Note: Descriptions are shown in the official language in which they were submitted.
Background of the Invention
The present invention relates generally to the
field of battery posts forming and/or burning, and more
particularly, to the field of burning battery posts with
battery cover bushings for the purpose of forming an inte-
grally fused battery terminal on the outer surface of the
battery case. This invention, therefore, relates to welding
in general, and specifically, for welding battery terminal
posts, as for example, the type of battery terminals used
in automobile batteries.
In the welding of various members together, it is
commonplace to use a welding rod having flux therein, for
many types of welding, such as arc welding. In other in-
stances, particularly when the materials 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 welded
together. In many instances,
-3-
such techniques are highly desired and quite meritorious,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 manufacture of electric storage batteries,
such as the lead acid batteries normally used in automobiles,
groups of battery plates and separators contained in
separate cells in a battery case are placed in the case,
after which time the various cells are joined in any of a
number of ways to form intercellular connections there-
between. At the end of the storage battery, slender battery
posts which will form the positive and negative terminals
of the battery extend abo~e the upper surface of the open
battery case, These battery cases, which are normally
composed of polypropylene or other plastic material, are
adapted to receive thereon a polypropylene battery cover,
which has formed therein two lead bushings adapted to be
pierced by the battery posts when the cover is fitted onto
the top of the case. A liqu~d-tight seal is then formed
between the battery case and battery cover, either by gluing,
ultrasonic welding, or by heat sealing means, and the final
mechanical assembly is completed by fusing the battery post
elements with the battery cover bushing elements to produce
the desired positive and negative battery terminals.
Followinq the burning of the battery bushing
elements and battery post elements to form positive and
negative terminals on the battery, acid filling, forming,
and other operations, may be conducted in order to produce
a Einished battery. Conse~uently, the burning process for
forming integra], leak-proof battery terminals is only one
step in the assembly of the complete electric storage
battery.
The present invention also relates to the art of
producing intercellular connections between pluralities of
cells within a battery. In each cell, there are disposed
a plurality of parallel but spaced plates, each having a
lug extending therefrom, with various lugs being inter-
connected by a battery strap, by any suitable means, such
as that disclosed in United States Patent No. 3,395,748.
~xtending from a strap of this type, which connects plates
of a given cell, is a post. Adjacent cells in a given
battery are separated by cell partitions. Posts or groups
of plates and adjacent cells must be connected for electri-
cal conductivity between the cells. Accordingly, it is also
this connectiQn of adiacent batte~y cell ~QS~t~S~ th~a~ ~s~ Qf
interest in this application.
Because of the presence of the cell partition
between the posts, the posts are somewhat spaced at their
upper end! in that the posts extend generally upwardly above
the height ofthe cell partitions, s~uch upward extension or
protrusion facilitating the application of heat thereto, for
obtaining an electrical connection between the posts across
the upper end of an associated plate. Because the necessity
of obtaining good electrical conductivity across such post
connections, the art of welding battery posts has become
hi~hly developed, with individuals for performing the same
having developed a high degree of skill with respect there-
to.
In welding battery posts, either during the fusing
process with hattery cover bushing elements or with adjacent
posts, it is possible to use a gas-oxygen torch or the like,
of an intensity which will permit the delivery of suffi-
ciently high temperature to the elements to be joined, while
at the same time preventing the material at the upper end of
the posts closest to the flame from reaching excessive tem-
peratures, such that early metal flow from the upper ends of
the posts commences, such flow continuing down into the
space between the posts and bushings and/or between the two
posts above the separator plates, and solidifying there,
before lower ends of the posts in the vicinity of the upper
end of the separator plate and/or at the base of the bush-
ings have become sufficiently heated, thereby resulting in
an incomplete fusion of metal at a location corresponding to
the base of the battery terminal to be formed and/or at the
upper edge of the cell partition. Thus, the result is that
while a good fusion may exist at the upper ends of the weldr
o~ten, at the lowermost ends of the weld the fusion is im-
perfect, with insufficient bond to provide sufficiently low
electrical resistance as a connector. In order to avoid
this, an operator may play the torch between the various
elements to be welded, however, particularly in the case of
the polypropylene battery cover, it is not possible to hold
the torch in close proximity to that battery cover for fear
that the battery cover will become scorched or damaged
around its ~unction with the bushing. Accordingly, the re-
sults of welding battery terminals often results in varia-
tions or lack of uniformity inweldments, depending upon the
particular operator or welder involved, as well as resulting
in an undesirable percentage of rejects due to welds that
have a sufficiently good
external appearance to pass customary quality controls,
but which are really poor weldments. FurthermOre, since
the appearance of battery terminals, unlike intercellular
connections, are available for visual inspection by the
intended consumer, even if a weld of high electrical
integrity is formed by the process, the battery is likely
to be rejected if the resulting battery terminal lacks a
solid, uniform appearance.
Summary of the Invention
lQ The present invention is directed towards overcoming
the above and other difficulties in connection with the
welding of battery terminal posts, as well as with welding
in general, by providing a novel method and apparatus
whereby adjacent members, such as battery terminal posts
and battery cover bushings, may be welded.
In one aspect the invention consists of an apparatus
for thermal welding at least one of a plurality of paired,
spaced apart, meltable lead alloy members together,
wherein at least one member of said pair is disposed on
opposite sides and above a partition, said apparatus
comprising: heating element means, said means having an
integrated template associated therewith, said template
being adapted to adjust said means for application to
batteries having widely disparate structural
characteristics and having at least one element adapted to
be heated to a temperature at least as high as the melting
point of said paired members, said elements being further
adapted to direct application to the members being welded
together; heating means associated with said heating
element means for applying heat to said element by a
plurality of generally opposed open flames angled
generally towards the members being welded, said flames
.~ 7 -
)
further acting to apply heat directly to at least a
portion of the paired members being welded, said heat
application causing said portion to melt; and means
associated with said heating element means for moving said
heated element into engagement with the paired members
being welded, said engagement continuing until the element
penetrates between said members to a position immediately
above said partition thus, displacing a portion of said
members in molten state, and for withdrawal of said
element relative to the molten portions of said members
whereby said molten portions flow together to form said
weld.
