Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF THE INVENTION
This invention relates to welding in general, and
specifically for welding posts of batteries, as for example of
the type used in automobiles.
In the welding of various members together, it is
commonplace to use a welding rod having a flux therein, for many
types of welding, such as arc welding. In other instances,
particularly when thematerials being welded together are soft,
such as those comprising pot metal, lead, lead alloys or like
materials, welding may be effected by application of open flame
to members that are to be ~7elded together. In many instances
such techniques are highly desired and quite meritorious.
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However, in some instances, as for example when
electrical conductivity is desired, it becomes paramount that
the connection between members being welded be such as to create
minimal electrical resistance.
In the art of battery manufacture, particularly wet
cell bztteries for automobile usagè and the like, it has become
commonplace to utilize wet cell batteries, having a plurality
of cells. In each cell, there are disposed a plurality of
parallel but spaced plates, each having a lug extending there-
from, with the various lugs being interconnected by a battery
strap, by any suitable means, such as that disclosed in U.S.
Patent No. 3,395,748. Extending from a strap of this type which
connects plates of a givencell~ is a post. Adjacent cells of a
given battery are separated by cell partitions. Posts of groups
of plates in adjacent cells must be connected, for electrical
conductivity between cells. Accordingly, it is this connection
of adjacent battery cell posts that i of primary concern in
this application.
Because of the presence of a cell partition between
20 the posts, the posts are somewhat spaced at their upper ends, in
that the posts extend generally upwardly above the height of the
cell partitions, such upward extension or protrusion facilitating
the application of heat thereto, for obtaining an electrical con-
nection between the posts across the upper end of an associated
25 plate. Because of the necessity of obtaining good electrical
conductivity across such post connections, the art of welding
battery posts has become highly developed, with individuals for
performing the same having developed a high degree of skill with
respect thereto.
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However, because such posts are generally spaced by
the thickness of a cell partition, the flame achieved by the
use of a gas-oxygen torch or the like must be raised to such
a temperature that will permit the delivery of a sufficiently
high temperature at the lower end~of the spacing between adja-
cent posts, if it is desired to adhere the posts together as
close as possible to the cell partition at the lower end of
the spacing. However, in raising the welding temperature to
such a level, excessive temperatures are reached at the upper-
most ends of the posts, most closely located relative to thetorch which accomplishes such "burning", such that early metal
flow from the upper ends of the posts commences, such flow con-
tinuing down into the space between the posts, above the
separator plate, and solidifying there, before lower ends of
the posts in the vicinity of the upper end of the separator
plate have become sufficiently heated, thereby resulting in an
incomplete fusion of metal at a location corresponding to the
upper edge of the cell partition. Thus, the result is that
while a good fusion may exist at the upper ends of posts thus
welded, often, at the lowermost ends of such posts, directly
above the separator plate, the fusion is imperfect, with insuf-
ficient bond to provide sufficiently low electrical resistance
as a connector. In order to avoid this, an operator may play
the torch between the posts, in order to assure a good weld in
the lower zone of such space above the separator plates or par-
titions, but such may cause the cell partitions to be scorched
or damaged. Accordingly, the ,esult is that present
techniques of; welding battery posts often results
in variations or lack of uniformity in weld-
ments of batteries, depending upon the particular
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operator or welder involved, as well as resulting in an un-
desirable percentage of rejects due to welds that have a
sufficiently good external appearance to pass customary
quality control, but which are really poor weldments.
Furthermore, batteries having poor weldments of battery
posts are more prone to cause operating difficulties.
SUMMARY OF THE INVENTION
The present invention is directed toward overcoming
the above and other difficulties in connection with the
welding of battery posts, as well as with welding in general
by providing a novel method and apparatus whereby adjacent
members, such as battery posts, and terminal posts may be
indirectly welded by the use of a solid heat sink which
penetrates the members to be welded, as it liquifies the
same, thereby carrying the temperature of welding through
the zone to be welded, in order to achieve uniformity in
welds, as well as for other purposes.
Accordingly, it is a primary object of this invention
to provide a novel method for welding together members that
are to be welded, prefereably by indirect application of
heat thereto.
