US3874933A — Method for casting battery terminals

Claim 1

Independent Claim 57 words

A METHOD FOR FORMING A METAL TERMINAL EXTENDING WITHIN AND THROUGH A WALL OF A BATTERY CONTAINER HAVING A THICKNESS OF LESS THAN ABOUT 0.2 INCHES AND FABRICATED OF A THERMALLY DEFORMABLE PLASTIC MATERIAL HAVING A SOFTENING POINT BELOW ABOUT 300*F. SAID TERMINAL PROVIDING ELECTRICAL CONDUCTION BETWEEN THE INTERIOR AND EXTERIOR OF SUCH CONTAINER WHICH METHOD COMPRISES:

Claim 2

Independent Claim 57 words

A METHOD FOR FORMING A METAL TERMINAL EXTENDING WITHIN AND THROUGH A WALL OF A BATTERY CONTAINER HAVING A THICKNESS OF LESS THAN ABOUT 0.2 INCHES AND FABRICATED OF A THERMALLY DEFORMABLE PLASTIC MATERIAL HAVING A SOFTENING POINT BELOW ABOUT 300*F. SAID TERMINAL PROVIDING ELECTRICAL CONDUCTION BETWEEN THE INTERIOR AND EXTERIOR OF SUCH CONTAINER WHICH METHOD COMPRISES:

Claim 3

Dependent Claim 16 words

PROVIDING A WALL OF SUCH CONTAINER WITH A PORT ADAPTED FOR RECEIVING AND HOLDING A TERMINAL

Claim 4

Dependent Claim 16 words

PROVIDING A WALL OF SUCH CONTAINER WITH A PORT ADAPTED FOR RECEIVING AND HOLDING A TERMINAL

Claim 5

Dependent Claim 57 words

INJECTING MOLTEN METAL UNDER HIGH PRESSURE INTO SUCH PORT AND WITHIN A DIE MOLD CAVITY POSITIONED ABOUT THE PORT TO SHAPE THE MOLTEN METAL INTO A TERMINAL OF A UNITARY MEMBER HAVING THE DESIRED SHAPE SAID HIGH PRESSURE BEING SUFFICIENT TO FORCE THE MOLTEN METAL INTO AND THROUGH THE DIE CAVITY AND IN THE DESIRED EXCESS QUANTITY

Claim 6

Dependent Claim 57 words

INJECTING MOLTEN METAL UNDER HIGH PRESSURE INTO SUCH PORT AND WITHIN A DIE MOLD CAVITY POSITIONED ABOUT THE PORT TO SHAPE THE MOLTEN METAL INTO A TERMINAL OF A UNITARY MEMBER HAVING THE DESIRED SHAPE SAID HIGH PRESSURE BEING SUFFICIENT TO FORCE THE MOLTEN METAL INTO AND THROUGH THE DIE CAVITY AND IN THE DESIRED EXCESS QUANTITY

Claim 7

Dependent Claim 57 words

injecting molten metal under high pressure into such port and within a die mold cavity positioned about the port to shape the molten metal into a terminal of a unitary member having the desired shape said high pressure being sufficient to force the molten metal into and through the die cavity and in the desired excess quantity

Claim 8

Dependent Claim 57 words

injecting molten metal under high pressure into such port and within a die mold cavity positioned about the port to shape the molten metal into a terminal of a unitary member having the desired shape said high pressure being sufficient to force the molten metal into and through the die cavity and in the desired excess quantity

Claim 9

Dependent Claim 84 words

The method of claim 1 wherein during the injection of the molten metal into the port and within the mold cavity and prior to solidification of the metal, the air within the port and mold cavity is removed to prevent entrappment of air in the solidifying metal and thus maintain desirable electrical properties for the terminal by entrapping portions of the air within the molten metal and removing the mOlten, air-containing metal from the port and mold cavity prior to solidification of the metal.

