Abstract:
A method of dispensing metered portions of molten lead comprises the steps of providing a heater body with a lead reservoir that produces sufficient heat to form molten lead and providing a lead dispensing shuttle plate with at least two lead metered cavities that are filled with molten lead in a fill position. The heater body is movable between a dispense position and a feed position. At least one of the metered cavities releases the molten lead when the heater body is moved to the dispense position. In one aspect, the method comprises supplying a strip of lead so that when the heater body moves to the feed position, it receives a portion of the strip of lead. In another aspect, the method comprises injecting inert gas over the lead reservoir and into the dispensing metered cavity to prevent air from entering the metered cavity.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a Division of U.S. patent application Ser. No. 09/862,792, filed on May 22, 2001, the entire text of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates generally to assembling lead acid batteries and more specifically to a battery assembling method which produces lead acid batteries which have many improvements over the prior art.  
         [0004]     2. Discussion of the Prior Art  
         [0005]     A present problem of lead acid battery manufacture is the rapid oxidation of molten lead which is exposed to the atmosphere when it is heated above the 625 degrees Fahrenheit melting point. The problem is greatly compounded when molten lead exposed to the atmosphere is further heated to nearly 1000 degrees Fahrenheit. Plate lugs of the battery cells enter such dispensed high temperature molten lead and fuse with it, the lugs further act as heat sinks for cooling the dispensed lead. At such elevated temperatures substantial drossing can occur which is wasteful, expensive, abrasive, clogging and toxic.  
         [0006]     Accordingly, there is a clearly felt need in the art for a battery assembling machine which does not expose molten lead to the atmosphere, thus preventing drossing of the molten lead.  
       OBJECTS OF THE INVENTION  
       [0007]     Accordingly, it is an object of the present invention to provide a battery assembling method which reduces the amount of equipment and manpower required.  
         [0008]     It is a further object of the present invention to provide a battery assembling method which is rapid, efficient and relatively inexpensive.  
         [0009]     It is yet a further object of the present invention to provide a battery assembling method which seals, but does not expose molten lead to the atmosphere, thus preventing drossing of the molten lead.  
         [0010]     It is yet a further object of the present invention to provide a battery assembling method which does not require venting of an open lead pot.  
         [0011]     It is yet a further object of the present invention to provide a battery assembling method which does not require lead to be pumped and a pumping device to be maintained.  
         [0012]     Finally, it is another object of the present invention to provide a battery assembling method which does not require a large quantity of lead to be maintained at a molten temperature with the associated energy costs.  
         [0013]     These and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification.  
       SUMMARY OF THE INVENTION  
       [0014]     The present invention provides a battery assembling method which is more efficient than that of the prior art. The battery assembling method includes a lead dispenser/heater unit, cover positioner, container positioner, and lead feeder. A battery container with battery plates contained therein is initially retained by a horizontal container positioner.  
         [0015]     Lug preparation is not required when utilizing some types of lead alloys. If needed, the lug preparation area includes at least one heating station. The lug preparation area may also include at least one fluxing station, and at least one tinning station. The inclusion of the fluxing and tinning stations is dependent upon the condition of the plate lugs of the battery, before insertion into the battery assembling device. The lug preparation area disclosed in this application is given by way of example and not by way of limitation. A lug preparation area may include any combination or order of the above disclosed stations.  
         [0016]     The horizontal container positioner indexes the battery container over the lug heating station and the lugs of the battery plates are heated before fluxing. The horizontal container positioner then indexes the battery container over the fluxing station and flux is applied to the lugs of the battery plates. The horizontal container positioner next indexes the battery container over the tinning station and the lugs are tinned with solder.  