In its broad scope the invention consists of a
method of thermal contact welding a battery terminal post
to a metallic bushing which forms a battery post hole com-
prising: (a) seating a mold means on the battery top to
surround said bushing and said post, while leaving an opening
in said mold means for receiving a heating element therein;
(b) heating a solid heat sink element to at least the melting
temperature of the bushing and post to be fused together;
(c) bringing the heated element into engagement with the
bushing and post and through said opening and melting portions
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of the bushing and post while progressiuely moving the heated
element further into the mold means until the heated element
is partially immerscd in the melt an amount sufficient for
portions of the melt to be displaced within the mold means;
and (d) withdrawing the heated element from the melt and
allowing the melt to flow back into the zone previously
occupied by the immersed element portion and solidify in
connecting relation with unmelted portions of the bushing
and post.
Other features and advantages of embodiments of the
present invention will be readily apparent from a reading of
the following brief descriptions of the drawing figures, de-
. tailed description of the preferred embodiment, and the
appended claims.
IN THE DRAWINGS
.
Fig. 1 is a side elevational view of an apparatus
for welding battery posts, in accordance with an embodiment
of this invention
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disposed above a battery that in itself is partially illus-
trated in section for clarity of illustration, with the bat-
tery being disposed on a conveyor.
Fig. 2 is an enlarged fragmentary transverse view, of
a portion of the apparatus illust~rated in Fig. 1, taken gener-
ally along the line 2-2 of Fig. 1.
Fig. 3 is a further enlarged fragmentary sectional
view, taken through one of the heat-applying devices of this
invention, taken generally along the line 3-3 o Fig. 2.
Fig. 4 is a perspective view of some of the welding
apparatus illustrated in Fig. 1.
Fig. 5a is a fragmentary view of a pair of upstanding
battery posts with a cell partition between adjacent battery
cells being disposed therebetween.
Fig. 5b is a fragmentary view of the pair of adjacent
battery posts of Fig. 5a, with a templet disposed thereover, and
with a welding element received within the templet, at the lower
end of its stroke of penetration of liquified post portions.
Fig. Sc is a fragmentary view of portions of the
illustration of Fig. 5b, at a later stage, after withdrawal of
a welding element from the void in the templet in which the
liquid mass will be molded into solid form.
Fig. 5d is a fragmentary transverse view of a completed
weld of battery posts of adjacent cells, welded across a parti-
tion, and with a battery cover being fragmentally illustratedin phantom disposed thereover, in order to best illustrate the
manner in which a cover may accurately fit over an accurate and
uniform battery post welded in accordance with this invention.
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Fig. 6 shows an assembled view of an alternate
illustrati~e embodiment of the principles of the present
invention which features flexibly adjustable locations for
the heating elements and also a flexible templet system.
Fig. 7 shows a cutaway of a portion of the Fig. 6
apparatus.
Fig. 8 shows in cutaway a variable position templet
embodying the principles of the present invention.
Fig. 9 shows an overlaying plate to regulate the
position of the heating elements, as desired.
Figs. lOa through lOd show the operation of the
appratus of Figs. 6 through 9 to secure terminal posts to
bushings therefor.
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D~SCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, reference
is first made to Fig. 1, and particularly to the lower end
thereof, wherein there is illustrated a battery, generally de-
signated by the numeral 10, disposed upon a conveyor 11, having
a plurality of transverse rollers 12, for movement of the bat-
tery 10 from left to right, as viewed in Fig. 1, across the
rollers 12.
A plurality of cells (six in number), such as those
13 and 14 are illustrated, in which are disposed a plurality
of plates 15 extending downwardly from plate straps such as
those 16 and 17, the plate straps 16 and 17 having been already
connected to the plates 15, by any suitable means, such as that
described in U.S. Patent No. 3,395,748, or by any other means.
The cells 13 and 14 are separated by suitable cell
partitions 18, constructed of an inert material, such as plastic
or rubber (due to the presence of battery acid within the cells
13, 14, etc.). The partition 18 extends vertically upwardly
between posts 20 and 21 of adjacent cells 14 and 13, respec-
tively, with the partition 18 terminating at its upper end
short of the upper ends of the posts 20 and 21, leaving a space
22 therebetween.
