Abstract: The invention relates to a device for fitting and equipping motor vehicle battery housings as a compact system, which comprises individual production stations and associated transport devices, wherein the battery plate packs to be processed are arranged in clamping cassettes and are provided to the device in the necessary pack width for the intended battery cells by a feeding station arranged upstream.

Abstract: The system includes a module fixture supporting a plurality of elements, the module fixture defining a plurality of bonding wells with each bonding well accepting a first portion of one or more of the elements with the module fixture including one or more apertures communicated with one or more of the bonding wells with the bonding wells having a nominal depth; and a dispensing system, coupled to the module fixture, for dispensing a high-wettability adhesive into each the bonding well and surrounding each the element substantially filling the bonding well up to the nominal depth without significant overfill, the adhesive being selectively curable upon application of a curing modality; and a curing structure for selectively exposing the adhesive to the curing modality as the adhesive emerges from the apertures during dispensation of the adhesive.

Abstract: A method for producing a stainless steel three-ply clad sheet for a fuel cell separator comprises heating a source blank and then performing rough rolling, hot rolling and cold rolling thereto, whereby the clad steel sheet for the fuel cell separator or a solid polymer type fuel cell separator thereby is obtained. The source blank for the clad steel sheet is composed of a stainless steel utilizing 0 to 0.3% B as a core component and a stainless steel containing 0.3 to 2.5% B as face component. The source blank is made using face components, a core component, tabs and protectors and performing steps including bonding of the tabs and protectors to the face components, removing portions of the tabs and protectors, piling of the face components to the core component, and further bonding of the face and core components together to form the source blank.

Abstract: Methods and systems for decreasing costs (expense, mass, and/or cure time) associated with use of adhesives when assembling modularized components, particularly for assemblies having many elements such as for example battery modules used in electric vehicles. The methods and systems enable use of high-wettability adhesives (defined generally in this application as low viscosity and/or low surface tension adhesives) for assembling such modularized components.

Abstract: A method and apparatus for welding of battery terminals to an interconnect includes: juxtaposing two or more battery cell terminals to each other to create a terminal stack including an innermost terminal and an outermost terminal; juxtaposing a battery cell interconnect with the innermost terminal of the stack; positioning an anvil in contact with the interconnect; directing an air stream against the outermost terminal so that the air stream compresses the terminal stack and urges the innermost terminal into contact with the interconnect; positioning a sonotrode horn in contact with the outermost terminal; and energizing the sonotrode horn to vibrate the terminal stack and thereby make an ultrasonic weld between the stacked terminals of the terminal stack and the interconnect. The air stream is directed at the terminal below the sonotrode horn to capture any debris and a suction removes the debris.

Abstract: A lead plate-attached coin-type battery is constituted from a combination of a coin-type battery and a positive lead plate. In the coin-type battery, a negative cap seals the aperture of a positive outer can. In a lateral view, the positive lead plate is crank-shaped, and one end thereof is attached to the outer surface of the positive outer can of the coin-type battery. A lead plate is not attached to the negative cap. One or more projections that project in the Z axis direction are provided on the negative cap. In the lead plate-attached coin-type battery, the positive lead plate and negative cap have been attached to respective conductive lands on a circuit board by a solder reflow method.

Abstract: The electrodes are formed by surface coating and cold compression on metal strips. They are then assembled, by hot pressing, with an electrolytic membrane. The metal strips are then removed, preferably by mechanical detachment. Current collectors are then formed on each of the electrodes by PVD type techniques that are conventional in microelectronics. The resulting thin micro-battery with high surface capacity can then be integrated in an integrated circuit, in particular by bonding by means of indium connecting balls.

Abstract: An improved bushing mold is disclosed for an apparatus for welding a battery terminal post to a battery bushing. The battery terminal post is electrically connected to a battery plate disposed within a battery case and the battery bushing is secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case. The bushing mold comprises an electrically conductive mold body having an insulating mold insert. The mold insert comprises a first and a second insert portion with the second insert portion being replaceable independent of the first insert portion.

Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: A plate of a battery is positioned so that a strap connected to the plate is located on a side of the plate, and a pedestal of a resin-wrapped post is fit in a notch formed in the strap. A first protection plate is installed between a contact portion of the pedestal with the notch and a resin portion of the resin-wrapped post, and a second protection plate is installed between the contact portion and the plate. A flame of a burner is applied onto the contact portion from above the strap and the pedestal at a spot between the both protection plates so as to weld the pedestal to the strap without causing the resin portion to become molten or the post from becoming misshapen.

Abstract: Process for spot-welding a flexible welding board to at least one and preferably a battery cells to form a battery pack, such as a NiCad battery pack. The flexible welding board is a nickel alloy material, laminated to a polyester film by a co-extruded adhesive. The spot-welding is accomplished by one spot-welder, and preferably two spot-welders, which spot-weld in alternating time intervals so as to assure electrical and electromechanical contact with each end of the battery cells by the nickel alloy material. The spot-welding is by DC current and voltage. The electrodes are small enough to form a configuration between the flexible circuit and the end of the battery cell. Three spot-welding electrodes would assume a triangular configuration. Four spot-welding electrodes would form a rectangular configuration.

Abstract: Process for spot-welding a flexible bare backed welding board to at least one and preferably a plurality battery cells to form a battery pack, such as a NiCad battery pack. The flexible bare backed welding board is a nickel or other metal alloy material, laminated to a polyester film by a co-extruded or otherwise applied adhesive. The spot-welding is accomplished by one spot-welder, and preferably two spot-welders, which spot-weld in alternating time intervals so as to assure electrical and electromechanical contact with each end of the battery cells by the nickel alloy material. The spot-welding is by DC current and voltage or alternatively can be AC welded. The electrodes are small enough to form a configuration between the flexible circuit and the end of the battery cell. Three spot-welding electrodes would assume a triangular configuration. Four spot-welding electrodes would form a rectangular configuration.

Abstract: Method and apparatus for joining lead battery parts (e.g., plate lugs, intercell connectors, terminals, etc.) together via a low resistance electrical coupling wherein substantially oxide-free, arc-melted, superheated molten lead is cast into a cavity between the parts. The parts are shielded from the arc while being bathed in a non-oxidizing atmosphere which is preferably formed from an ionizable, non-oxidizing gas heated by the lead-melting arc and spewed onto the parts along with the molten lead to provide additional heat thereto.

Abstract: In accordance with the invention, a novel electrochemical cell and a method for making same is provided which is particularly suitable for use in a battery of the type employing one or more cells. One feature of the cell includes a sealed non-metallic pouch of thin flexible material which forms a cell adaptable to varying battery configurations as well as cell shapes. A second feature of the cell includes a novel feedthrough arrangement wherein a pair of electrically conductive members are located on respective sides of an interjacent through-hole formed in the housing material. The pair of electrically conductive members are coupled through the through-hole to form the feedthrough. An electrode of anode material is electrically coupled to the internally located member of one feedthrough pair. An electrode of cathode material is electrically coupled to the internally located member of the other feedthrough.

Abstract: An apparatus and method for fusing the ends of battery cell terminal posts and the ends of hollow bushings fixed in the plastic cover of a battery being assembled and within which the terminal posts are concentrically disposed. The apparatus includes a pair of induction heating coils which each concentrically support a mold cavity insert adapted to receive the ends of the terminal posts and bushings to be fused and a ferrite insert adapted to concentrate induced current in the ends of the terminal post and bushings upon energization of the coils. An electrical control is provided for selectively generating a radio-frequency oscillating current in the coils to effect heating, melting, and fusion of the ends of the terminal posts and bushings to consistent fusion depths while the plastic battery case remains substantially uneffected.

Abstract: Ultrasonically joining a plurality of discrete lead parts into a shaped, substantially metallurgically homogeneous joint. Preshaped lead pieces are placed in an ultrasonically vibrated mold for fusing the pieces and shaping the joint. The method is exemplified in the making of terminal posts for Pb-acid storage batteries.