         [0017]     The horizontal container positioner finally indexes the battery container over the lead dispenser/heater unit. The container positioner grips the battery container and the horizontal container positioner releases its grip on the battery container. The lead dispenser/heater unit includes a container heating platen, a cover heating platen, a heater body, a lead dispensing shuttle plate, a lead reservoir and an inert gas cavity. The container heating platen is disposed on a top of the heater body and the cover heating platen is disposed on a bottom thereof. The lead reservoir is disposed in a top of the heater body. A strip opening is formed in a lead reservoir cover plate which is attached to a top of the heater body above the lead reservoir. The inert gas cavity is disposed above the lead reservoir. The inert gas cavity is filled with inert gas from a supply tank. The inert gas displaces and prevents regular air from entering the lead reservoir and drossing the molten lead.  
         [0018]     The lead dispensing shuttle plate is disposed in a middle of the heater body. The lead dispensing shuttle plate includes at least two lead metered cavities for dispensing molten lead which forms plate straps and terminals in the battery cover. The lead dispensing shuttle plate has a fill position for retaining molten lead and a dispense position for dispensing molten lead into the battery cover.  
         [0019]     The container positioner lowers the battery container such that an edge of an open end thereof contacts a container heating platen and the cover positioner raises the battery cover such that an edge of an open end contacts the cover heating platen. The lead dispensing shuttle plate is slid into a dispense position to direct molten lead into plate strap mold wells in the battery cover and into terminal molds to form plate straps and terminals. A dispenser actuator pulls the lead dispenser/heating unit back such that the strip opening aligns with a lead strip of the lead feeder. The lead that was dispensed for previous battery is replaced with new lead from the lead feeder.  
         [0020]     As the dispenser actuator pulls the combination lead dispenser/heating unit, the container positioner is lowered and the cover positioner raised such that the edge of the open end of the battery container is attached to the edge of the open end of the battery cover. The container and cover heating platens heat the open end of the container and the open end of the cover such that the cover may be sealed to the container. Once the lead in plate straps and terminals solidify, the battery is grasped by a conveyer gripper and aligned with a conveyor by a conveyer actuator. A vertical conveyer actuator is raised to meet the battery. The conveyer gripper is released and the conveyer transports the completed battery to an external location. The battery assembling method is capable of producing batteries disclosed in U.S. Pat. Nos. 5,885,731 and 6,059,848. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]      FIG. 1  is a cross sectional view of a battery assembling method with two batteries at different positions of the process in accordance with the present invention.  
         [0022]      FIG. 2  is an enlarged cross sectional view of a lead dispenser/heater unit in accordance with the present invention.  
         [0023]      FIG. 3  is a cross sectional view of a battery assembling method where cover and container positioners have brought a second battery cover and container in contact with a lead dispenser/heater unit in accordance with the present invention.  
         [0024]      FIG. 4  is a cross sectional view of a battery assembling method where terminal molds have been brought in contact with a second battery cover in accordance with the present invention.  
         [0025]      FIG. 5  is a cross sectional view of a battery assembling method showing a first battery container indexed over a fluxing station; and a shuttle plate slid to a dispense position in accordance with the present invention.  
         [0026]      FIG. 6  is a cross sectional view of a battery assembling method showing plate lugs of a first battery container being fluxed; plate strap and terminal molds of a second battery cover being filled with molten lead in accordance with the present invention.  
         [0027]      FIG. 7  is a cross sectional view of a battery assembling method showing plate lugs of a first battery container after fluxing; plate strap and terminal molds of a second battery cover filled with molten lead in accordance with the present invention.  
         [0028]      FIG. 8  is a cross sectional view of a battery assembling method showing a first battery container indexed over a tinning station; battery cover and container positioners bringing a second battery cover and container away from a lead dispenser/heater unit in accordance with the present invention.  
         [0029]      FIG. 9  is a cross sectional view of a battery assembling method showing plate lugs of a first battery container being tinned; a lead dispenser heater unit withdrawn such that thereof is replenished with lead in accordance with the present invention.  
         [0030]      FIG. 10  is a cross sectional view of a battery assembling method showing a second battery cover being heat sealed to a second battery container in accordance with the present invention.  