It is this space 22 that, upon welding by the use of
open flame being applied to posts 20 and 21, may become filled
with molten or liquid lead (or other post material) from the
upper ends of the posts 20 and 21, and flow downwardly to
solidify in the space 22 just above the separator plate 18,
without application of a proper amount of heat to
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those portions of the posts 20 and 21, below the upper ends
thereof as illustrated in Fig. 5a, in the vicinity of the upper
end of the cell partition 18.
A templet 23, constructed of some material (preferably
metal) having a melting point substantially in excess of that
of the material of the posts 20 and 21, is provided, on the
battery, at the upper ends thereof, as illustrated in Fig. 1,
with pairs of posts 20 and 21 extending upwardly through voids
24 therein. It will be clear that the voids 24 extend entirely
through the templet 23, and that the voids 24 comprise central
portions 25 of a desired size and configuration corresponding
to the posts, to easily receive and contain the same.
The upper and lower ends of the voids 24 are counter-
sunk as at 26 and 27, to permit reception of posts 20 and 21
lS through the lower ends 27 of the voids 24, and to provide a
dished portion 26 at the upper end of each void 24, to accommo-
date the reception of molten metal during the welding operation,
with the lower countersink or cut-away portion 27 also facili-
tating the removal of the templet 23 after the welding opera- -~
tion is complete, with the weldments solidified. It will fur-
ther be noted that the templet 23 is received on the upper lip
of the casing 28 of the battery 10, as illustrated in Fig. 1.
With particular reference to Figures 5a, 5b and
5c, it will be seen that a heated element 30 that has been
heated by means later to be described herein, to a tempera-
ture sufficient to melt the upper ends of posts 20 and 21 of
adjacent battery cells, across the top of a partition 18, is
lowered in.o engagement with the upper ends of the posts
20 and 21, and proceeds to melt the same, into a liquid
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state, and then to continue its downward movement, pene-
trating the liquid portions of the post members 20 and 21
being progressively melted as the element 30 moves down-
wardly, throughout a predetermined vertically downward
stroke of movement of the element~30, such stroke also in-
cluding a dwell time at the lower end thereof, as illustra-
ted in Fig. 5b, if desired (but such dwell not being re-
quired), followed by retraction, or vertically upward move-
ment of the element 30, in the direction of the arrow 31
illustrated in Fig. 5c, whereby the mass of liquid melt dis-
placed into the zone 26 of the templet 23 during that portion
of the operation illustrated in Fig. 5b, is free to fill the
zone 25 of the void 24 of the templet 23, above the upper end
of the partition 18, as illustrated in Fig. 5c, for cooling
and solidification of the melt in the zone 25. It will be
noted that a plurality (five in number) of such elements 30
may be utilized simultaneously, in order to simultaneously
effect five different welds, between posts of adjacent battery
cells, or in fact any desired number of such weldments may
be effected, for battery cells, or for any other purpose, by
the above-mentioned method of maintaining a constant temper-
ature for the element 30 and delivering such temperature com-
pletely throughout the zone of the posts 20 and 21, or other
members, in which the weldment is desired.
Furthermore, it will be noted that the voids 24,
and particularly the central portions 25 thereof, comprise
molds for the welds, during solidification and cooling thereof.
After the welds are solidified, the templet 23 may be removed
from the casing 28 of the battery 10, for reuse, as desired.
With particular reference to Fig. 5d, it will
be apparent that a battery cover 32, having an annular
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cylindrical protrusion 33, for each pair of battery posts
welded together, may be disposed over the upper end of the
battery, with each weld 34 being received within a corres-
ponding annular protrusion 33, for purpose of aligning the
battery cover 32, if desired, and for facilitating the
covering of the welds 34 and retèntion of the cover 32 on
the battery lO.
It will further be noted that the welds 34 are
simultaneously effected, for a given battery, and are all
uniform, as regards their electrical qualities, and as re-
gards their general height and other physical characteristics.