The invention also provides an apparatus for thermal
welding at least one of a plurality of paired spaced apart
meltable lead alloy members together, wherein each of said
paired members is disposed with one member of said pair on
opposite sides and above a partition, said apparatus com-
prising: heating element means, said means having an
integrated template associated therewith, said template
being adapted to adjust said means for application to
batteries having widely disparate structural character-
istics and having at least one element for direct appli-
cation to said members being welded together; heating
means associated with said heating element means for
applying heat to said element by an open flame to a
temperature at least as high as the melting point of said
meltable members, such that at least a portion of the
combustion products of said flame contacts at least a
portion of said plurality of members when at least one of
said elements is applied to said members; and means
associated with said heating element means for moving said
~1- 7a -
element into engagement wit'. said paired members so that
at least a portion of said members is melted, said
movement continuing until said element penetrates said
molten of said members to a position immediately above
said partition so as to melt and displace portions of each
of said members and for withdraw of said element relative
to the molten portions of said members whereby said molten
portions flGw together to form said weld.
In another aspect the invention also consists of an
apparatus for thermal welding at least one of a plurality
of paired, spaced apart, meltable lead alloy members
together, wherein each of said paired members is disposed
one member of said pair on opposite sides of and above a
partition, said apparatus comprising: heating element
means, said means having an integrated template associated
therewith, said template being adapted to adjust said
means for application to batteries having widely disparate
structural characteristics and having at least one element
for direct application to said members being welded
together; heating means associated with said heating
element means for applying heat to said element by an open
flame to at least the melting point of said meltable lead
alloy members; means associated with said heating element
means for moving said element into engagement with the
members to be welded to melt at least a portion thereof,
said movement continuing until the element penetrates said
portion of said members to a position immediately above
said partition and for withdraw of said element relative
to said molten portions of said members, said heating
means for applying heat to said element by an open flame
also being directed toward said melt such that at least a
~- 7b - I
.,
portion of the combustion products of said flame impinge
upon at least a portion of the melt.
In the preferred embodiment of the present invention
an apparatus is provided comprising a head means, movable
along the vertical axis, having mounted thereon a mold
means which is adapted to matably encircle the battery
bushing element and battery post element to be fused, and
to act as a mold when the head means is in its molding
position along that axis. A burning means capable of
1~ producing a variable intensity flame for preheating,
melting and post warming said battery elements is mounted
in slidable engagement on said head means. The heat which
is applied thereby is automatically modulated not only by
the proximity of the burning means as it moves towards and
away from the battery elements to be melted, but also by a
preselected variation of the intensity of the flame pro-
duced by the burning means, which variation is produced as
the burnin~ means moves between the pilot and the burning
position. The novel flame regulation of the preferred
embodiment of the present invention is accomplished
through the use of a fixed trip member mounted on the head
means, which cams with a lever means which is adapted to
regulate the gas flow of the burner. Consequently, by
reason of movement and the variable flame intensity
described above, applicant has provided modulated heat
application which produces an extremely uniform battery
terminal.
- 7c -
4~
Accordingly, an object of a preferred embodiment of
the present invention is the provision of a battery post
burn station which is fully automated. To this end, a
novel conveyor means is also provided which is adapted to
sequentially store and move batteries from a first hold
position to a second operating position. This conveyor
means further provides clamp means for transversely forc-
ing each of said batteries into a battery element fusing
position with respect to the vertical axis of travel of
said burning means and said mold means. A feed sensing
means is mounted on the apparatus for sensing the longi-
tudinal advancement of a battery from the hold position
towards the operating position, and for causing the stop
means to move from the normal position which does not
impede the longitudinal movement of batteries to the stop
position wherein batteries are halted at said hold and
operating positions. The feed sensing means further
causes the movement of the clamp means from its retracted
to its clamped position in timed response to the sensing
of the longitudinal movement of batteries. An alignment
sensing means then determines the movement of the clamp
means to the fully clamped position, and
causes a cylinder means to move a head means from its stand-
by to its molding position, wherein molds which are adjust-
ably mounted on the head means, matably encircle said bat-
tery elements to define a void therearound of the shape of
the desired battery terminal. As the head means moves to
the molding position, an abort means senses the lac~ of a
battery in the battery fusing position, as might occur where
a battery has been manually removed or where the apparatus
has otherwise malfunctioned. This abort means then over-
rides the remaining portion of the operating cycle of theapparatus, preventing the flame from firing and causing the
head means to return to the standby position and the stop
means to move from the stopped to the normal position so
that the next battery may be introduced into the apparatus.
Alternatively~ battery sens~ng means are proyided
to determine the presence of a battery in the fusing posi-
tion when the head means assumes the molding position, which
battery sensing means causes a hydraulic cylinder to move
the burning means from its pilot to a burning position. As
described above, the burning means further comprises a lever
means for contacting a trip member fixedly engaged on the
head means, there~y automatically regulating the intensity
of the flame from a minimum pilot flaMe when the burning
means is in the pilotposition to a maximum when the burning
means is in the ~urn position. As a result, as the burning
means moves towards the elements to be fused, the intensity
of heat administered to those elements increases as the
result of the proximity of the flame to those elements, and
also by reason of the intensity of that
_9._
flame. Upon movement of the burning means to the burning
position, a travel sensing means determines the presence
of said burning means in that burning position and causes
the aforementioned hydraulic means to immediately begin
moving the burning means back to said pilot position. The
aforementioned trip member and lever means similarly
respond to the retraction of the burning means by
gradually reducing the intensity of the flame to its pilot
condition. As a result of this novel burner action, the
battery elements to be fused are preheated prior to
melting, which preheating helps to eliminate the
productiuon of a cold joint such as might occur had the
high intensity flame initially been directly applied to
the cold battery elements. During the melting portion of
the cycle, the high intensity flame is in close proximity
to the elements, causing the complete melting thereof.