Claim 10

Dependent Claim 61 words

The method of claim 1 wherein prior to the injection of the molten metal, an internally threaded, metal insert is first positioned within the port so that when the molten metal is later injected such metal flows about the insert and upon solidifying locks the insert within the terminal to provide a threadable means for external mechanical connection to the terminal.

Claim 11

Dependent Claim 114 words

regulating the quantity of heat energy introduced into the die cavity so that the metal freely flows to form the desired shape of the terminal and solidifies without destroying the structure or composition of such port and wall, said regulation achieved by controlling the temperature of the metal initially within the range of from about 620* to 750*F and by injecting a quantity of molten metal into the die cavity in excess of the volume of such cavity and allowing such excess to flow out of the cavity prior to solidification of the metal, said excess ranging from about 3.0 to about 6.0 volumes of metal per unit volume of the die cavity, and

Claim 12

Dependent Claim 114 words

regulating the quantity of heat energy introduced into the die cavity so that the metal freely flows to form the desired shape of the terminal and solidifies without destroying the structure or composition of such port and wall, said regulation achieved by controlling the temperature of the metal initially within the range of from about 620* to 750*F and by injecting a quantity of molten metal into the die cavity in excess of the volume of such cavity and allowing such excess to flow out of the cavity prior to solidification of the metal, said excess ranging from about 3.0 to about 6.0 volumes of metal per unit volume of the die cavity, and

Claim 13

Dependent Claim 115 words

REGULATING THE QUANTITY OF HEAT ENERGY INTRODUCED INTO THE DIE CAVITY SO THAT THE METAL FREELY FLOWS TO FORM THE DESIRED SHAPE OF THE TERMINAL AND SOLIDIFIES WITHOUT DESTROYING THE STRUCTURE OR COMPOSITION OF SUCH PORT AND WALL, SAID REGULATION ACHIEVED BY CONTROLLING THE TEMPERATURE OF THE METAL INITIALLY WITHIN THE RANGE OF FROM ABOUT 620* TO 750*F AND BY INJECTING A QUANTITY OF MOLTEN METAL INTO THE DIE CAVITY IN EXCESS OF THE VOLUME OF SUCH CAVITY PRIOR TO ALLOWING SUCH EXCESS TO FLOW OUT TO THE CAVITY PRIOR TO SOLIDIFICATION OF THE METAL, SAID EXCESS RANGING FROM ABOUT 3.0 TO ABOUT 6.0 VOLUMES OF METAL PER UNIT VOLUME OF THE DIE CAVITY, AND

Claim 14

Dependent Claim 115 words

REGULATING THE QUANTITY OF HEAT ENERGY INTRODUCED INTO THE DIE CAVITY SO THAT THE METAL FREELY FLOWS TO FORM THE DESIRED SHAPE OF THE TERMINAL AND SOLIDIFIES WITHOUT DESTROYING THE STRUCTURE OR COMPOSITION OF SUCH PORT AND WALL, SAID REGULATION ACHIEVED BY CONTROLLING THE TEMPERATURE OF THE METAL INITIALLY WITHIN THE RANGE OF FROM ABOUT 620* TO 750*F AND BY INJECTING A QUANTITY OF MOLTEN METAL INTO THE DIE CAVITY IN EXCESS OF THE VOLUME OF SUCH CAVITY PRIOR TO ALLOWING SUCH EXCESS TO FLOW OUT TO THE CAVITY PRIOR TO SOLIDIFICATION OF THE METAL, SAID EXCESS RANGING FROM ABOUT 3.0 TO ABOUT 6.0 VOLUMES OF METAL PER UNIT VOLUME OF THE DIE CAVITY, AND

Claim 15

Dependent Claim 46 words

RECOVERING THE CONTAINER WITH THE SOLIDIFIED TERMINAL EXTENDING WITHIN AND THROUGH THE WALL IN THE DESIRED SHAPE WITH DESIRABLE ELECTRICAL PROPERTIES AND PROVIDING A FLUID TIGHT SEAL ABOUT THE TERMINAL BETWEEN THE INTERIOR AND EXTERIOR OF THE CONTAINER WITHOUT THE NECESSITY OF ANY FURTHER SEALING PROCEDURE.