Particularly as regards the height of the same-, it will be
noted that, all being of the same general height, the battery
cover 32 will more easily fit thereover, with posts having
welds 34 at the upper ends thereof, all being uniformly re-
ceived in uniformly sized annular protrusions 33 of the covers
32.
Referring now to the welding apparatus of this
invention specifically illustrated in Figures 1 through 4,
it will be seen that an apparatus 40 is presented, for
carrying a plurality of heating elements or heat sinks 30
protruding outwardly (downwardly) from the lower end thereof.
The apparatus 40 comprises a post 41 of cylindrical
configuration, connected by any suitable means, such as
threading or the like, as at 42, through a manifold head 43,
and through a base member 44, to be secured by means of a
nut 45 therebeneath. The base member 44 is of channel-like
construction, being generally of inverted U-shape in trans-
verse cross-sectional configuration, as best illustrated in
Figures 2 and 4. The manifold head 43 is secured to the
upper end of the base 44, by any suitable means, such as
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screws or the like. The manifold head 43 is provided with
a pair of conduits 46 and 47 extending longitudinally there-
through, each connected at one end to an associated gas distri-
bution conduit 48 or 50, provided with associated on-off inlet
valves 51, as desired. The conduits 48 and 50 are connected to
suitable sources of gases, such as natural gas and oxygen, res-
pectively, or any other gases that will facilitate and support
combustion at the desired temperatures. Thus, acetylene gas
may replace the natural gas if desired, as may a mixture of
other gases, such as air, replace the oxygen, if desired.
The left-most end of each of the manifold channels 46
and 47 is closed, as blind conduits (not illustrated).
Five element heating means, generally designated each
by the numeral 52 are provided, each of substantially identical
construction, so that only one need be described in detail, and
each of which is carried at the lower end of the base member 44,
by a suitable horizontal plate 53, secured by means of a cap
headed screw 54 or the like extending threrthrough, in engage-
ment within a nut 55 disposed within the base 44. Thus, the
position of any given element heating means 52 may be altered by
loosening the screw 54, and repositioning such desired element
heating means by moving the plate 53 longitudinally of the base
member 44.
Each of the heating means 52 is constructed as an in-
dependent torch, being provided at its upper end with a mixingdevice 57, having upper inlets 58 and 60 for receiving for exam-
ple gas and oxygen therein from respectively associated hoses 61
and 62 that, in turn are respectively connected to associated
manifold ducts 46 and 47, for supplying gas and oxygen to a
chamber 63 disposed within the device 57, in which they are
mixed.
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Accordingly, the inlets 58 and 60 communicate res-
pectively with the chamber 63. A pair of needle adjustments
64 and 65 are provided, associated with respective inlets 58
and 60, each comprising a thumb screw or the like 66, operative
through a boss 67 in threaded engagement with the device 57 at
68, for adjusting the position of a needle 70 in the associated
inlet, for regulating the amount of gas be be mixed with oxygen,
and the converse. Upon arriving at a desirable gas-oxygen mix-
ture, the mixture passes through the conduit 71, to discharge
from the device 57, through a distribution line 72, that in turn
is connected to an element holder 73, by suitable nuts 74 or the
like in threaded engagement with threàds 75, wherein the deli-
very line 76 is bifurcated at 77, into a pair of delivery lines
78 and 80 that are inwardly bent at the lower ends, and have
nozzles 81 and 82 respectively carried thereby, in the vicinity
of the upper ends of the elements 30, for heating the elements
at a location spaced above the lowermost, or free ends thereof.
The elements 30 are contained within bores or recesses 83, by
suitable screws 84, for ease of replacement.
