Battery terminal, cold forming-process and relating apparatus for manufacture said battery terminals

Abstract: A battery terminal (10) with high torque resistance utilizing three sided frusto-conical recesses (15) and mating protrusions extending from the battery terminal and method of making the terminal by a cold forming process that forms a finished battery terminal from a preworked lead slug (40) by driving one end of a punch (52) through the slug to remove excess material and form an axial through hole, a second (55) and third (53) portion of the punch to close the die chamber and a fourth portion (55) of the punch to radially expand the lead slug into a finished battery terminal. The dies for forming the battery terminal include a movable multiple-segmented die (60,61,62,63) for collapsing radially inward around the slug and a frusto-conical die (72) for forming the top portion of the battery terminal. An ejector sleeve (74) removes the finished battery terminal after the cold forming process. In one method of the invention includes a cold-forming method of making a finished battery terminal with a necked down flange by first expanding the metal radially outward until the battery terminal die cavity is partially filled with metal and then upsetting the metal to complete the deformation filling of the battery terminal die cavity and to simultaneously form a necked down region in the flange on the battery terminal.

Description: FIELD OF THE INVENTION This invention relates generally to battery terminals and an improved method of making battery terminals by cold forming. Our corresponding prior art application discloses cold forming battery terminals through the process of forming a lead slug into a cylindrical cup and then punching out the end of the lead slug while expanding the lead slug radially outward into a die having the shape of a finished battery terminal. The present invention comprises improvements to the aforementioned process by permitting one to cold form a battery terminal with a necked down region extending around the flanges of the battery terminal. BACKGROUND OF THE INVENTION The process of cold forming metals is well known in the art. Typically a deformable or malleable metal is deformed at room temperature through a series of compression and/or expansion steps. Cold forming has been used to form various articles including automotive items such as spark plug housings and battery terminals. Typically, spark plug housings are made of steel alloys and other articles, including battery terminals, are made of softer metals such as lead or lead alloys While cast battery terminals have been used satisfactorily, cold formed battery terminals may be preferable since the working of the metals during the cold forming process appears to remove air pockets. The result is a more dense terminal that hinders electrolyte from escaping through the terminal. Although lead can be cold formed quite readily the leak-proof sealing of lead terminals to battery containers after the terminal has been formed is difficult since the battery terminal also needs to have a leak-proof seal between the terminal and the battery wall. Sealants have now been developed that enable battery manufactures to seal cold formed battery terminals to the battery container in a leakproof relationship. The present invention provides a process for cold forming a lead slug into a finished battery terminal with a necked down region that can be directly inserted into a battery container. A process for cold forming battery terminals is also known from EP-A-426 312. The process disclosed therein which allows the shaping of a metallic preform without reducing its mass uses two progressive cold forming die-sets. A further process for cold forming battery terminals from substantially cylindrically shaped blanks is also known from EP-A-261 311. The electrical battery pole obtained by this method requires a further blanking or milling step. Therefore, it is an object of the present invention to provide a cold forming process allowing the shaping of a finished battery terminal from a pre-worked lead slug by single-step manufacture in a compound die. This and further objects are achieved by the cold forming processes and respective apparatuses as defined in the appended claims. BRIEF DESCRIPTION OF THE DRAWING Figure 1 shows a perspective view of a battery terminal inserted in battery cover; Figure 2 is a cross-sectional view taken along lines 2-2 of Figure 1; Figure 3 is a view taken along lines 2-2 of Figure 1 with the battery terminal not shown in section; Figure 4 is a cross-sectional view taken along lines 4-4 of Figure 3; Figure 5 shows a cylindrical metal slug for use to cold form into a battery terminal in accord with the teaching of this invention; Figure 6 shows the cylindrical slug of Figure 5 after its faces have been squared off; Figure 7 shows the cylindrical slug of Figure 6 with a cylindrical cavity or recess formed at one end; Figure 8 is a cross-sectional view of a movable die case and a coacting stationary die case for cold forming the slug into a battery terminal with the dies located in the open position; Figure 8A is a view of the movable die case taken along lines 8A-8A of Figure 8; Figure 9 is a view of the movable die case and the coacting stationary die case of Figure 8 in a partially closed position; Figure 10 is a view of the movable die case and the coacting stationary die case of Figure 8 in a further closed position; Figure 11 shows the movable die case and the coacting