         [0031]      FIG. 11  is a cross sectional view of a battery assembling method showing plate lugs of a first battery container removed from a tinning station; a cover positioner withdrawing from under a second battery container in accordance with the present invention.  
         [0032]      FIG. 12  is a cross sectional view of a battery assembling method showing a first battery container grasped by a container positioner; a second assembled battery grasped by a conveyer gripper and aligned with a conveyor in accordance with the present invention.  
         [0033]      FIG. 13  is a cross sectional view of a battery assembling method showing a movable conveyor section raised to meet a second assembled battery; a lead dispenser/heater unit positioned to receive a new second battery container in accordance with the present invention.  
         [0034]      FIG. 14  is a cross sectional view of a battery assembling method showing a new first battery indexed over a heating station; a new second battery container loaded into a container positioner in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0035]     With reference now to the drawings, and particularly to  FIG. 1 , there is shown a cross sectional view of a battery assembling method. With reference to  FIGS. 2-14 , the battery assembling method includes a lead dispenser/heater unit  12 , cover positioner  14 , container positioner  16 , and lead feeder  18 . A first battery container  200  with battery plates  202  contained therein is retained by a horizontal container positioner  20 . The horizontal container positioner  20  includes a horizontal container actuator  21  and gripper fingers  23 . The above items are preferably retained in some type of frame  22 .  
         [0036]     A lug preparation area  10  is not required when utilizing some types of lead alloys. If needed, the lug preparation area includes at least one heating station  24 . The at least one heating station  24  preferably includes a heating actuation device  26 , a mounting plate  28 , and at least one heating element  30 . Preferably, an inductive heating element is used, but other types of heating devices may also be used. The lug preparation area  10  may also include at least one fluxing station, and at least one tinning station. The inclusion of the fluxing and tinning stations is dependent upon the condition of the plate lugs of the battery and the lead alloy used in the battery, before insertion into the battery assembling device  1 .  
         [0037]     The lug preparation area  10  disclosed in this application is given by way of example and not by way of limitation. A lug preparation area may include any combination or order of the above disclosed stations. As disclosed by example in this application, a lug actuator  32  is used to provide vertical movement to a lug plate  34 . A fluxing pan  36  is attached to a top of the lug plate  34  and contains a quantity of flux  204 . A tinning pan  38  is attached to a top of the lug plate  34  and contains a quantity of molten solder  206 . At least one heater element  40  is used to maintain the solder at a molten temperature. The container positioner  16  includes a container actuator  17  and container gripping fingers  19  which are attached to a moving end of the container actuator  17 .  
         [0038]     With reference to  FIG. 2 , the lead dispenser/heater unit  12  includes a heater body  42 , a container heating platen  44 , a cover heating platen  46 , a lead dispensing shuttle plate  48 , and a dispenser actuator  50 . The container heating platen  44  is attached to a top of the heater body  42  with a cover insulator  52  inserted therebetween. The lead dispensing shuttle plate  48  preferably includes a top plate  49  and a bottom plate  51 . At least two lead entrance openings  53  are formed through the top plate  49 . At least two lead metered cavities  55  are formed in the lead dispensing shuttle plate  48  in line with the at least two lead entrance openings  53 . A lead exit opening  57  is formed through a bottom of each lead metered cavity  55 . A shuttle slot  54  is formed in a bottom of the heater body  42 . The shuttle slot  54  is sized to slidably receive the lead dispensing shuttle plate  48 .  
         [0039]     A shuttle retention plate  56  retains the lead dispensing shuttle plate  48  under spring force. At least two spring loaded bolts  58  force a top of the shuttle retention plate  56  against a bottom of the lead dispensing shuttle plate  48  and a top of the lead dispensing shuttle plate  48  against a top of the shuttle slot  54 . The force fit between the top and bottom of the lead dispensing shuttle plate  48  is required to prevent molten lead from leaving the lead metered cavities  55  and smearing on the top or bottom of the lead dispensing shuttle plate  48 . The cover heating platen  46  is attached to a bottom of the shuttle retention plate  56  with a container insulator  60  inserted therebetween. The container and cover insulators allow the container and cover heating platens to be maintained at a different temperature than the heater body  42 .  
