Positive displacement bonding

Claim 2

grinding a bromide-salt to form a powder; and,

Claim 3

Apparatus for bonding n (where n is equal to two or more) meltable component parts together by a positive displacement molecular fusion bonding process, said apparatus comprising, iN combination: a. means for supporting said n meltable component parts on a work axis; b. a frame; c. a bonding head carried by said frame in a position overlying the component parts and with freedom for movement relative thereto along x and y coordinates; d. a barrel carried by said bonding head for movement along said work axis into sealing engagement with the component parts to be bonded; e. a ram carried by said bonding head for movement along said work axis, said ram being coaxial with said barrel and capable of axial movement therethrough; f. means for shifting said head in x and/or y oriented directions so as to align said coaxial ram and barrel with said work axis; g. means for relatively advancing said barrel and said ram along said work axis into engagement with said component parts; h. means for heating said ram to a temperature sufficiently high to melt and form a cavity in those portions of the component parts in the path of ram movement; i. ram advancing means for positively displacing the molten material formed by engagement of said heated ram with the component parts into said barrel and storing the molten material therein in heat transfer relation with said heated ram; j. means for axially retracting said ram from said component parts so as to enable the displaced molten material stored in said barrel to flow back to said cavity where said material is permitted to cool and solidify to form a uniform molecular fusion bond between said component parts with said bond being coextensive with the degree of penetration of said ram into said component parts; and, k. means for effecting relative axial retraction of said barrel from engagement with said component parts following cooling and solidification of said molten material.

Claim 4

Apparatus for bonding n (where n is equal to two or more) meltable component parts together by a positive displacement molecular fusion bonding process, said apparatus comprising, iN combination: a. means for supporting said n meltable component parts on a work axis; b. a frame; c. a bonding head carried by said frame in a position overlying the component parts and with freedom for movement relative thereto along x and y coordinates; d. a barrel carried by said bonding head for movement along said work axis into sealing engagement with the component parts to be bonded; e. a ram carried by said bonding head for movement along said work axis, said ram being coaxial with said barrel and capable of axial movement therethrough; f. means for shifting said head in x and/or y oriented directions so as to align said coaxial ram and barrel with said work axis; g. means for relatively advancing said barrel and said ram along said work axis into engagement with said component parts; h. means for heating said ram to a temperature sufficiently high to melt and form a cavity in those portions of the component parts in the path of ram movement; i. ram advancing means for positively displacing the molten material formed by engagement of said heated ram with the component parts into said barrel and storing the molten material therein in heat transfer relation with said heated ram; j. means for axially retracting said ram from said component parts so as to enable the displaced molten material stored in said barrel to flow back to said cavity where said material is permitted to cool and solidify to form a uniform molecular fusion bond between said component parts with said bond being coextensive with the degree of penetration of said ram into said component parts; and, k. means for effecting relative axial retraction of said barrel from engagement with said component parts following cooling and solidification of said molten material.

Claim 5

mechanically blending the powder with petroleum jelly; c. positioning a bonding head having a ram and a coaxial barrel over the lead components with the ram disposed on the work axis; d. relatively moving the ram and barrel into engagement with the lead components; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially into the lead components to at least partially penetrate the components as those portions of the latter within the path of ram movement melt, and displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted lead components and the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the lead components where such molten lead is permitted to cool and solidify; and, i. relatively retracting the barrel from the lead components upon cooling and solidification of the molten lead.

Claim 6

mechanically blending the powder with petroleum jelly; c. positioning a bonding head having a ram and a coaxial barrel over the lead components with the ram disposed on the work axis; d. relatively moving the ram and barrel into engagement with the lead components; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially into the lead components to at least partially penetrate the components as those portions of the latter within the path of ram movement melt, and displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted lead components and the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the lead components where such molten lead is permitted to cool and solidify; and, i. relatively retracting the barrel from the lead components upon cooling and solidification of the molten lead.

Claim 7

Apparatus as set forth in claim 1 further including means for introducing an inert gas into said barrel during a bonding operation for the purpose of entraining and removing oxidants present in the region of said bond.