Finally, as the torch carriage returns towards the pilot
position, a post-heating phase of the cycle occurs which
prevents the outer surfaces of the terminal from
prematurely cooling, thereby creating a puddling effect on
the top of the melted terminal which produces an even,
uniform terminal. As a final result, the novel burning
cycle of the present invention produces a fused joint
which is extremely even and in which there is little or no
layering or antimony precipitation.
Accordingly, an important feature of the apparatus is
the provision of an electric storage battery post burner
which produces a high quality, integral battery terminal.
Another aim is to provide a fully automated post burning
station which rapidly and reliably processes batteries on
which said terminals are to be formed.
- 10 - I
An alternate embodiment of the present invention is
intended to provide a novel method and apparatus whereby
adjacent members, such as battery terminal bushings and
battery 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
embodiment of the present invention to provide a novel
method for welding together members that are to be welded,
preferably by indirect application of heat thereto.
Further features of embodiments of this invention
reside in the construction and particularly novel welding
apparatus, more fully described hereinafter. Other
advantages of the apparatus particularly directed towards
the welding of battery terminal posts, will be readily
apparent, as will objects of a generally broader nature,
from a reading of the following brief description of the
2~ drawings, detailed description of the preferred
embodiment, and the
,~ .,
-- 1 1 --
V
appended claims.
Brief Description of the Drawings
Fig. 1 is a side elevational view of an apparatus
for welding battery terminal posts in accordance with an
alternate embodiment of the present invention, showing this
embodiment disposed above a battery that, in itself, is partially
illustrated in section for clarity of illustration, with the
battery being disposed on a conveyor;
Fig. 2 is an enlarged fragmentary transverse view of
a portion of the apparatus illustrated in Fig. 1, taken generally
along the lines 2-2 of Fig. l;
Fig. 3 is a further enlarged fragmentary sectional view,
taken through one of the alternate embodiments of the heat
applying devices of this invention, taken generally along the
lines 3-3 of Fig. 2;
Fig. 4 is a perspective view of some of the welding
apparatus illustrated in Fig. l;
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 template disposed thereover,
and with a welding element received within the template, at the
lower end of its stroke of penetration of liquified post
portions;
Fig. 5c 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 template in which the
liquid mass will be molded into solid form;
- 12 -
Fig. 5d is a fragmentary transverse view of a com-
pleted weld of battery posts of adjacent cells, welded
across a partition, and with a battery cover being frag-
mentally illustrated in phantom disposed thereover, in order
to best illustrate the manner in which a cover may accurate-
ly fit over an accurate and uniform battery post welded in
accordance with this invention;
Fig. 6 shows an assembled view of an alternate
illustrative embodiment of the principles of the present
invention which features flexibly adjustable locations for
the heating elements and also a flexible template system;
Fig. 7 shows a cutaway of a portion of the Fig. 6
apparatus;
Fig. 8 shows in cutaway a variable position tem-
plate e~bodying the pxinciples 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
apparatus of Figs. 6 through 9 to secure terminal posts to
bushings therefor;
Fig. 11 is a front view of an apparatus for burn-
ing battery terminal posts and battery cover bushings in
accordance with the preferred embodiment of the present
invention;
Fig. 12 is a peXspective view of a portion of the
molding and burning apparatus as illustrated in Fig. 11;
Fig. 13 is a greatly enlarged cross section of the
portion of the apparatus shown in Fig. 12, taken as indica-
ted by the lir.es and arrows 13-13 in Fig. 12; and
Fig. 14 is a schematic representation of the
various sensing means of the preferred embodiment of the
present invention shown in association with a front eleva-
tion of an apparatus in accordance with the preferred
embodimen~ of the present invention, similar to that shown
in Fig. 11.
Detailed Description of the Drawings
Although specific forms of the invention have been
selected for illustration the drawings, and the following
description is drawn in specific terms for the purpose of
describing these forms of the invention, this description is
not intended to limit the scope of the invention which is
defined in the appended claims.
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
designated by the numeral 10, disposed upon a conveyor 11,
having a plurality of transverse rollers 12 for movement of
the battery 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 ~o the plates 15, by any suit-
able means, such as that described in U.S. Patent 3~395~743!
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 with-
in the cells 13, 14, etc.). The partition 18 extends
-14-
vertically upwardly between posts 20 and 21 of adjacent
cells 14 and 13, respectively, with the partition 18 termin-
ating 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 down- ;
wardly to solidify in the space 22 just above the separator
plate 18, without application of a proper amount of heat to
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 template 23, constructed of some material
s~ ~preferably ~etal~ having a meltin~:po~t ~sAu~stant~all~y~ ~n :~ :~ excess of that of the material of th.e posts 20 and 21, tS
provided, on the battery, at the upper ends thereof, as
illustrated in F~g. 1, with pairs of posts 20 and 21 extend-
. ing upwardly through voias 24 therein It ~iI-l ~e clear that
, .
the Yoids 24 extend entirely through the template 23, and
~!: that the ~oids 24 comprise central portions 25 of a desired
s ze and configurat~on corresponding to the posts, to easily
receive and contain the same.
~; ~ The upper and low~er ends of the voids 24 are
:~ cQuntersunk as at 26 and 27, to permit reception of posts
~: 20 and 21 through the lower ends 27 of *he voids 24, and to
provide a d2shed porti~on 26 at the upper end of each void
24, to accommodate the reception of molten metal during the
welding operation, with the lower countersink or cut away
portion 27 also facilitating the removal of the template 23
after the welding operation is complete, with the weldments
: -15-
solidified. It will further be noted that the template 23
is received on the upper lip of the casing 28 of the battery
10, as illustrated in Fig. 1.
With particular reference to Figs. 5a, 5b and 5c,
it will be seen that a heated element 30 that has been heat-
ed by means later to be described herein, to a temperature
sufficient to melt the upper ends of posts 20 and 21 of
adjacent battery cells, across the top of a partition 18,
is lowered into engagement with the upper ends of the posts
20 and 21, and proceeds to melt the same, into a liquid
state, and then to continue its downward movement, penetrat-
ing the liquid portions of the post members 20 and 21 being
progressively melted as the element 30 moves downwardly,
throughout a predetermined vertically downward stroke of
move~ent of the ele~ent 30, such stroke alsQ including a
dwell time at the lower end thereof, as illustrated in Fig.