stationary die case of Figure 8 in an open position after formation of a battery terminal; Figure 12 shows the movable die case and the coacting stationary die case of Figure 8 in the ejection position; Figure 13 shows an enlarged view of the retaining lip for removing waste lead; Figure 14 shows an enlarged view of the lead slug prior to final deformation; Figure 15 shows the lead slug after final deformation just before the dies are opened; Figure 16 is a side view of the punch of the present invention; Figure 17 is a cross sectional view of a lead slug cold formed in a shape of a cylindrical cup; Figure 18 is an enlarged sectional view showing a flash on a battery terminal; Figure 19 is a cross sectional view illustrating transition zone forcing excess lead out of the die; Figure 20 is a cross sectional view showing the punch forcing excess lead from the die; Figure 21 is a front view of a battery terminal having a flange with a necked down region; Figure 22 is a sectional view of the battery terminal of Figure 21 showing the necked down region on the flange of he battery terminal; Figure 23 is an enlarged view of a portion of Figure 22; Figure 24 shows two dies at the beginning of the stroke to cold form the battery terminal of Figure 21; Figure 25 shows a die punch radially expanding the metal outward into a flanged battery terminal cavity; Figure 26 shows a slidable sleeve die at the beginning of the stroke to necked down the flange on the battery terminal; Figure 27 shows the slidable sleeve die at the bottom of its stroke; and Figure 28 shows the slidable sleeve die in its retracted condition after formation of the finished battery terminal of Figure 27. SUMMARY OF THE INVENTION The invention produces a battery terminal as defined in claim 9 with high torque resistance utilizing three sided frusto-conical terminal recesses that coact with mating protrusions extending from the battery container. The method according to claim 1 is a horizontal cold forming process to form a finished battery terminal from a preworked lead slug by driving one end of a punch through the slug so that the one end forms an axial opening through the slug and removes excess material, a first and second portion of the punch closes the die chamber and a third portion of the punch radially expands the lead slug into a completed or finished battery terminal. The dies for forming the battery terminal include a movable four-segmented die for collapsing radially inward around the slug and a frusto-conical die for forming the top portion of the battery terminal. An ejector sleeve removes the finished battery terminal after the cold forming process is completed. In addition the invention includes a cold-forming method according to claim 6 of making a finished battery terminal with a necked down flange by first expanding the metal radially outward until the battery terminal die cavity is partially filled with metal and then upsetting the metal to complete the deformation filling of the battery terminal die cavity and to simultaneously form a necked down region in the flange on the battery terminal. Apparatus for carrying out the said methods are defined in claims 4 and 7. DESCRIPTION OF THE PREFERRED EMBODIMENT In Figure 1, reference numeral 10, generally identifies a cold formed high torque lead battery terminal as it appears in a thermoplastic battery container 11. Figure 2 shows terminal 10 with a central or axial through passageway or opening 14 which will be subsequently filled with molten lead to form a mechanical and electrical connection to a battery grid within the battery container. Figure 2, Figure 3 and Figure 4 show battery terminal 10 integrally formed or secured to battery container 11 in a torque resistant relationship by the coaction of terminal torque lock regions 15 and a moldable container material 19 such as a thermoplastic resin. Annular rings 19a of the container material 19 fill a set of annular openings located between parallel spaced acid-sealing rings 16, 17 and 18 which extend radially outward from terminal 10. Battery terminal 10 has a frusto-conical shaped hollow top portion 12 with an outer facing 13 for forming electrical connection with a battery connector. As viewed in figure 2a protrusion member 20 has a massive base since the protrusion member extends vertically upward from annular cover member 20a that abuts against acid ring 16. The result is protrusion members 20 that are vertically restrained in container 11 by terminal ring 13a and acid ring 16. Figure 3 shows an end view of torque locks 15 that form a series of three sided general pyramid-like recesses 15 in the skirt of battery post 10. The recesses 15 are characterized in that they have a base dimension W 1 which is substantially larger than the top dimension W 2 so that the mating protrusions in battery container material 19, which fit into recesses 15, have a massive support base which tapers toward a narrower top. Figure 4 shows a sectional view taken along line 4-4 of figure 3 to illustrates how the battery container material, which forms three sided pyramid-like protrusions members 20, projects into torque locks 15 to thereby form circumferentially spaced retaining lugs for locking battery terminal 10 to container 11. Torque locks 15 are located circumferentially around terminal 10. Torque locks 15 are equal distance from one another with center lines C x extending through each of the torque locks to intersect at a central point P. The use of the torque locks 15 in battery terminal allows one to