         [0040]     A lead reservoir cover plate  62  covers a top of a lead reservoir  64  formed in a top of the heater body  42 . A lead strip opening  66  is formed through the lead reservoir cover plate  62 , adjacent the lead reservoir  64 . A lead passage  65  is formed adjacent the lead reservoir  64 . At least one lead cross passage  67  is formed adjacent the lead passage  65 . At least two lead feed openings  69  are supplied with molten lead  210  from the lead passage  65  or at least one lead cross passage  67 . An inert gas reservoir passage  68  is formed over the lead reservoir  64 . The inert gas reservoir passage  68  receives inert gas through an inlet pipe  70 . An inert gas tank  72  supplies the inert gas  208 . The inert gas  208  prevents drossing of the molten lead  210  in the lead reservoir  64 . An inert gas passage  71  is formed in a bottom of the container heater platen  44 . At least two inert gas passage openings  74  are formed through the container insulator  52  and the heater body  42 . A shuttle actuator  76  is used to slide the lead dispensing shuttle plate  48  from a fill position to a dispensing position. An end of the shuttle plate  48  is attached to a moving end of the shuttle actuator  76 .  
         [0041]     At least two lead dispense openings  78  are formed through the shuttle retention plate  56 , container insulator  60 , and cover heating platen  46  in line with the at least two lead metered cavities  55  when in a dispense position. Preferably, a lead dispense bushing  80  is formed partially through the shuttle retention plate  56 , and through the container insulator  60 , and cover heating platen  46 . When the lead dispensing shuttle plate  48  is in a dispense position inert gas flows behind the molten lead  210  through the lead dispense openings  78 .  
         [0042]     The inert gas  208  prevents air from entering through the at least two lead dispense openings  78  until the lead dispensing shuttle plate  48  is moved to a fill position. The inert gas  208  bubbles through the molten lead  210  to the inert gas reservoir passage  68  as the at least two lead metered cavities  55  are filled with molten lead  210 . If air were allowed to fill the at least two lead metered cavities  78 , the air would dross the molten lead  210 .  
         [0043]     At least two container heaters  82  are formed in the container heating platen  44 . At least two cover heaters  84  are formed in the cover heating platen  46 . At least two retainer heaters  86  are formed in the shuttle retention plate  56 . At least two body heaters  88  are formed in the heater body  42 . A plurality of lug clearance openings  90  are formed in a top of the container heating platen  44 .  
         [0044]     With reference to  FIG. 1 , the cover positioner  14  includes a cover base  92 , a cover actuator  93 , a mold actuator  94 , and at least two terminal molds  96 . A bottom of the cover base  92  is attached to a moving end of the cover actuator  93 . The cover actuator  93  provides vertical motion to the cover base  92 . A cover cavity  98  is formed on a top of the cover base  92  to receive the battery cover  212 .  
         [0045]     A retainer plate  100  is attached to a moving end of the mold actuator  94 . Terminal cavity  102  is formed in a top of each terminal mold  96 . Each terminal mold  96  is slidably retained on a slide rod  106  and urged upward with a spring  104 . The retainer plate  100  restricts the upward movement of the terminal mold  96 . At least one liquid coolant path  108  and at least one mold heater  109  are formed in the body of each terminal mold  96 .  
         [0046]     Gripper fingers  110  extend from a moving end of a conveyor actuator  112 . A battery conveyor  114  includes a vertical conveyor actuator  116 , stationary conveyor base  118 , moveable conveyor section  120 , and a coolant spray  122 . The moveable conveyor section  120  is attached to a moving end of the vertical conveyor actuator  116 . The coolant spray  122  is attached to a bottom of the moveable conveyor section  120 .  