5~, if desired (but such dwell not being required), followed
;~
~ by retraction, Qr vextically upward movement of the elemeht
i` 30, in the direction of the arrow 31 illustrated Ln Fig. Sc,
whereby the mass of liquid melt displaced into the zone 26
~f 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 parti-
tion 18, as illustrated in Fig. 5c, for cooling and solidi-
fication of the melt inthe zone 25. It will be noted that
a pluxality (five in number) of such elements 30 may be
utilized simultaneQusly, in order to simultaneously ef~ect
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 a~Qve-mentioned method of maintaining a constant
~ 16-
temperature for the element 30 and delivering such
-16a-
temperature completely 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 2~,
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 cylin-
drical 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 corresponding
annular protrusion 33, for purpose of aligning the battery
cover 32, if des red, and for facilitating the covering of
the welds 34 and retention of the cover 32 on the battery
10 .
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
regards their general height and other physical characteris-
tics. 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 received 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
t'~"f~
protruding outwardly (downwardly) from the lower end thereof.
The apparatus 40 co~prises a post 41 of cylindri-
cal 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 iscfchannel-like
construction, being generally of inverted U-shape in trans-
verse cross sectional configuration, as best illustrated in
Figs. 2 and 4. The manifold head 43 is secured to the upper
end of the base 44, by any suitable means, such as screws or
the like. The manifold head 43 is provided with a pair of
conduits 46 and 47 extending longitudinally therethrough,
each connected at one end to an associated gas distribution
conduit 4~ 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,
respectively, 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 pro~ided, each of substantially
identical construction, so that only one need be described
in detail, and each cf whichis carried at the lower end of
the base member 44, by a suita~le horizontal plate 53,
secured by means of a cap headed screw 54 or the like
extending therethrough, in engagement within a nut 55 dis-
posed within the base 44. Thus, the position of any given
-18-
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
independent torch, being provided at its upper end with a
mixing device 57, having upper inlets 58 and 60 for receiv-
ing, for example, 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 andoxygen to a chamber 63 disposed within the
device 57, in w~ich they are mixed.
Accordingly, the inlets 58 and 60 communicate
respectively with the chamber 63. A pair of needle adjust-
ments 64 and 65 are provided, associated with respective
~nlets 58 and 60, each comprising a thumb screw or the like
66, operative through a boss 67 in threaded engagement with
thedevice 67 and 68, for adjusting the position of a needle
70 in the associated inlet, for regulating the amount of gas
to be mixed with oxygen, and the converse. Upon arriving
at a desirable gas-oxygen mixture, 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 threads 75, wherein the delivery
lines 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 ~1 and 82 respectiv~ey carried thereby, in the
vicinity of theupper ends of the elements 30, for heating
3~ the elements at a location spaced above the lowermost, or
free ends thereof. The elements 30 are contained within
,,~ 19
4$i~
bores or recesses 83, by suitable screws 84, for ease of
-lga-
b
replacement.
Thus, the application of open flame due to the
elimination 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 facilitate this
end the elemen~ 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 Sc, throughout its engage-
ment 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
of 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 con-
stantly replenished by the application of heat to the ele-
ments 30, by virtue of the application of open flame thereto
as descri~ed a~ove, or by induction heating, or the like.
Furthermore, it will be noted that the heating elements or
tips 30 may take on various desired physical configurations
and sizes, depending upon theparticular application.
Another feature of this invention resides in the
use of a plate 90 secured to the mem~er 44, by a pair of
screws such as 91 and92, for ease of removal of the same,
with the plate 90 having a plurality of openings, voids,
notches or thelike, disposed in a uppermost set 93, and a
lowermost set 94. The lowermost set 94 is arranged to
-20-
3 ~f~
accommodate plates 53, in accordance with a desired pre-
determined 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, and also relative to
the templet 23 mounted on the battery 10 and disposed there-
beneath. 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 battery, for
example. However, the assembly illustrated in Fig. 4 may
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, whereby
another placement of the element 30 relative to each other
may readily be effected quickly and economically, with mini-
mum set-up time.
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 suitable frame 97. The
cylinder 96 is provided with suitakle fluid inlets 98 and
100, respectively, for providing a downward driving force,
for lowering the elements 3n ~ or for retracting the same,
depending uponthe 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 cylinder g6 would
be driven either upwardly or downwardly, dependin~ upon the
setting of the valve 101.
It will be noted that the stroke of the piston
contained within the cylinder 96 is controlled to automati-
cally 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 template 23, or relative to anything else
wherein it is desired to prevent a striking of the same by
the element 30, or even in the event that a battery 10 is
raised, 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 iike 102, which is particu-
larly responsive to pressure required to lower the piston
contained within the cylinder 96, and consequently respon-
sive to resistance to vertical downward movement that the
elements 30 may meet, will be operative to actuate the valve
101, to cause an upward movement, or retraction of the
assembly 40, and consequently 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 wi~h 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 o this
invention is adapted toward accomplishin~ its desired ends,
-22-
both in broad respects, and in specific respects, regarding
the construction of multiple-cell lead-acid storage batter-
es .
It will further be noted that the particular in-
wardly bent orientations of the nozzles 81 and 82, present
the application of heat to adjacent areas, thereby concen-
trating the heat on the elements 30 themselves. It will
also be noted that the element 30 may be adjustable posi-
tioned vertically within the blind hole 83, by merely
loosening the screw 84 and repositioning the element 30.
Further, in operation, a proper 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 desire~.
In view of the above-discussed invention, it has
been possible to cut down the time necessary for completing
a weld from thirty seconds to ~our seconds. Accordingly,
aside from accomplishing improved welds, both insofar as
their physical appearance and construction is concerned,
and insofar as improving the uniformity and electrical con-
ductivity of the same is enabled, the overall economics ofbattery manufacture is greatly improved, due to the automa-
tion of what has previously been a manual function.
