US3793086A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of constructing a battery connector
Assignee: General Battery Corp
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Filing: 1972-04-13
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Granted: 1974-02-19
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Expires: 1992-04-13
Abstract
Abstract A method is disclosed for producing through-the-partition battery intercell electrical connections. Flat surfaced connector lugs are placed on each side of a battery partition wall, adjacent an aperture. The connector lugs are each cold formed by a pair of opposed electrodes under the application of high shear force sufficient to extrude the lugs into the aperture until they meet. The high initial shear force on the electrodes then is reduced to a lower secondary shear force, and an electrical welding current is then applied. The welding current is increased as the metal-to-metal contact of the opposed connector lugs increases until the welded connector lugs fills the aperture with metal. The welding current then ceases and the welded connector lugs are allowed to cool while still under the lower secondary shear force. The electrodes are removed from connection and the battery casing, containing liquid-tight intercell battery connections, is ready for further manufacturing or assembling steps.
Inventors
- 👤 J Badger
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 18:45
CPC Classifications
H; H01; H01M; H01M50/00; H01M50/50; H01M50/528; H01M50/529; Y; Y02; Y02E; Y02E60/00; Y02E60/10
Claims Analysis
Total Claims: 7
Claim 1
Independent Claim
173 words
A method for making a battery intercell electrical connection through an aperture in a battery partition wall which comprises the steps of (1) placing opposed conductive connector elements adjacent the aperture on each side of said partition wall, said connector elements having a flat face adjacent said aperture, (2) cold forging said connector elements by applying thereto an initial high compressive load to drive portions of said flat face into said aperture to provide metal-to-metal contact of said connector element faces within said aperture, (3) reducing said compressive load to a secondary loading of less than half of said initial high load (4) passing an electric welding current through said contacting connector elements through said aperture, and increasing said welding current as said metal-to-metal contact increases due to continued deformation of said connector elements, until said connector elements fill said aperture in said partition wall, (5) stopping said electric current to cool said welded metal while maintaining secondary compressive load on said elements, and (6) releasing said elements from said secondary compressive load.
Claim 2
Independent Claim
173 words
A method for making a battery intercell electrical connection through an aperture in a battery partition wall which comprises the steps of (1) placing opposed conductive connector elements adjacent the aperture on each side of said partition wall, said connector elements having a flat face adjacent said aperture, (2) cold forging said connector elements by applying thereto an initial high compressive load to drive portions of said flat face into said aperture to provide metal-to-metal contact of said connector element faces within said aperture, (3) reducing said compressive load to a secondary loading of less than half of said initial high load (4) passing an electric welding current through said contacting connector elements through said aperture, and increasing said welding current as said metal-to-metal contact increases due to continued deformation of said connector elements, until said connector elements fill said aperture in said partition wall, (5) stopping said electric current to cool said welded metal while maintaining secondary compressive load on said elements, and (6) releasing said elements from said secondary compressive load.
Claim 3
Independent Claim
177 words
A method for making a battery intercell electrical connection through an aperture in a battery partition wall which comprises the steps of (1) placing opposed conductive connector elements adjacent the aperture on each side of said partition wall, said connector elements having a flat face adjacent said aperture, (2) cold forging said connector elements by engaging said elements exteriorly with a pair of opposed converging extruder die plates having projecting tips thereon, said plated applying to said connector elements an initial high clamping force sufficient to drive portions of said flat face into said aperture to provide metal-to-metal contact of said connector element faces within said aperture, (3) reducing said clamping force to a secondary low value less than half of said initial value and passing an electric welding current through said projecting tips and through said contacting connector elements until said connector elements fill said aperture in said partition wall, (4) stopping said electric current to cool said welded metal while maintaining clamping force on said elements, and (5) releasing said elements from said clamping force.
Claim 4
Independent Claim
177 words
A method for making a battery intercell electrical connection through an aperture in a battery partition wall which comprises the steps of (1) placing opposed conductive connector elements adjacent the aperture on each side of said partition wall, said connector elements having a flat face adjacent said aperture, (2) cold forging said connector elements by engaging said elements exteriorly with a pair of opposed converging extruder die plates having projecting tips thereon, said plated applying to said connector elements an initial high clamping force sufficient to drive portions of said flat face into said aperture to provide metal-to-metal contact of said connector element faces within said aperture, (3) reducing said clamping force to a secondary low value less than half of said initial value and passing an electric welding current through said projecting tips and through said contacting connector elements until said connector elements fill said aperture in said partition wall, (4) stopping said electric current to cool said welded metal while maintaining clamping force on said elements, and (5) releasing said elements from said clamping force.
Claim 5
Dependent Claim
31 words
The method of claim 2 wherein said electric welding current is initially applied at a low amperage and is increased throughout the welding sequence as metal-to-metal contact of the element increases.
Claim 6
Dependent Claim
46 words
A method of making a battery intercell electrical connection through an aperture in a battery partition wall, as recited in claim 2, wherein said current passing step further includes increasing said welding currEnt as said metal-to-metal contact increases due to continued deformation of said connector elements.
Claim 7
Dependent Claim
44 words
A method of making a battery intercell electrical connection through an opening in a battery partition wall, as recited in claim 2, wherein said initial high clamping force is between 6, 500 and 10,000 psi, and said secondary low value is about 3,000 psi.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-02-18 | 1977-08-20 | 1978-02-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-02-18 | 1981-08-20 | 1982-02-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-02-18 | 1985-08-20 | 1986-02-19 | $7700.00 | Window Closed / Lapsed |