Thus, the application of open flame due to the elimin-
ation of gas and oxygen from nozzles 81 and 82, to the elements
30, will heat the elements 30 as aforesaid. It will be noted
that elements 30 may also be heated by induction heating (not
illustrated), or by other suitable means, if desired. In any
event, heat is built up and stored in the element 30, and in
order to racilitate this end the element 30 may be constructed
of a high temperature alloy, ceramic, or any other suitable
material. It will be noted that the flame may continually be
applied to the element 30 during the descent thereof and its
retraction, as illustrated in Figures 5b and 5c, throughout
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its engagement with and projection into the material of the
battery posts 20 and 21, if desired, or the heat may be applied
to the elements 30 only when the same are in their uppermost or
retracted positions, as desired. In any event, there will be a
transfer of heat from the elements 30 to the upper ends of the
battery posts 20 and 21, that will be constantly replenished by
the application of heat to the elements 30, by virtue of the
application of open flame thereto as described above, or by
induction heating, or the like. Furthermore, it will be noted
that the heating elements of tips 30 may take on various desired
physical configurations and sizes, depending upon the particular
application.
Another feature of this invention resides in the use
of a plate 90 secured to the member 44, by a pair of screws such
as 91 and 92, for ease of removal of the same, wi~h the plate 90
having a plurality of openings, voids, notches or the like, dis-
posed in a uppermost set 93, and a lowermost set 94. The lower-
most set 94 is arranged to accommodate plates 53, in accordance
with a desired predetermined spacing of element 30 relative to
each other, as measured horizontally, and relative to posts 20
and 21 of a battery 10 to be welded therebeneath. Accordingly,
placement of the plates 53, in~desired ones of the notches 94,
will readily accurately position the elements 30, in accordance
with the desired position for welding the posts of a given bat-
tery, for example. However, the assembly illustrated in Fig. 4may readily accommodate an alternative placement of the elements
30, by merely removing the plate 90, and inverting the same such
that the notches 93 are disposed downwardly, where~y another
placement of the element 30 relative to each other may readily
be effected quickly and economically, with minimum set-up time.
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With particular reference to Fig. 1, it will be noted
that the rod 41 is either mounted to, or comprises, the piston
rod of a piston (not shown), disposed within a piston cylinder
96, mounted on a suitable frame 97. The cylinder 96 is provided
S with suitable fluid inlets 98 and~100, respectively for pro-
viding a downward driving force, for lowering the elements 30,
or for retracting the same, depending upon the position of the
two way valve 101. It will be noted that the fluid supplied
through the lines 98 and 100 may be any desirable hydraulic,
pneumatic fluid or the like, and that the piston within the cy-
linder 96 would be driven either upwardly or downwardly, depend-
ing upon the setting of valve 101.
It will be noted that the stroke of the piston con-
tained within the cylinder 96 is controlled to automatically
re-set the valve, upon the piston disposed therein reaching
the lower end of a predetermined stroke, in order that the
elements 30 may be retracted prior to striking the separator
plates or partitions 18. However, in the event of misalignment
of elements 30 relative to posts 20, 21, or relative to the
templet 23, or relative to anything else wherein it is de-
sired to prevent a striking of the same by the element 30, or
even in the event that a battery 10 is raisea, for example at
one end, due to the presence of a foreign item between the
lower end of the battery and the conveyor rollers 12, such
that the battery is "cocked", upon the striking of the
elements 30 against any solid member, a sensor of pressure,
force or the like 102, which is particularly responsive to
pressure reauired to lo~er the piston contained within the
cylinder 96, and consequently responsive to resistance to
vertical do~.~ward movement that the elements 30 may meet,
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will be operative to actuate the valve 101, to cause an up-
ward movement, or retraction of the assembly 40, and conse-
quently of the elements 30 carried thereby, in order to prevent
damage to the apparatus, or to batteries being welded.
Also, with reference to Fig. 1, it will be noted
that the rod 41 is provided with a guide, comprising a plate
103 having a boss 104 disposed about the rod 41, and carried
by the plate 103, and with a guide rod 109 being provided,
mounted in a suitable bushing 105 carried by a plate 106, such
that, upon downward movement of the rod 41, the same is guided
against undesirable lateral movement, due to the presence of
the guide plate and rod 103 and 109.
It will thus be seen that the apparatus of this inven-
tion is adapted toward accomplishing its desired ends, both
in broad respects, and in specific respects, regarding the
construction of multiple-cell lead-acid storage batteries.