An additional advantage over prior techniques of
~attery post weldment is also made possible with weldments
of this invention. Such resides in the formation of a hcmo-
geneous weldment of ad~acent battery posts. Spectrographic
analysis of battery posts welded by con~entional appLication
of gas and oxygen flame directly to the post results in a
tendency 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
-23-
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 there-
fore cools evenly, without causing an antimony precipitation
that would result in an antimony concentration. Consequent-
ly, the possibility of electrolysis at the antimony inter-
face 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 substantial discontinui-
ties that would be formed by such antimony precipitation.
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 tem-
plates lowered over the battery to form molds for the fore-
going heating and melting process of the terminal posts.Moreover, the embodiment of Figs. 6 through 9 features the
heating elements and the molds in an integral adjustable
confiyuration such that batteries having widely disparate
structural characteristics may be processed efficiently
without requiring extensi~e overhaul of the processing
mechanism.
In the follo~ing description, many elements are
identical bcth in structure and in function to correspond-
ing elements in the foregoing discussion. Many of these are
3~ numbered similarly to the identical corresponding element,
but further including a prefixed "7". Thus, for example,
-24-
heating elements 730 in Figs. 6 and 7 correspond identi-
cally to the heating ele~ents 30 in Figs. 1 through 5d.
Unless otherwise specified, these identical elements shall
not be discussed in detail, but shall be assumed to be dis-
closed completely in the foregoing.
In Fig~ 6, a welding mechanism is set up for form-
ing two termianl posts for batteries. Thus, while the fore-
soing 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 ter-
minal posts. It is to be understood, however, that any
desired number of heating elements might be included in
order to fulfill the desired welding requirements for given
batteries. Likewise, the embodiment of Figs. 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 repre-
sented generally as 752 are affixed to a pair of mounting
blocks 612 and 613, which in turn are slidably mounted on a
transverse rod 6110 This transversely movable mounting
permits lateral adjustment of the heating elements 752 to
accommodate batteries having terminal posts located at
different points. The ~ransverse rod 611 upon which the
blocks 612 a~d 613 are mounted is terminated at either end
by a pair of elements 609 and 610. Overlaying both of the
mountin~ blocks 612 and 613 and af~ixed to the elements 609
and 610 is a plate 623 which affords control of the adjust-
ability function and which shall be described in more detail
hereinafter. Also mounted on the rod 611 is a fixed block
930 which is in turn connected to the piston 830 of a pneu-
-25-
matic or hydraulic cylinder 630. Together, the bloc~s 609,
610, 612, 613 and 93~, 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 60g 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 cylinder 630 and piston 830, the carriage arrangement
including the 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 embodi-
ments, the gases pass through the conduits 746 and 747,
through hoses 761 and 762 and into mixing devices 757, and
thence 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 cylinder 630 whereby the mounting
carriage ~or the heating means 752 is movable.
~n aspect o~ the embodiment of Figs. 6 through 9
which exhibits substantial operational efficiency but which
-26-
r ~
was not shown in detail in the foregoing embodiments 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 mountin~ carriage for the heating
means 752 but furthermore are separately movable together by
means of the sliding of shafts 626 and 627 through the
mounting blocks 612 and 613.
The molds 619 and 620 are advantageously con-
structed to provide superior operational efficiency, which
in turn is enhanced by their adaptability to process hat-
teries of variable size. This may be appreciated by consid-
eration of the various cutaway views in Figs. 7 and 8. The
principal structural 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 ~lat
portion of the structural housing 6~9 is a mold member 621
which mates with the structural housing and which actually
forms the ~oids in which the melting and casting process
takes place. The mold members 621 an~ 62~ ~it into a hole
through the structures 619 and 620 and are locked therein by
means o~ 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 iimits the rotary motion
of the key by cooperating with extension members 902 and 90
lhe mold members 621 and 622 are configured as
shown to define voids 721 having an upper portion which is
contersunk. 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 element 730 is removed, the level settles
baC~ 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 ter-
minals of ~atteries are o~ different dimen$ion in order to
facilitate proper connection with external 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 rearranged between the molds 619 and 620 as
desired. Moreover, the molds 621 and 622 shown may be
freely interchanged with other similar me~bers of different
inner-configuration to process ~attery elements of varying
size and configuration, as desired.
Fig. 9 shows a view of the overlying plate 623
which is af~ixed 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 o~ the heating
means 752. More particularly, the securement means 624 and
625 fi~ ~hrough slots 306 and 911 in the plate 623 and screw
or bolt into the terminating blocks 60~ and 610. The face
of the plate defines first and second sets of openings 907
-28-
v
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 establish the vertical
location of the plate 623. Thereupon, a position is estab-
lished for the support blocks 612 and 613 because 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
desired) to which the blocks 612 and 613 shall be mounted.
It is to be understood that by alteration o~ 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 estab-
lished for the molding apparatus 619 and 620 on the lower
shaft 618. Likewise, in order to accommodate 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 prac-
ticed in the art. Thereupon, as the casing is assembled, a
terminal post 921 fits into the metallic bushing, to be
welded thereto by application of apparatus embodying the
principles of the present in~ention. In order to prepare
the machinery of Figs. 6 through 9 for operation, the plate
-29-
623 first is adjusted as desired to locate the heating means
and the molding means appropriately over batteries to be
processed. Once a battery is positicned beneath the Fig. 6
apparatus by means of a conveyor or the like, not shown, the
cylinder 630 and piston 830 are ener~ized to lower the car-
ria~e assembly andthe moldin~ apparatus downwardly onto the
battery as shown in Fig. 10a. The first portion to 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 car;
riage assembly, as shown in Fig. 10b, and a sliding of the
carriage over the downward shafts 607, 608, 626, and 627
results, such as shown in phantom in Fig. 7. Once the heat-
ing means 752 are lowered to the desired position, as shown
in Fig. 10c, the melting process of bushing ''20 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 presentinvention provide substantial flexibility, in
that variable numbers of heating means 752 may be utilized,
but all are freely adjustable in accordance with the estab-
lished structure of the Plate 623. By utilizing associated
molding mechanisms, further adapta~ility is provided since,
first, unitary mold mechanisms are not needed, and secondly,
the interchangeable mold members 621 and 622 ~acilitate
processes ofdifferent types.