provide a substantially strong and rigid torque resistant support between battery terminal 10 and container 11. That is, tests have shown that by using torque locks 15 and three sided protrusions 20 extending from the molded container into the torque locks of a positive battery terminal produces such tenacious and integral connection between the container and the positive battery terminal that, in some cases, when the top portion 12 is subjected to a twisting high torque the top portion 12 of the battery terminal shears off before the terminal twists free of the container. In the preferred embodiment the inward projecting members 20 are spaced circumferentially around the periphery of the battery terminal 10 and project inward. Twelve three sided projecting members 20 are located around the periphery of battery terminal 10 to integrally engage twelve torque locks on terminal 10. The terminal 10 is readily adaptable to forming through a horizontal cold forming process that converts an extruded lead slug into a finished battery terminal for mounting in a battery container. Figure 5 shows a cylindrical lead slug 40 formed through a conventional extrusion process. Lead slug 40 has a cylindrical outer surface 42, a first end 43 and a second end 41. The diameter of the slug is designated by D 1 and the length of the slug is designated by L 1 . Prior to forming slug 40 into a finished battery terminal the slug is worked and shaped to square up the ends and the diameter of the slug so that the cold forming of the battery terminal can be performed in a single cold forming operation. In addition the pre-working of the lead is desirable since the lead cold forms better if the lead has been pre-worked Figure 6 shows lead slug 40 after further partial pre-working. Slug end faces 41 and 43 have been squared while the diameter D 2 remains substantially the same as diameter D 1. As a result of the end squaring process, the length L2 of slug 30 may be slightly shorter than the length L 1 of the slug prior to the pre-working step. Figure 7 shows the cylindrical lead slug 40 after the final pre-working step that produces a slug for cold forming. During the final preworking step a cylindrical punch has been directed into a central portion of end 41 of slug 40 to produce a cylindrical cavity 44 that extends about half the depth of the lead slug with a diameter D 4 . In this step, slug 40 increases in length because the punch forces the lead in the central portion of the slug to flow onto the end of the slug as the lead slug is confined by a cylindrical chamber (not shown) of diameter D 2 . After the final preworking step slug 40 has an outer diameter of diameter D 2 and a cavity of diameter D4. After the final preworking steps the slug is now ready for cold forming into a finished battery terminal. As pointed out the purpose of the preworking of the lead slug is to prepare the metal for cold forming since preworked metal is easier to cold form. In addition the cold forming produces suitable dimensions on the lead slug to permit the cold forming process through coaction of a die and punch. While slug 40 is shown with a cavity 44 that extends about half way into slug 40, the cavity 44 may be formed in different depths. In certain applications, cavity 44 could extend completely through the lead slug and in other applications lead slug 40 can be processed without any cavity. Figures 8 through 12 show the process of forming the pre-worked cylindrical lead slug 40 into a battery terminal in greater detail. Reference numeral 50 identifies a movable die case and reference numeral 70 identifies a stationary die case. Reference numeral 49 identifies upper and lower members for moving movable die case along central axis 48. Preworked lead slug 40 is shown located on end 57 of a punch 52 which includes numerous cylindrical stepped sections as well as frusto-conical connecting regions. Punch 52 includes a cylindrical end face 53, a frusto-conical connecting region 54, a cylindrical section 55, a further frusto-conical connecting region 56, a cylindrical section 57 having an end surface 58. The diameter of section 57 is slightly more than the diameter D 4 so that lead slug 40 is maintained on punch section 57 through frictional engagement between slug 40 and punch section 57. Punch 52 is powered by a source (not shown) and slides within a sleeve 63 which sliding supports a four-part radially collapsible die section 50a which is axially displaceable in die case 50. Quadrant segments 60 and 61 of die section 50a are shown in figure 8. Figure 8A shows an end view of movable die 50 to illustrate all four segments 60, 61, 62 and 63. Die segments 60, 61, 62 and 63 slide on frusto conical surface 64 to permit each of the die segments to be displaced axially and radially around lead slug 40. A set of radial pins 50c, 50d, 50b, and 50e extend inward to act as stops for the die segments, a set of cross pins 60a, 61a, 60b, and 61b act as lateral guides to permit the die segments to move radially inward while maintaining alignment with each other. The front of movable die case 50 contains a frusto conical guide surface 64 so that die segments 60, 61, 62 and 63 can be collapsed around slug 40. While the die segments 60, 61, 62 and 63 can be collapsed around lead slug 40 the die segments 60, 61, 62 and 63 do not do any deforming of the lead slug 40 during the collapsing step. That is the die segments 60, 61, 62 and 63 collapse to form a die chamber having the shape of the lower portion of a battery terminal which