Claim 8

An improved method for molecular fusion bonding of n (where n equals two or more) lead components comprising the steps of: a. positioning the n lead components on a work axis; b. applying to at least one of the lead components a bromide-salt flux formed by the preliminary steps of:

Claim 9

An improved method for molecular fusion bonding of n (where n equals two or more) lead components comprising the steps of: a. positioning the n lead components on a work axis; b. applying to at least one of the lead components a bromide-salt flux formed by the preliminary steps of:

Claim 10

The method of claim 3 wherein said bromide salt flux comprises a mixture of hydrazine monohydrobromide and petroleum jelly.

Claim 11

The method of claim 4 wherein said mixture consists of on the order of 90% petroluem jelly and 10% hydrazine monohydrobromide.

Claim 14

The method as set forth in claim 6 further characterized in that said inert gas is nitrogen.

Claim 15

In a method of forming lead-to-lead bonds between a series of pairs of coaxial lead components with a heated ram, the steps of positioning a first adaptor housing defining a mold cavity and reservoir about a first pair of coaxial lead components, advancing the heated ram into said coaxial components to melt the lead and displace the molten lead into the reservoir, retracting the ram and permitting the molten lead in the reservoir to return to the mold cavity where it cools and solidifies, positioning a second adaptor housing identical to said first housing about a second pair of coaxial lead components, advancing and retracting the heated ram into and from said second housing so as to form a second bond, shifting the first housing to a third pair of coaxial components, again advancing and retracting the heated ram into and from said first housing so as to form a third bond, and repetitively manipulating said first and second housings and said ram with respect to successive pairs of coaxial lead components so as to form successive molecular fusion bonds between such pairs in alternate ones of said first and second housings.

Claim 16

In a method of forming lead-to-lead bonds between a series of pairs of coaxial lead components with a heated ram, the steps of positioning a first adaptor housing defining a mold cavity and reservoir about a first pair of coaxial lead components, advancing the heated ram into said coaxial components to melt the lead and displace the molten lead into the reservoir, retracting the ram and permitting the molten lead in the reservoir to return to the mold cavity where it cools and solidifies, positioning a second adaptor housing identical to said first housing about a second pair of coaxial lead components, advancing and retracting the heated ram into and from said second housing so as to form a second bond, shifting the first housing to a third pair of coaxial components, again advancing and retracting the heated ram into and from said first housing so as to form a third bond, and repetitively manipulating said first and second housings and said ram with respect to successive pairs of coaxial lead components so as to form successive molecular fusion bonds between such pairs in alternate ones of said first and second housings.

Claim 17

An improved method for securing lead battery plates to a lead battery strap, comprising the steps of: a. providing a battery strap having a plurality of slots passing through the strap and terminating in raised locating collars surrounding the slots and disposed on a first side of the strap; b. providing battery plates having mounting lugs adapted to be passed through said slots from a second side of the strap; c. positioning a plurality of battery plates with their mounting lugs passing through respective different ones of said slots; d. positioning a bonding head having a ram and a coaxial barrel adjacent said first strap side; e. moving the ram and barrel into engagement with the first strap side with the barrel surrounding the locating collar while supporting the opposite strap side and the mounting lugs on a stationary work surface; f. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; g. moving the heated ram through the barrel and at least partially through the strap and mounting lug with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; h. retracting the ram from engagement with the portions of the unmelted lead components and the molten lead; i. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the strap and mounting lugs where such molten lead is permitted to cool and solidify; and, j. retracting the barrel from the strap upon cooling and solidification of the molten lead.