It will also be noted that, while the invention
is described and illustrated above~ it is principally for
-30-
use with multiple-terminal applications, the same may be
used for single ap~lications, regarding the welding of
batteries, and with respect to other types of welding. The
preferred embodiment of the present invention is illustrated
in a front elevational view in Fig. 11. In Fig. 11 it may
be seen that the automatic post burn station of the present
invention is primarily defined by vertical support members
201 and 202 which are positioned and supported by means of a
transverse structural member 205 and by a bifurcated roller
system including vertical supports 204 and 206. Batteries
such as 218 pass along the roller system 203 for welding at
the station, which welding occurs in a position under the
welding assembly 2i3 as defined by stop roller 259. The
assembly 213 includes a plurality of burning tips matable
over the battery cover bushings o~ a battery such as 218.
The assembly 213 is vertically movable by means of rods 214
and 216, bearing asse~blies 248 and 249, a pair of counter-
weights 306 and 307, and an air cylinder and piston assembly
241 and 245.
As may be clearly understood from Fig. 11, the
mechanism whereby a battery such as 218 is positioned for
testing, and where~y other batteries are precluded from
interfering with the testing process, is the use of upwardly
pivota~le rollers from the conveyor which there~y serve as
stop mechanisms along the conveyor. Thus, under control of
a cylinder 279 and a piston 231, through connections of
lever arms 278 and 299 and tie rod 280, rollers 259 and 267
may be pivoted upwardly and over their next adjacent rollers,
thereby forming a stop for batteries. Whenever air pressure
in the cylinder 279 is increased, the piston 281 moves out-
wardly, along with tie rod 280 and rollers 259 and 267 again
-31-
move downwardly to their normal positions. The batteries
are then free to move down the conveyor.
Once a battery such as 218 is in abutment with the
pivoted roller 259, as shown, two fingers 236 and 286 are
pivoted upwardly and between the rollers, against the bat-
tery 218, and further until the battery 21~ is locked into
place in a predetermined position with respect to a horizon-
tal axis transverse to the longitudinal axis of advancement
of the batteries, The upward pivoting of fingers 286 and 287
occurs by means of yet another cylinder and piston arrange-
ment 283, energized by means of appropriate control systems
which will be more fully described herein.
Whenever the battery 218 is positioned as shown in
Fig. 11, the welding assembly designated generally 213 will
be lowered into place. This occurs chiefl~ by means of the
cylin~er 241 and the piston 245 arrangement which is con-
nected to a shaft adaptor block 301 of the welding assembly
designated generally 213. In order to facilitate this
operation, the welding assembly designated generally 213
includes upwardly depending rods 214 and 216 which are con-
nected, by means of lines 508 and 509, respectively, to a
pair of counterweights 306 and 307. These counterweights
axe located conveniently within the upper portion of ver-
tical support ~embers201 and 202. In preferred embodiments,
the rods 214 and 216 pass through bearing assem~ly 248 and
249, and the lines 508 and 509 pass over pulleys located on
cantilevered support arms 219 and 221. ~y means of the
counterweights 506 and 507, the assembly designated gen-
erally 213 may also be kept in a nearly balanced condition,
such that minimal force is necessary from the cylinder 241
and the piston 245 for ei~her upward or downward movement.
As seen in Fig. 11, the welding assembly designated gen-
erally 213 is comprised of a head means movable with respect
to the frame of the apparatus along a vertical axis by means
of the operation of the cylinder 241 and rod 245 as describ-
ed above, and a mold means adjustably mounted on said head
means for slidably engaging said head means along that ver-
tical axis. ~he head means of the preferred embodiment of
the prese~t invention comprises air cylinder 241, cylinder
rod 245, shaft adaptor block 301, shaft manifold rods 303
and 305, respectively, manifold block 307, carriage blocks
390 and 311, respectively, and upwardly depending rods 214
and 216. The mold means, which is adjustably mounted in said
head means, is mounted on longitudinal supporting rod 313
extending between carriage bloc~s 309 and 311. The mold
carriage blocks 315 and 317 act as the supportin~ structure
for molds 319 and 321, which will be more fully described
hereinafter. The apparatus shown in Fig. 11 illustrates the
position wherein the head means is in its molding position
by means of the full extension of rod 245, as indicated by
the clearance of upwardly extending rods 214 and 216 and the
space disposed between shaft adaptor block 301 and bearing
assemblies 248 and 249. Upon activation of cylinder 241,
which is a double-acting cvlinder, the head means may be
moved from the molding position as shown in Fig. 1 to a
standby position wherein shaft adaptor bloc~ 301 is sub-
stantially contiguous to bearing assemblies 248 and 249.
The burning means of the present invention is capable of
selectively producing a flame for melting the battery ele-
ments to be fused, said burning means being mounted in
slidable engagement along the vertical axis of movement of
the head means, being slidably movable in that axis with
respect to said head means. Hydraulic cylinder 323, which
is a double-acting hydraulic cylinder, and rod 325, which is
associated therewith, are actuatable to produce the movement
of torch carriage 327 along the lower portions of manifold
shafts 303 and 305. As may be seen in Fig. 11, locating
template 329, similar in function to the locating template
described above in other embodiments of the present inven-
tion, are provided on the torch carriage for precisely
positloning the burning tips 228 and 233 within the long-
itudinal axis Qf advancement of the batteries along conveyor203. As illustrated in Fig. 11, the torch carriage 327 is
in the front burning position, as indicated by the close
proximity ~etween the burning tips 228 and 233 and the molds
219 and 321, respectively. Movement to the burning position
has been produced by the extension of rod 32~ in response to
the activation of hydraulic cylinder 323. Not shown in Fig.