contains the protrusions and recesses to form acid sealing rings 16,17 and 18. The companion to movable die case 50 is stationary die case 70, which includes an outer member 71 and a die 72 for forming the top portion 12 of a battery terminal. Die 72 contains a frusto-conical section 73 which forms the cavity 73 for forming the top portion of a battery terminal. An ejector sleeve 74 slides within die 72. Ejector sleeve 74 includes an end surface 74a, a first inner surface 75 and a second inner surface 77 of slightly larger diameter. A waste retaining lip 76 connects first inner surface 75 and second inner surface 77. Located to the right of ejector sleeve 74 is a passage 78 for discharging lead removed during the cold working of the lead slug. The end of die 70 includes members 80 which abut against the closed four split die segments 60, 61, 62 and 63 when die 50 is moved axially against stationary die 70. Figures 9 and 10 illustrate the cooperative relationship of die 50 and die 70. Figure 9 shows lead slug 40 confined in the die segments 60, 61, 62 and 63 and die section 72. An end of slug 40 is shown partially displaced by end 58 of punch section 57. Punch section 57 is completing the formation of a through hole in lead slug 40 by forcing a portion 40a of lead slug 40 through the interior of ejection sleeve 74. During this first through hole punching phase with cylindrical punch section 57 lead slug 40 is not radially expanded outward although the die segments 60, 61, 62 and 63 and die section 72 do not prevent radially outward deformation of lead slug 40. Figure 10 illustrates the cold forming process in a more advanced state with slug 40 radially deformed and separated from excess lead 40a. Figure 10 shows that cylindrical punch section 55 has radially expanded the hollowed lead slug radially outward into die segments 60, 61, 62 and 63 and die section 72 to form a finished battery terminal. Waste lead 40a is located on the inside of ejector sleeve 74 and pushes waste lead slugs 40b located in ejector sleeve 74. In operation, waste lead 40c is pushed out of ejector sleeve 74 by waste lead 40a and waste lead 40b as shown in figure 10. Waste lead 40c falls out passage 78. Figure 11 illustrates movable die 50 in a retracted position with lead slug 40 formed into a finished battery terminal which is frictionally held by the sides of die section 72 of die 70. Figure 12 illustrates ejector sleeve 74 forcing finished battery terminal 40 out of stationary die 70. Thus, in the process of the present invention, a cylindrical cupped shaped lead slug is placed into a die and in a single operation a stepped punch forms a through opening in the lead slug, removes excess lead from the lead slug and radially deforms the remaining portion of the lead slug into a finished battery terminal ready for mounting into a battery container. To understand the operation of the removal of waste lead 40a with ejection sleeve 74. refer to Figure 13 which is an enlarged view of interior cylindrical surfaces 74 and 75 which are connected by a cylindrical lip 76. The purpose of lip 76 is to provides a means for catching the waste lead 40a so that as pin 57 is withdrawn from slug 40 lip 76 prevents waste slug 40a from being pulled back with punch 57. During the cold forming process the punch and ejector sleeve coact so that the proper amount of lead remains within the dies during the final cold forming phase. Figure 14 illustrate the final expansion of the lead slug as the first portion of cylindrical punch 55 seals off one end of the die chamber around lead slug 40. Figure 14 shows an enlarged view of lead slug 40 at the moment the die chamber for forming the lead slug into a battery post or terminal is completely confined. The cylindrical punch surface 55 has an outside diameter that closely fits within the opening of ejector sleeve 74 to seal off one end of the die chamber for the lead slug. That is, when frusto conical base surface 56 (region 56a) engages the inner surface 75 of ejector 74 it completely seals off one end of the die chamber for lead slug 40 as well as shears waste lead 40a from slug 40. Similarly, punch face 53 completely seals off the opposite end of the die chamber. Figure 14 shows that at the moment of beginning shear of the waste lead portion 40a, the base section 53 of punch pin 52 is spaced a distance x from the final position. That is, prior to the final expansion of lead slug 40 waste lead 40a is separated from lead slug 40 and the die chamber is sealed at both ends. Even though the die chamber around the lead slug is sealed off there is sufficient amount of punch pin travel left before the final radial expansion and deformation of lead slug 40 is completed. That is, the portion of lead slug 40 remaining in the chamber has in effect been measured for the proper amount of lead for the final compression phase. During the final compression phase punch face 53 may travel the complete or partial distance x to complete the final formation of the battery terminal. Since lead is relatively deformable but incompressible the pressure on the die dramatically increases when the lead fills the closed die chamber. To prevent breaking of the dies pressurized chambers with a compressible gas (not shown) are used to close segments 60, 61, 62, and 63 so that sufficient pressure can be applied to pin 52 to produce the final deformation of lead slug 40. Consequently, this ensures that sufficient pressure is applied to lead slug 40 to completely deform slug 40 into a finished battery terminal. While