         [0047]     The battery assembling method preferably operates in the following manner. With reference to  FIG. 1 , if the lug preparation area  10  is required, the horizontal container positioner  20  indexes the battery container  200  over the lug heating station  24  and the lugs  209  of the battery plates  202  are heated before fluxing by the at least one heating element  30 . With reference to  FIG. 5 , the horizontal container positioner  20  then indexes the battery container  200  over the fluxing pan  36 . With reference to  FIG. 6 , the lug actuator  32  raises the fluxing pan  36  to coat the lugs  209  with flux  204 . With reference to  FIGS. 7 and 8 , the lug actuator  32  lowers the fluxing pan  36  so that the horizontal container positioner  20  may index the battery container  200  over the tinning pan  38 . With reference to  FIG. 9 , the lug actuator  32  raises the tinning pan  38  to tin the lugs  209  with solder  206 . With reference to  FIGS. 11 and 12 , the lug actuator  32  lowers the tinning pan  38  and the horizontal container positioner  20  indexes the battery container  200  over the lead dispenser/heater unit  12 .  
         [0048]     The container gripping fingers  19  grasp the battery container  200  and then the gripping fingers  23  release thereof. With reference to  FIG. 3 , the container actuator  17  lowers the battery container  200  such that an edge of an open end thereof contacts a heating surface  45  of the container heating platen  44 . The cover actuator  93  raises the battery cover  212  such that an edge of an open end contacts the heating surface  47  of the cover heating platen  46 . With reference to  FIG. 4 , the mold actuator  94  raises the retainer plate  100  such that the at least two terminal molds  96  rise to contact terminal openings in the battery cover  212 . Each terminal mold  96  is heated with the heater  109 . With reference to  FIG. 5 , the lead dispensing shuttle plate  48  is slid into a dispense position by the shuttle actuator  76 . The molten lead  210  descends through the lead exit openings  57 , the openings in the shuttle retaining plate  56 , and the lead bushings  80 . The molten lead drops into plate strap mold wells in the battery cover  212  and the terminal molds  96  form plate straps and terminals.  
         [0049]     After the molten lead has filled the plate strap mold wells and terminal molds  96 , the shuttle actuator  76  pulls the dispensing shuttle plate  48  back to the fill position. With reference to  FIG. 9 , the dispenser actuator  50  pulls the lead dispenser/heater unit  12  back such that the strip opening  66  aligns with a lead strip  124  of the lead feeder  18 . The lead  210  that was dispensed for previous battery is replaced with new lead from the lead feeder  18 . With reference to  FIG. 8 , the battery container  201  is raised and the battery cover  212  lowered and the lead dispenser/heater unit  12  pulled toward the lead feeder  18 .  
         [0050]     With reference to  FIG. 10 , after the lead dispenser/heater unit  12  is cleared away, the battery container  201  is lowered and the battery cover  212  raised such that the edge of the open end of the battery container  201  is attached to the edge of the open end of the battery cover  212 . The container and cover edge heating platens heat the open ends of the battery container and cover such that the battery cover  212  may be sealed to the battery container  201 . The at least two plate straps and terminals are substantially simultaneously cast as the battery cover is sealed to the battery container.  
         [0051]     The mold heater  109  is turned-off and coolant is run through the at least one coolant path  108 . With reference to  FIG. 13 , once the lead in plate straps and terminals solidify, the assembled battery  214  is grasped by the conveyer gripper  110  and aligned with the conveyor  114  by a conveyer actuator  112 . The moveable conveyor section  120  is raised by the vertical conveyer actuator  116  to meet the assembled battery  214 . The assembled battery  214  is sprayed with coolant  123  from a coolant spray device  122 . With reference to  FIG. 14 , the conveyer gripper  110  is released and the moveable conveyor section  120  lowers the assembled battery  214  even with the stationary conveyor base  118 . The conveyer  114  transports the assembled battery  214  to an external location where the assembled battery  214  is ready to be filled with electrolyte.  
         [0052]     While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.