11, but important to the functioning of the torch carriage
in a safe manner~ is the provision of spring biased means
extending between the manifold block 307 and the torch car-
20 xia~e designated genexally 327, which spring biased meansact to return the torch means to its pilot position in the
eVent of power failure. In normal operation, however, the
~orch carriage is returned to its pilot position thro~gh
activation of hydraulic cylinder 323, which causes the re-
traction of rods 325 and consequently draws torch carriage
327 towards mani~old block 307,so that the torch carriage
and mani~old klock are substantially contiguous to each
other. In the burning position, as shown in Fig. 11, the
trip ~ar 34Q is shown engaging and depressing trip levers
30 341 and 342, which are attached to torches 343 and 344
respectively, and which trip levers act to control the
~-34-
intensity of the flame produced at burning tips 228 and 233
-34a- '
respectively. Oxygen and combustible gas are provided to
torches 343 and 344 by means of gas supply line 345 and 346,
which are in communication with suitable sources of nxygen
and other combustible gases.
Referring now to Fig. 12, which is a perspective
view of the welding assembly designated generally 213, the
operation of the preferred embodiment of the present inven-
tion can best be explained. As seen in Fig. 12, the torch
carriage designated generally 327 is in its pilot postion,
at which time the flames emanating from burning tips 228 and
233 would be of the minimum intensity. Carriage blocks 315
and 317 are seen to be mounted in sliding engagement along a
longitudinal axis on longitudinal bar 313, which is support-
ed at either end by carriage blocks 309 and 311. Torches
343 and 344 are mounted at an acute angle with respect to
the vertical axes of radial symmetry of burning tips 228
and 233 so that torch levers 341 and 342 are disposed over
trip bar 340. L brackets 371 and 372 are fixedly attached
to manifold shafts 303 and 305 respectively by means of U
bolts 373 and 374. Trip bar 340 is held in rotating engage-
ment between L brackets 371 and 372 by means of cotter pins
piercing said trip bar 340, which engagement allows trip bar
340 to rotate upon engagement with torch levers 341 and 342.
As seen in Figs. 12 and 13, as the torch carria~e designated
generally 327 moves from its pilot position to the burning
position, as shown in phantom in Fig. 13, the torch 344 and
torch lever 342 are brought down to engage the trip bar 340,
shown in cross section in Fig. 13. Since the torch lever
342 is a~apted to control the intensity of the flame pro-
duced at the burning tip 233, it may be seen that as thetorch carriage designated generally 327 moves in the direc-
--35-
tion of the arrow shown in Fig. 13 from the pilot to the
burning position, the intensity of the flame produced at the
burning tip 233 is correspondingly increased. As may clear-
ly be seen in Fig. 13, the disposition of the burning tip
233 with respect to mold 320 allows the flame produced at
burning tip 233 when the torch carriage is near the pilot
position to preheat in a gentle manner the bushing and bat-
tery terminal posts which would normally be disposed within
the mold 320 when the head means was in the molding posi-
tion. The mold carriage block 317 which acts as a supportfor mold 320 is seen to have disposed therewithin at least
one circulating chamber having cooling fluid 397 disposed
therein for cooling the mold carriage block 317 during the
molding process. Furtherm~ e, the block itself is selected
for its high heat transfer capacity, and is therefore com-
posed of aluminum or other high hea'c transfer material.
Similarly, and in direct opposition to the prior art teach-
ing with respect to lead molds, the mold 320 is itself com-
posed of aluminum or other high heat transfer material. As
seen in Fig. 13, the engagement of mold 320 with mold car-
riage block 317 is tight, therefore allowing good heat
transfer between these elements and cooling fluid 397 which
is constantly being circulated therethrough. The interior
surfaces 396, 395 and 394 of mold 320 'nave disposed thereon
an aluminum oxide coating or, that is, the interior surfaces
3g4, 395 and 396 are anodized in order to create a thermal
barrier between the mold void defined by the mold 320 and
the solid aluminum which composes the mold.
The remainder of the apparatus of the head means
and burning means may be seen in Fig. 13 to comprise verti-
cal guide rods 399 and 400, which transversely align the
-36-
rt~
mold 320 with the burning tip 233 as that burning tip moves
from the pilot to the burning position. Longitudinal guide
rod 393 for allowing longitudinal adjustment of the position
of the burning tips with respect to the longitudinal axis of
the batteries is seen in cross section in Fig. 13, as is a
cut away portion of the torch carriage designated generally
327 to reveal conduit 392 having a threaded bushing 391 and
390 attached to tubing 389. Tubing 389 provides a gaseous
conduit for the mixture of oxygen and combustible gas which
is produced upon activation of the lever 342 within torch
344. Bushing means 388 are provided for interconnecting
the tubing 389 with the torch 344. Along the lower surface
of the torch carriage designated generally 327 and disposed
between the torch carriage 327 and the burning tip 233 is
seen to be a barrel on which the burning tip may easily
removably be mounted. The gas supply conduit 346 is seen
to be attached to the remote end of torch 344, enter and are
disposed within manifold block 307, and are seen to emerge
from manifold block 307 in Fig. 12, from whence they will be
20 connected to suitable oxygen and combustible gas sources.