the present process is shown with regard to a cylindrical slug that is formed into a cylindrical terminal the process is equally well suited for forming battery terminal with lateral extending members as shown in U.S. Patent 4,662,205. Figure 16 reference numeral 52 identifies the improved step punch which is generally shown in Figures 8-12. At the front portion of punch 52 is a frusto-conical section 56 which forms a transition section between end cylindrical section 57 and the intermediate cylindrical section 55 of punch 52. It has been discovered that controlling the transition cone angle theta on punch 52 generally reduces the flash present in the finished part. To illustrate flash in a battery terminal, refer to Figure 18 which shows an enlarged portion of the battery terminal 12 with flash 101 extending outward from the inside corner of terminal 12. Typically, flash 101 comprises a thin section of extruded metal which extends radially inward a distance y and downward a distance x. While the size of the flash may vary, the typical flash may have an x dimension of of .005 Inches and a y dimension of of .005 inches with a thickness z of .0001 inches. Since the internal region 103 is to be filled with lead, the presence of flash 101 in the interior region normally causes no problems. However, if the terminals are handled roughly, flash 101 may flake off and fall into the plastic used to mold the battery cover around the battery terminal, thereby creating the possibility for introducing a short in the battery. The improvement in the process comprises a method and means for eliminating the flash. One of the known ways to eliminate flash is to have the exact amount of lead necessary to expand into die 130. Another is to have the lead positioned in the die so it uniformly fills the die during the cold forming process. Unfortunately, precisely controlling the amount of lead to fill up the die is difficult to do during a cold forming process. An alternate approach is to form a lead slug with a known amount of excess lead and then remove the excess lead during the cold forming process. In the present process, excess lead is removed in two steps. First, the end of the cylindrical lead slug is punched out and then the remaining excess lead is forced out in an annular shaped member extending around pin 52. It should be pointed out that slug 100 (Figure 17) is shown having a bottom thickness designated by b t. The purpose of having a cylindrical bottom 100a is to facilitate handling of the lead slug during the forming steps; that is, the bottom section 100a of slug 100 allows end of pin 57 to positively engage slug 100 and force the slug to seat against the end of sleeve 74 (Figure 9 and 19). Once seated, the end 100a of slug 100 is removed as the end of pin 57 continues forward to remove the excess lead in the shape of a cylindrical plug 100a (Figure 19). Thus, it is envisioned that if other means were used to seat slug 100 in the die, one could use an annular slug rather than a cylindrical cup-shaped slug for radial deformation of a battery terminal in die 130. While flash is a problem in cold forming parts, one of the additional problems in closed cold deformation of a lead slug and particularly in high speed cold forming of parts is that air may not be completely purged from the die prior to closing the die. Consequently, local irregular deformation of the cold formed part may occur. To alleviate the problem of local deformation due to trapped air, we provide peripheral spaced elongated die vent holes proximate the end of the die where excess material is forced out. Figure 19 shows die 130 and multi-step punch 52 coacting to radially expand lead slug 100 into a battery terminal. In Figure 19, punch 52 is shown with a portion of the forward travel of the punch yet to be completed, and Figure 20 shows punch 52 with the forward travel completed. Figure 19 illustrates that during the radial expansion process, excess lead 101 extends in an annular shaped section 101 and is forced forward of section 56 as punch 52 moves forward. Located peripherally around die 130 are a series of narrow, elongated vent passages 120 and 121. Vent passage 121 connects to a larger discharge passage 123, and vent passage 120 connects to a larger discharge passage 122. The vent passages are narrow to allow air to escape and are placed at the end of the die to prevent the vent passage from acting as a die cavity. Typically, vent passages 120 and 121 may have a width of up to 0.125-inches but have a depth d x of only about 0.0005-inches. The small depth vent passages allow air to escape and thus avoid local deformation as a result of air trapped within the die. While only two vent passages are shown, one may prefer to radially space more or less vent passages. Typically, four to six vent passages radially spaced around die 130 provide means for removing trapped air from the die. Figure 19 illustrates another feature of the process. Note, end plug 100a located on the end of pin 57. End plug 100a was forced out of the bottom of slug 100 (Figure 17) to provide an annular slug 100 for radially expansion within die 130. Due to the rapid forward motion (indicated by arrows) of pin 52, end plug 100a is forced outward of ejector sleeve 74 and drops off the end of pin 57 (Figure 20) as pin 52 reaches the end of its forward travel. Thus, a first portion of excess lead 100a is removed from slug 100 by pin 57 with a shearing or punching process. The second portion of excess lead removed from slug 100 comprises