Claim 16

Dependent Claim 46 words

RECOVERING THE CONTAINER WITH THE SOLIDIFIED TERMINAL EXTENDING WITHIN AND THROUGH THE WALL IN THE DESIRED SHAPE WITH DESIRABLE ELECTRICAL PROPERTIES AND PROVIDING A FLUID TIGHT SEAL ABOUT THE TERMINAL BETWEEN THE INTERIOR AND EXTERIOR OF THE CONTAINER WITHOUT THE NECESSITY OF ANY FURTHER SEALING PROCEDURE.

Claim 17

Dependent Claim 46 words

recovering the container with the solidified terminal extending within and through the wall in the desired shape with desirable electrical properties and providing a fluid tight seal about the terminal between the interior and exterior of the container without the necessity of any further sealing procedure.

Claim 18

Dependent Claim 46 words

recovering the container with the solidified terminal extending within and through the wall in the desired shape with desirable electrical properties and providing a fluid tight seal about the terminal between the interior and exterior of the container without the necessity of any further sealing procedure.

Claim 19

Dependent Claim 28 words

The method of claim 3 wherein the terminal metal contains lead and the metal insert is composed of a metal having greater wear resistance than the terminal metal.

Claim 20

Dependent Claim 62 words

The method of claim 1 wherein the mold cavity is contoured so that the molten metal when injected is shaped to form a main body portion extending through the wall and flared end portions extending laterally over and flush with the adjacent portions of the interior and exterior surfaces of the wall to anchor the cast terminal in place through the wall.

Claim 21

Dependent Claim 74 words

The method of claim 5 wherein the mold cavity is contoured so that the molten metal when injected is shaped to form an L-shape with the main body portion forming one leg extending horizontally through the side wall of the container and the flared end portion adjacent the interior surface of the wall forming the the other leg extending vertically upward and having an exposed surface for making an electrical contact interior the container.

Claim 22

Dependent Claim 56 words

The method of claim 1 wherein the port comprises a boss structure with a circular ring portion extending outwardly from the wall and defining an opening through the wall into which the molten metal flows during injection and upon solidification the metal within such opening anchors the solid terminal in a locked position within the port.

Claim 23

Dependent Claim 52 words

The method of claim 7 wherein the circular ring portion of the boss comprises a plurality of ring projections defining hollow concentric spaces therebetween into which the molten metal flows during the injection and upon solidification the metal within such spaces anchors the solid terminal in a locked position within the port.

Claim 24

Dependent Claim 57 words

The method of claim 7 wherein the port is provided with a plurality of lugs disposed about the internal periphery of the port and extend radially inwardly over which the molten metal flows during injection and upon solidification the lugs become embedded within the solid metal to anchor the terminal in a locked position within the port.

Claim 25

Dependent Claim 26 words

The method of claim 1 wherein the molten metal ranges from about 4.5 to about 4.9 volumes of metal per unit volume of the die cavity.

Claim 26

Dependent Claim 13 words

The method of claim 1 wherein the metal contains a preponderance of lead.

Claim 27

Dependent Claim 58 words

The method of claim 1 wherein the temperature of the metal in the die mold cavity is controlled by regulating the contact time of the molten and resultant solidified metal with the port and wall so that the metal is cooled at least below the heat distortion temperature of the port and wall prior to recovering the container.

Claim 28

Dependent Claim 16 words

The method of claim 1 wherein the thermally deformable material of the container is a polyolefin.

Claim 29

Dependent Claim 10 words

The method of claim 13 wherein the polyolefin is polypropylene.

Claim 30

Dependent Claim 25 words

The method of claim 1 wherein the molten metal is injected under a pressure of from about 850 to about 1050 pounds per square inch.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1978-03-31	1978-09-30	1979-04-01	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1982-03-31	1982-09-30	1983-04-01	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1986-03-31	1986-09-30	1987-04-01	$7700.00	Window Closed / Lapsed

Method for casting battery terminals

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