060101); B22C 9/22 (20060101); B22D 29/00 (20060101);