Abstract: A lead anode for electrowinning metals from sulfuric acid solutions is formed by soldering a sheet of lead anode material endwise in a slot, which extends longitudinally along and partially through a lead alloy coated copper bus bar and into which the sheet fits tightly, and thereafter depositing lead alloy filler at all joints between the bar and anode. Anodes thus constructed have a uniform, smooth joint between the bar and sheet and thus are corrosion resistant and exhibit uniform conductivity.

Abstract: An electrode assembly comprising an electroconductive support, an electrode body, and a flange extending from the body with a plurality of tabs. The flange is attached to the electroconductive support by fastening some but not all of the tabs to the support. This permits removal of the electrode by separating the electrode body from the tabs attached to the support. The electrode is reinstalled by fastening at least one of the remaining tabs to the support.

Abstract: Apparatus and method for mechanically and electrically interconnecting the individual electrochemical cells for a battery. A cell-holding fixture maintains the cells in fixed relationship and includes a conductive electrode disposed adjacent each terminal to be interconnected. Projecting cell terminals are partially bent about the conductive electrodes by pivotal arms and the fixture is then moved toward the ends of the arms Zto complete the bending of the terminals so that they lie in a common plane. A conductive link is placed over the bent terminals and a pair of welding electrodes, one in contact with the conductive link and the other in electrical contact with the conductive electrode of the fixture, passes a welding current through the link and terminal to effect the weld. The fixture is passed over an adhesive strip applicator for taping together the bottom surfaces of the cells prior to their removal from the fixture.

Abstract: Thermocompression methods of forming sodium-sulfur cell casings are described. One method includes positioning an assembly within a die, the assembly having an inward flange at one end of an open ended metallic container positioned against an aluminum washer adjacent each opposite major surface of an electrically insulating ceramic ring, applying pressure to each flange within its respective container, and heating the assembly in an inert atmosphere to bond the containers to the ceramic ring. Another method includes the above steps except that the pressure is applied to the opposite edge of each container.

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: A method for interconnecting adjacent batteries applicable to the combination of a plurality of batteries into a single battery system. An alloy having a melting point in a range of from 40.degree. C to 180.degree. C and formed into a foil is inserted between the terminals to be connected together, or between a terminal and a conductor to be connected together, and the alloy is then heated to a temperature higher than its melting point.

Abstract: A novel system for assembling industrial or motive power batteries is described which basically comprises a conveyor surface, a plurality of stacking box means freely movable across said conveyor surface, tilt table means for engaging in tilting said stacking box, and a novel burning apparatus for forming battery straps on any of a plurality of different sized battery stacks formed within said stacking box means. Additionally, a novel automated burning apparatus is provided wherein a plurality of torches are adapted for a square movement across the terminal lugs of the battery stack, thereby facilitating the formation of battery straps and terminal posts on each of a plurality of battery stacks during a single operation. Utilization of the present system facilitates the efficient manufacture of industrial or motive power batteries of any of a number of different sizes.

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: A process for soldering a metal substrate coated with an electrodeposited non-peelable coating comprising 35-65 wt parts of methacryl ester, 10-40 wt parts of acrylonitrile, 2-15 wt parts of methacrylic acid, 3-10 wt parts of acrylamide and/or vinyl acetate, in 100 parts of resin.

Abstract: Improved extrusion-fusion-type intercell connectors and process involving: casting the plate strap lugs to be welded from a hypoeutectic lead-antimony alloy containing at least about 2 percent by weight antimony; initially extruding the lugs into contact through an aperture in a battery intercell partition, the contact area being between 15 and 75 percent of the area of the aperture; and gradually heating the lug extrusions through a softening stage, an antimony-rich-phase melting stage, and an antimony-lean-phase melting stage. Force applied by rapid-response, declining-force welding electrodes causes (1) the softened extrusions to reshape somewhat prior to melting, and (2) the antimony-rich-phase of the alloy to exude out of the welding zone filling voids in the aperture before any substantial melting of the antimony-lean-phase occurs.