It will further be noted that the particular inwardly
bent orientations of the nozzles 81 and 82, present the appli-
cation of heat to adjacent areas, thereby concentrating the
heat on the elements 30 themselves. It will also be noted that
the element 30 may be adjustably positioned vertically within
the blind hole 83, by merely loosining the screw 84 and re-
positioning the ele~ent 30. Furthermore, in operation, a pro-
per positioning of the battery can actuate a switch (not
shown), that in turn will cause the piston within the cylinder
96 to be actuated, if desired.
In view of the above-discussed invention, it has
been possible to cut down the time necessary for co~pleting
a weld from thirty seconds to four seconds. Accordingly,
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aside from accomplishing improved welds, both insofar as
their physical appearance and construction is concerned, and
insofar as improving the uniformity and electrical conductivity
of the same is enabled, the overall economics of battery manu-
facture is greatly improved, due to the automation of what haspreviously been a manual function.
An additional advantage over prior techniques of
battery post weldment is also made possible with weldments
of this invention. Such resides in the formation of a
homogenous weldment of adjacent battery posts. Spectrographic
analysis of battery posts welded by conventional application
of gas and oxygen flame directly to the post results in a ten-
dency toward concentration of antimony from the posts at or
near the bond of the weld, apparently caused by more severe
heat at such locations relative to less heat applied to other
areas of the weld, In thermal relay welding as taught by the
instant invention, spectrographic analysis will reveal similar
grain structures throughout the weld, in that the entire post
area is heated uniformly and therefore cools evenly, without
causing an antimony precipitation that would result in an
anitmony concentration. Consequently, the possibility of
electrolysis at the antimony interface that forms the junction
of dissimilar metals upon use of the battery in an electrical
circuit is avoided by this invention, along with any corrosion
attendant thereto. Furthermore, the structural strength of
the post weldment is better, because of the absence of sub-
stantial discontinuities that would be formed by such antimony
precipitation.
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The foregoing discussion has emphasized the structure
of the heating elements and the apparatus whereby combustible
gases are delivered for the heating thereof. Figs. 6 through
9 show an alternate illustrative embodiment wherein the heating
elements are integrated with the templets lowered over the
battery to form molds for the foregoing heating and melting
process of the terminal posts. Moreover, the embodiment of
Figs. 6 through 9 feature the heating elements and the molds
in an integral adjustable configuration such that batteries
having widely disparate structural characteristics may be pro-
cessed efficiently without requiring extensive overhaul of
the processing mechanism.
In the following description, many elements are iden-
tical both in structure and in function to corresponding ele-
ments in the foregoing disucssion. Many of these are numberedsimilarly to the identical corresponding element, but further
including a prefixed "7". Thus, for example, heating elements
730 in Figs. 6 and 7 correspond identically to the heating
elements 30 in Figs. 1 through 5d. Unless otherwise specified,
these identical elements shall not be discussed in detail, but
shall be assumed to be disclosed completely in the foregoing.
In Fig. 6, a welding mechanism is set up for forming
two terminal posts for batteries. Thus, while the foregoing
embodiment included six welding mechanisms for cell to cell
relays in batteries, the embodiment of Figs. 6 through 9 is
configured only to form the positive and negative terminal
posts. It is to be understood, however, that any desired num-
ber of heating elements might be included in order to fulfill
the desired welding requirements for given batteries. LiXewise,
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the embodiment of Fig. 6 through 9 includes several features
which enhance the adaptability and therefore the utility of
thermal welding apparatus embodying the principles of the
present invention.
In the figures, a pair of heating elements represented
generally as 752 are affixed to a pair of mounting blocks 612
and 613, which in turn are slidably mounted on a transverse
rod 611. This transversely movable mounting permits lateral
adjustment of the heating elements 752 to accomodate batteries
having terminal posts located at different points. The trans-
verse rod 611 upon which the blocks 612 and 613 are mounted is
terminated at either end by a pair of elements 609 and 610.