annular lead member 101 (Figure 19) which is being formed around transition section 56 as lead is being forced radially outward and forward in front of section 56. As punch 52 continues its forward journey, annular waste lead member 101 is sheared from the end of slug 100 by co-action of punch section 55 with die 130 and the end of sleeve 74. Extending centrally through punch 52 is a central axis 110. Central axis 110 is concentric with die 130 and sleeve 74. Figure 19 shows frusto-conical transition section 56 located between and smoothly connecting cylindrical pin sections 55 and 57 to each other. The transition zone 56 is maintained at an angle theta which is less than 15 degrees. Preferably an 11 degree transition angle is preferred. It has been discovered that the larger the angle theta, the greater the pressure build-up in the die and the greater the chances for flash occurring during the cold forming of the terminal through a radial expansion process. On the other hand, the less the transition angle, the longer the transition zone 56. To avoid the transition zone from extending too far and consequently extending the required length of travel of pin 52, it is preferred to have the transition angle theta a minimum of about 8 degrees. It has been found that with a transition zone 56 of about 11 degrees, the excess metal 101 is sheared from the end of terminal 101 without creating excess deformation forces that force metal in the form of a flash between the outside of a die section 55 and the interior sleeve 74. While the optimal transition zone angle may vary with different components, one can readily determine the proper angle by observing the finished part. If the finished part is not completely filled out, the transition angle may be too shallow. Conversely, if the transition angle is too high, excessive deformation pressure is provided in the die forcing flash from parting surfaces between die 130 and sleeve 74. While cold forming of battery terminals is preferred, there are certain battery terminal configurations which can not be cold formed to the proper dimensions. This is particularly true of battery terminals which have an outer flange with some type of a groove or acid-sealing ring located on the underside of the flange. Figures 21 and 22 illustrate such a battery terminal which is difficult to cold form. Figure 21 shows a side view of such a battery terminal, and Figure 22 shows a cross sectional view of the terminal. Figure 21 shows the battery terminal 150 having a frusto-conical top 151, a radially extending cylindrical flange 152 with a radial extending cylindrical skirt 153 located therearound. A series of rectangular shaped lugs 154 extend downward from flange 154 and radially outward from lower terminal section 155. Figure 22 shows a V-shaped groove 156 extending completely around the underside of flange 152. The presence of the V-shaped groove 156 creates problems in conventional cold forming of battery terminals. That is, in the process of cold forming battery terminals, the lead is deformed radially outward by a punch until a die cavity is completely filled, thereby forming the finished battery terminal. For the lead to be deformed radially outward for forming the battery terminal shown in Figures 21 and 22, the lead must not only flow radially outward but it must flow backward around the narrowed portion of the V-shaped groove 156. The V-shaped groove is shown in greater detail in Figure 22. Note that flange 152 extends radially outward with a skirt 153 located radially outward of groove 156. The arrows indicate the general radial outward flow of metal during the cold forming process. If the V-groove 156 is not present, the metal can be radially formed outward as illustrated in Figures 8-12. However, the deformation of metal around the apex of 156 in order to form skirt 153 becomes difficult since excessive pressures are required which may cause flashing between the dies and, in certain instances, voids may be left in the cavity resulting in a defective battery terminal. The present process provides a method and apparatus for cold forming battery terminals which have a narrowed neck or necked down region located in the flange of the battery terminal. To appreciate the process of applicant's apparatus for forming a battery terminal flange with a necked down region, reference should be made to Figures 24-28. Figure 24 shows a movable die 200 and a stationary die 201. Die 201 is similar to die 70 and includes a die cavity 220 having a frusto-conical recess 221 for forming the top portion of a battery terminal. An injector sleeve 223, similar to injector sleeve 79, is located in die 201 for injecting the finished part. Movable die 200 includes a slidable punch 202. Punch 202 includes an annular end face 213, a cylindrical section 203, a frusto-conical connecting region 205, a further frusto-conical region 206, and a cylindrical section 207 having an end surface 216. The diameter of section 207 is slightly larger than the inside diameter of the lead slug 40 so the lead slug is maintained in frictional contact on punch section 207 through frictional engagement between slug 40 and punch section 207. Punch 202 is powered by a source not shown and slides within a sleeve 263. Located on pin 202 is a sleeve die 204 for forming the annular V-shaped groove in the underside of the battery terminal flange as well as the locking lugs located around the periphery of the battery terminal shown in Figures 21 and 22. To understand the process of forming a