Having described the apparatus of the preferred
embodiment of the present invention, the operation of that
apparatus in fusin~ battery cover bushings to battery ter-
minal posts may be described as follows:
Figure 14 is a schematic representation of the
yarious sensing means of the preferred embodiment of the
present invention shown in association with a front eleva-
tion of an apparatus in accordance with the preferred em-
bodiment of the invention similar to that shown in Fi~ure
11. Figure 14 shows and is intended to highlight the auto-
mated features of the preferred embodiment which, under nor-
mal operating conditions, will function entirely without an
operator being present. The conveyor means in Figure 214 is
shown with the battery 218 in the fusing position. The bat-
tery 218 is brought into the fusing position by its intro-
duction from the hold position, shown in phantom in Figure
14 to its operating position. Upon the longitudinal ad-
vancement of the battery 218 from the hold position to the
operating position, movable rollers are in the normal posi-
tion, feed sensing means Sl shown in Figure 14 is activated
by the passage of the battery thereby. Consequently, the
feed sensing means Sl is mounted on the apparatus for
sensing the longitudinal advancement of a battery from the
hold position towards the operating position, and ~or
causing the stop means to move from the normal position
which does not impede the longitudinal advancement of bat-
teries to the stop position wherein batteries are held at
the hold and operating positions. The feed sensing means
further causes the delayed activation of clamp means com-
prising hydraulic cylinder 283 and fingers 286 and 287 which
are pivoted upwardly and between the rollers against battery
218 and are further driven by cylinder 283 until battery 218
is locked into place in a predetermined position with re-
spect to a horizontal axis transverse to the longitudinal
axis of advancement of the batteries. In the preferred em-
bodiment of the present invention the feed sensing means is
adapted to activate the clamp means including cylinder 2~3
in a timed response interval which is between 0.2 and 5
seconds after the sensing o~ the passage of battery 218
from the hold to the operating po~ition. This time delay
-38-
interval is selected to allow battery 218 to abut roller
259 prior to the activationo~ the clamp means. Alignment
sensing means S2 is provided to sense the full extension of
fingers 286 and 287 either directly, or indirectly as shown
in Figure 14 by sensing the degree of rotation of a protru-
sion mounted on a shaft which rotation corresponds to the
rotation of finger.s 286 and 2~7. Once the alignment
sensing means S2 determines the full movement of the clamp
means to the fully clamped position, indicating that the
battery has been forced from the operating to the fusing
position, cylinder 241 is then activated to move the head
means, which comprises the welding assembly designated
generally 213 in the direction as indicated by arrow A.
Since the battery 218 is in precise alignment with respect
to the welding assembly 213, the ~old carriage blocks 315
and 317, and the corresponding molds contained therein will
matably encircle the battery bushing elements and battery
post elements protruding from the top of battery 218. In
the event that bat.ery 218 has been removed from the appa-
ratus or, in the event that no batt.ery has been introducedinto the apparatus due to machine malfunction, abort means
S7 will be activated by the travel of the welding assembly,
and particularly, by the travel of rod 214 beyond the
normal molding position. Upon the activation of a~ort
means S7 caused by the absence o~ a battery in the fusing
position~ the remaining portion of the operating cyc~e of
the apparatus is then overridden, preventing the activation
of the burning or torch carriage and causing the immediate
return of the head means and welding assembly to the stand-
3~ ~y position, and further causing the stop means to movefrom the stop to the normal position so that the next
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r~s~
battery may ~e introduced into the apparatus. If a battery,
such as battery 218 shown in Figure 14, is present when the
welding assembly designated generally 213 moves from the
standby to the molding position, battery sensing means S3
will sense the presence of a battery in the fusing position
and will thereby activate hydraulic cylinder 323 to produce
movement of the torch carriage 327 along the lower portions
of manifold shafts 303 and 305. As hereinabove described,
the burning means mounted on the torch carriage comprises
lever means for contacting a trip member which automatically
regulates the intensity of the flame from a minimum pilot
flame when the burning means is in the pilot position to a
maximum when the burning means is in the burn position as
shown in Figure 14. Consequently, the battery sensing means
produces a mo~ement of the torch carriage designated gen-
erally 327 in the direction as indicated ~y arrow B in
Figure 14 to a point as shown in Figure 14 in the burning
position wherein a maximum flame intensity is directed at
the battery bushing element and battery post element en-
circled by each mold.
Upon movement of the torch carriage designatedgenerally 327 to its fully extended burning position, a
travel sensing means S4, which is mounted on the head means
as shown in Figure 14 senses the presence of the burning
means in that burning position and c~uses the aforemention-
ed hydraulic cylinder 323 to immediately begin moving the
burning means ~ack to the pilot position, as designated in
Figure 14 by arrow C. The aforementioned trip member and
lever ~eans respond to this retraction by reducing the in-
tensity of the flame until, when the torch carriage reachesthe pilot position, a return sensing means S5 which is
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mounted on the torch carriage designated generally 327determines the return of the burning means to the pilot
position and causes cylinder 241 to ~ove the head means to
the standby position as indicated by arrow D in Figure 14 in
timed response thereto. In the preferred embodiment of the
present invention, cylinder 241 is activated by a delay in-
terval of between 0.2 to 5 seconds, which time period
creates a post chill time following the return of the torch
carriage to the pilot position which is sufficient to allow
at least partial solidification of the battery terminal
posts. Activation of cylinder 241 to return the head means
along the direction of arrow D shown in Figure 14 causes the
head means to return to the standby position. Reset sending
means S6 mounted on the head means, or alternatively, on the
traansverse structural member 205 senses and determines the
movement of said head means to said standby position causing
the stop means to move from the stop to the normal position,
thereby allowing the passage of the battery which terminals
were fused out of the fusing position while simultaneously
allowing for the introduction of t~e next battery to be
processed into the operating position as heretofore describ-
ed. In oxder to facilitate this longitudinal advancement of
ba$t~ries, the clamp means is similarly caused to move to
the retracted position by the reset means S6 thereby causing
fingers 286 and 287 to withdraw to the retracted position,
thereby also resetting alignment sensing means S2.
As a result of the above description, it is ap-
parent that the apparatus of the present invention is fully
automated facilitating the rapid and reliable production of
batteries incorporating high ~uality integrally fused bat-
tery terminals.
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It will be understood that various changes in the
details, materials and arrangement of parts which have been
described and illustrated in order to explain the nature of
this invention, may be made by those skilled in the art
within the principle and scope of the invention as expressed
in the appended cliams.
It will further be understood that the "Abstract
of the Disclosure" set forth above is intended to provide a
non-leqal technical statement of the contents of the disclo-
sure in compliance with the Rules of Practice of the United
States Patent Office, and is not intended to limit the scope
of the invention described and claimed herein.
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