Overlaying both of the mounting blocks 612 and 613 and affixed
to the elements 609 and 610 is a plate 623 which affords control
of the adjustability function and which shall be described in
more detail hereinafter. Also mounted on the rod 61i is a
fixed block 930 which is in turn connected to the piston 830
of a pneumatic or hydraulic cylinder 630. Together, the
blocks 609, 610, 612, 613 and 930, with the rod 611 and the
plate 623, form a "carriage" to which the heating elements 752
are attached, by means of which the heating elements may be
moved vertically (such as shown in phantom in Fig. 7) and
upon which the respective heating elements may be adjusted
transversely.
The terminating blocks 609 and 610 of the carriage
upon which the heating elements 752 are mounted are in turn
slidably mounted on posts 607 and 608, respectively, by means
of bearings, not shown. Thus, under the control of the cylin-
der 630 and piston 830, the carriage arrangement including the
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heating elements 752 is moved vertically on the posts 607
and 608 which are connected at their tops and bottoms, as shown,
to elements 616, 617 and 631. Topmost element 631 in turn is
mounted on posts 632 and 633, which constitute part of a
structural frame for the mechanism.
- Also fixedly mounted on the posts 607 and 608 is
!' a manifold head 743 which defines conduits 746 and 747 fed by
lines 601 and 602 with a combustible gas for flame heating of
the heating elements 730. As in the foregoing embodiments, the
; 10 gases pass through the conduits 746 and 747, through hoses
761 and 762 and into mixing devices 757, and thense downwardly
into the heating means 752. As shown, only two sets of hoses
connect the heating means 752 with the manifold head 743, but
it is clear that any number, as desired, might similarly be
connected. Also mounted on the manifold heads 743-is the cylin-
der 630 whereby the mounting carriage for the heating means ¦
752 is movable.
An aspect of the embodiment of Figs. 6 through 9 whichexhibits substantial operational efficiency but which was not
shown in detail in the foregoing emhodiments is the inclusion
of a pair of molds 619 and 620 which respectively are connected
to the mounting blocks 612 and 613 for the heating means 752.
The molds 619 and 620 are slidably mounted on a transverse
post 618 through bearings such as 818 and are respectively
mounted on shafts 626 and 627 which are slidably movable through
the blocks 612 and 613. It may therefore be seen that the
molds 619 and 620 are movable as a unit with the upper mounting
carriage for the heating means 752 but furthermore are separ-
ately movable together by means of the sliding of shafts 626
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and 627 through the mounting blocks 612 and 613.
The molds 619 and 620 are advantageously constructed
to provide superior operational efficiency, which in turn is
enhanced by their adaptability to process batteries of vari-
able size. This may be appreciatëd by consideration of thevarious cutaway views in Figs. 7 and 8. The principal struc-
tural member of the molds 619 includes a hollow channel 834
which is fed and exhausted by a pair of lines 634 and 934.
The channel 834 provides a circulation route for water or other
similar cooling fluids to be passed through, and thereby to
prevent damage due to the extreme amounts of heat applied by
the heating elements 730 to make the molten terminal posts.
Centrally located on the flat portion of the structural hous-
ing 619 is a mold member 621 which mates with the structural
housing and which actually forms the voids in which the melting
and casting process takes place. The mold members 621 and 622
fit into a hole through the structures 619 and 620 and are
locked therein by means of a slotted key 901 which locks the
mold member 621 in place when situated as shown in Figs.7 and
8, but which allows for removal of member 621 when rotated
180 because the slot 905 then clears the outer periphery of
the member 621. Lever arm 903 on the key 901 limits the rotary
motion of the key by cooperating with extension members 902
and 904,
The mold members 621 and 622 are configured as shown
to define voids 721 having an upper portion which is counter-
sunk. Thus, when the heating member 730 is lowered as shown
in phantom in Fig. 7 to heat and melt the terminal posts as
shown in Figs. lOa through lOd the level of the molten metal
rises up into the countersunk portion, but when the heating
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element 730 is removed, the level settles back into the lower
portion of the void 721 to dry in the standard configuration
of a terminal post. In accordance with standardized procedures,
positive and negative terminals of batteries are of different
dimension in order to facilitate proper connection with exter-
nal apparatus. In order to accommodate the wishes of various
customers, the mold members 621 and 622 may have different
sized voids 721, and may be re-arranged between the molds 619
and 620 as desired. Moreover, the molds 621 and 622 shown may
be freely interchanged with other similar members of different
inner-configuration to process battery elements of varying size
and configuration, as desired.