finished battery terminal in a two-step operation, reference should be made to Figures 24-28. Figure 24 shows lead slug 40 held on pin 207 in a position between die 200 and 201. In this position, the slug is ready to begin the process of deformation. Figure 25 shows the die 200 abutting against die 201 with punch 202 extending into and through lead slug 150. Figures 25 shows lead slug 40 being forced radially outward into the cavity 221a. The end of slug 175 is shown being forced out of die 201. In the condition shown in Figure 25, the end of die sleeve 204 rests against punch end face 213 through the action ofa compression spring 215 located in annular chamber 216. Note that in the position shown in Figure 25, the metal 150a only partially fills the battery terminal cavity 221a. Figure 26 illustrates the beginning of the formation of the neck in the flange area of a battery terminal. Note that die sleeve 204 is moved forward a distance x p by cylindrical end face 213. Spring 215 compresses to allow forward motion of die sleeve 204. The lead 150b located radially outward forms flange 152 with the slidable die 204 axially slidable along pin 202 to form the V-groove in the underside of flange 152. Figure 27 shows pin 202 at the bottom of its stroke with sleeve 204 extending a distance noted by x f. Note that spring 15 is fully compressed in annular chamber 216. This is in a later portion of the stroke. The opposite end of sleeve 202 actually deforms and necks down the flange 152 to form the V-shaped groove or acid ring on the underside of flange 152. With the die sleeve in the position shown in Figure 27, the battery terminal 150 is in the finished condition and is ready for use. Figure 28 shows the dies 200 and 201 separated with the finished battery terminal 150 ready for removal by ejector sleeve 223. Note that die sleeve 204 returns to its retracted condition with compression spring 215 expanding to displace die sleeve 204 to the left into a position for forming another battery terminal. Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.

Claims: A process of cold forming a finished battery terminal (10) from a preworked lead slug (40) in one working stage by: placing said lead slug (40) having a first end (43) and a second end (41) between two dies (50, 70) at least one (50a) of said dies (50, 70) being segmented; forming a die chamber in the shape of a battery terminal around the lead slug by closing the two dies (50, 70) and by radially collapsing said segmented die (50a) around the lead slug (40); punching out the first end (43) of the lead slug (40) by forcing the end (57) of a punch (52) through the end (41) of the lead slug (40); driving the end (57) of the punch (52) through the lead slug (40) to force excess lead (40a) out of the die chamber; continuing to drive the punch (52) through the first end (43) of the lead slug (40) until the excess lead (40a) is sheared from the first end (43) of the lead slug (40); thereby deforming the lead slug (40) into the shape of a finished battery terminal (10) defined by the die chamber; separating the die segments (60, 61, 62, 63) of said segmented die (50a) around the lead slug (40) so that the die chamber is free of the external features of the finished battery terminal (10); and ejecting the finished battery terminal (10) from the die chamber. The process of claim 1 including the step of closing the die chamber with two different regions (53, 55) of the punch (52). The process of claim 1 or 2 including the step of radially expanding the lead slug (40) into the die chamber while forcing excess lead (40a) axially forward in the die chamber by driving a stepped punch (52) having cylindrical stepped sections (55, 57) with a frusto-conical transition zone (56) therebetween through the lead slug (40) with the transition zone (56) forming an angle of about 11° to the central axis of the punch (52) to thereby limit the radially expanding forces on the lead slug (40) by simultaneously forcing a portion of the lead (40a) radially and a further portion of lead (40a) axially forward of the transition zone (56) until the further portion (40a) is outside of the die chamber to thereby cold form a substantially flash free finished battery terminal (10). An apparatus for forming a finished battery terminal (10) comprising: a first stationary die case (70) and a second moveable die case (50); a first die (72) having a cavity in the shape of one portion of a battery terminal (10); a segmented second die (50a) having a cavity when closed in the shape of another portion of a battery terminal (10); an ejector sleeve (74) having a central opening therein, said ejector sleeve (74) slidable with respect to said first stationary die case (70) for ejection of a finished battery terminal(10) from said first die (72); a stepped punch (52) for forming a finished battery terminal (10) when said segmented second die (50a) is collapsed around a lead slug (40), said stepped punch (52) having a first region (57) for punching out the end (41) of the lead slug (40) located in said segmented second die (50a), said punch (52) having, a second region (56) for severing waste material (40a) and a third region (55) for sealing one end of a chamber containing the lead slug (40), said punch (52) including a fourth region (54) for radially expanding the remaining portion of the lead slug (40) into a finished battery terminal (10) as said punch (52) is driven into said lead slug (40) so that after said punch (52) forms the finished battery terminal (10) said