Fig. 9 shows a view of the overlying plate 623 which
is affixed in the carriage assembly to end blocks 609 and 610
by means of cam means 624 and 625, and which, when so situated,
- determines the lateral position of the heating means 752. More
particularly, the securement means 624 and 625 fit through
slots 906 and 911 in the plate 623 and screw or bolt into the
terminating blocks 609 and 610. The face of the plate defines
first and second sets of openings 907 and 910, and a plurality
of sets of openings such as 908 and 909 extending across the
face of the plate. Once the securement members 624 and 625
mount the plate onto the carriage assembly, set screws such
as 912 through select ones of the end holes 907 and 910 estab-
lish the vertical location of the plate 623. Thereupon, a
position is established for the support blocks 612 and 613
~ecause they are affixed to the plate 623 by screws 628 and 629
through appropriate ones of the holes 908 and 909. Thus, use
of particular ones of the holes 907 and 910 establish which of
the holes 908 and 909 (or any other such sets of holes, as
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.
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. ,
desired) to which the blocks 612 and 613 shall be ~ounted. It
` is to be understood that by alteration of the holes such as
908 and 909, any desired position of the heating means 752 on
the shaft 611 may be established. Since the molding apparatus
619 and 620 is affixed to the respective blocks by means of
posts 626 and 627, similar positioning is established for the
molding apparatus 619 and 620 on the lower shaft 618. Likewise,
in order to accomodate different numbers of heating means 752,
it would only be required to establish correspondingly more
sets of holes in the plate 623.
In a preferred mode of operation, the embodiment
in Figs. 6 through 9 operates as shown in Figs. 10a through
10d. In Figs. 10a through 10d, a bushing 920 is mounted around
the post hole of the battery casing 732 as is practiced in the
art. Thereupon, as the casing is assembled, a terminal post
921 fits into the metallic bushing, to be welded thereto by ;
J application of apparatus embodying the principles of the present
invention. In order to prepare the machinery of Figs 6 through
9 for operation, the plate 623 first is adjusted as desired to
20 locate the heating means and the molding means appropriately
over batteries to be processed. Once â battery is positioned
beneath the Fig. 6 apparatus by means of a conveyor or the like,
not shown, the cylinder 630 and piston 830 are energized to
lower the carriage assembly and the molding apparatus downwardly
t 25 onto the battery âS shown in Fig. 10a. The first portion to
f make contact with the battery includes the molding means, which
seat as appropriate over the portion to be processed as shown
in Fig. 10b. Thereupon, however, the cylinder 630 and piston
830 continues to exert downward force upon the carriage assem-
30 bly, as shown in Fig. 10b, and a sliding of the carriage over
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the downward shafts 607, 608, 626 and 627 results, such
as shown in phantom in Fig. 7. Once the heating means 752
are lowered to the desired position, as shown in Fig. 10c,
the melting process of bushing 920 and post 921 as described
hereinbefore is conducted, after which the heating means 752
first are withdrawn and sufficient time is allowed for the
molten terminal post to set, as shown in Fig. 10d, and the
entire assembly is then withdrawn upwardly.
It may therefore be seen that the principles of the
present invention provide substantial flexibility, in that
variable numbers of heatina means 752 may be utilized, but
all are freely adjustable in accordance with the established
structure of the plate 623. By utilizing associated molding
mechanisms, further adaptability is provided, since, first, -
unitary mold mechanisms are not needed, and, secondly, the
interchangeable mold members 621 and 622 facilitate processes
of different types.
It will also be noted that, while the invention is
described and illustrated above, it is principally for use
with multiple-terminal applications, the same may be used for
single applications, regarding the welding of batteries, and
with respect to other types of welding. Furtherm~re, various
changes in the details, materials and arrangement of parts,
as well as in the use and operation thereof may be effected,
all within the spirit and scope of the invention as recited
in the appended claims.