punch (52) can be withdrawn from the finished battery terminal (10) and said segmented second die (50a) can be expanded radially to allow said segmented second die (50a) to move free of the finished battery terminal (10). The apparatus of claim 3 wherein the segmented second die (50a) has four parts (60, 61, 62, 63) and wherein said punch (52) includes a fifth region (53) for closing the opposite end of the chamber containing the lead slug (40) so that said further driving of said punch (52) into the chamber causes the remaining portion of the lead slug (40) to completely fill the die chamber to thereby form a finished battery terminal (10), and wherein said second region (56) of the punch is a frusto-conical transition section connecting said first region (57) being a cylindrical section to said third region (55) being a cylindrical section with said transition section (56) having a transition zone angle (Θ) that is less than 15° so that when lead is expanded radially in said die (72), lead is sheared from said slug (40) without increasing the pressure on the lead to a point where a flash is formed around the battery terminal (10). A process of cold forming a finished battery terminal (150) having a necked down region (153) on a flange (152) extending outward from the battery terminal (150) from a preworked lead slug (40) in one working stage comprising: placing said lead slug (40) having a central axis, a first end, and a second end, between two dies (200, 201) having a die cavity in the shape of a semi-finished battery terminal (150a); radially expanding the lead slug (40) outward into the die cavity to partially fill the die cavity to thereby form a semi-finished cold formed battery terminal (150a) having a partially radially extending flange; and driving a further axially moveable sleeve die (204) into the radially extending flange to complete formation of the flange (152) with a necked down region (153) to thereby form a finished battery terminal (150) with a flange (152) having a necked down region (153). An apparatus for forming a finished battery terminal (150) comprising: a first die (201) having a cavity in the shape of one portion of a semi-finished battery terminal (150a); a second die (201) having a cavity in the shape of a further portion of a semi-finished battery terminal (150a) ; a stepped punch (202) having at least two cylindrical stepped sections (203, 207) and two frusto-conical transition zones (205, 206) therebetween for driving into and radially expanding a lead slug (40), a further sleeve die (204) axially slidable with respect to said stepped punch (202) so that when said stepped punch (202) is driven into the lead slug (40), to form a semi-finished battery terminal (150a) said further sleeve die (204) deforms the lead slug (40) in an axial and radial direction to thereby form a finished battery terminal (150) with a necked down flange (152). The apparatus of claim 7 including a compression spring (215) acting in substantially axial direction on that further sleeve die (204) for normally maintaining said further sleeve die (204) in a retracted condition, wherein said compression spring (215) is sufficiently weak so as to compress during a portion of the stroke of said punch (202), and said further sleeve die (204) has an annular V-shaped protrusion (153) thereby forming a necked down portion (153) on the flange (152) of a battery terminal (150). A battery terminal (10) formable in accordance with one or more of claims 1-3 lockable in a leakproof relation with a battery container (11) to prevent accidental freeing of the battery terminal (10) from the battery container (10) comprising: a cylindrical lead battery terminal (10) for connecting to the grid post of a battery, said cylindrical lead battery terminal (10) having a container engaging portion (13a, 16, 17 18) and a non-container engaging portion (12), said container engaging portion (13a, 16, 17, 18) including a plurality of acid rings (16, 17, 18) to help prevent an electrolyte from leaking past the junction formed between the acid rings (16, 17, 18) and a battery container (11), said container engaging portion (13a, 16, 17, 18) including an annular flange (13a), said annular flange (13a) having a plurality of frusto conical shaped cavities (15) located at least partially on the outer circumference of said flange (13a), said frusto conical shaped cavities (15) having a base region (W1) and an apex region (W2) with said base region (W1) being larger then said apex region (W2), said base region (W1) located radial outward of said apex region (W2) so that a protrusion (19) on a battery container (11) can mateingly engage one of said frusto conical shaped cavities (15) to lock the battery container (11) to said cylindrical lead battery terminal (10) to help prevent a user from accidently torquing said cylindrical lead battery terminal (10) free of the battery container (11). The battery terminal of claim 9 wherein each of said frusto conical shaped cavities (15) have a central axis with the central axis of each of said frusto conical shaped cavities (15) converge at a common point radially inward of said frusto conical shaped cavities (15) and each of said frusto conical shaped cavities (15) is spaced equidistant from an adjacent frusto conical shaped cavity (15).

Inventors: CAIN RONALD, PETERSON NORMAN, RATTE ROBERT, CAIN, RONALD, PETERSON, NORMAN, RATTE, ROBERT
Applicants: WATER GREMLIN CO, WATER GREMLIN COMPANY
Application year: 1993
Main classification: H01M2
IPC codes: H01M2, B21K21