Claim 18

An improved method for securing lead battery plates to a lead battery strap, comprising the steps of: a. providing a battery strap having a plurality of slots passing through the strap and terminating in raised locating collars surrounding the slots and disposed on a first side of the strap; b. providing battery plates having mounting lugs adapted to be passed through said slots from a second side of the strap; c. positioning a plurality of battery plates with their mounting lugs passing through respective different ones of said slots; d. positioning a bonding head having a ram and a coaxial barrel adjacent said first strap side; e. moving the ram and barrel into engagement with the first strap side with the barrel surrounding the locating collar while supporting the opposite strap side and the mounting lugs on a stationary work surface; f. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; g. moving the heated ram through the barrel and at least partially through the strap and mounting lug with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; h. retracting the ram from engagement with the portions of the unmelted lead components and the molten lead; i. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the strap and mounting lugs where such molten lead is permitted to cool and solidify; and, j. retracting the barrel from the strap upon cooling and solidification of the molten lead.

Claim 19

The product produced by the process of claim 9.

Claim 20

An improved method for assembling lead battery plates in groups comprising the steps of: a. positioning a battery plate on a supporting work surface on a work axis; b. positioning a lead spacer having an upstanding lead collar on top of the plate with the lead collar coaxial with the work axis; c. positioning a bonding head having a ram and a coaxial barrel adjacent the spacer with the ram disposed on the work axis; d. moving the ram and barrel into engagement with the spacer with the barrel surrounding the locating collar; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially through the spacer and into and at least partially through the plate with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted portions of the lead spacer and plate and from the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the spacer and plate where such molten lead is permitted to cool and solidify; i. retracting the barrel from the spacer upon cooling and solidification of the molten lead; j. positioning a second plate of like polarity on top of the spacer and a second spacer on top of the second plate in coaxial relation to the work axis; and, k. again advancing and retracting the barrel and ram in the manner set forth in steps d) through i) above to bond the second spacer and plate to one another and to the first spacer and plate.

Claim 21

An improved method for assembling lead battery plates in groups comprising the steps of: a. positioning a battery plate on a supporting work surface on a work axis; b. positioning a lead spacer having an upstanding lead collar on top of the plate with the lead collar coaxial with the work axis; c. positioning a bonding head having a ram and a coaxial barrel adjacent the spacer with the ram disposed on the work axis; d. moving the ram and barrel into engagement with the spacer with the barrel surrounding the locating collar; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially through the spacer and into and at least partially through the plate with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted portions of the lead spacer and plate and from the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the spacer and plate where such molten lead is permitted to cool and solidify; i. retracting the barrel from the spacer upon cooling and solidification of the molten lead; j. positioning a second plate of like polarity on top of the spacer and a second spacer on top of the second plate in coaxial relation to the work axis; and, k. again advancing and retracting the barrel and ram in the manner set forth in steps d) through i) above to bond the second spacer and plate to one another and to the first spacer and plate.

Claim 22

The product produced by the process of claim 11.

Claim 23

An improved method for assembling lead battery plates in a group of positive plates interleaved with and separated from a group of negative plates comprising the steps of: a. positioning a first battery plate on a supporting work surface on a work axis; b. positioning a first lead spacer having an upstanding lead collar on top of the first plate with the lead collar coaxial with the work axis; c. positioning a first separator on the first plate; d. positioning a second battery plate having a polarity opposite the first plate on the first separator; e. positioning a second lead spacer having an upstanding lead collar on top of the second plate and on a second work axis spaced from the first work axis; f. positioning a first bonding head having a ram and a coaxial barrel adjacent the first spacer with the ram disposed on the first work axis; g. positioning a second bonding head having a ram and a coaxial barrel adjacent the second spacer with the ram disposed on the second work axis; h. moving the rams and barrels of the first and second bonding heads into engagement with respective different ones of the first and second spacers with the barrels surrounding the locating collars thereon; i. heating the rams to a temperature sufficient to convert the lead components in the paths of ram movement to the molten state; j. moving the first and second heated rams through their respective barrels and, respectively, axially through the first and second spacers and into and at least partially through the first and second plates with the rams displacing the molten lead thus formed upwardly into the barrels in surrounding relation with the rams; k. retracting the rams from engagement with the unmelted portions of the lead spacers and plates and from the molten lead; l. returning the molten lead theretofore displaced into the barrels back to the areas of ram penetration into the spacers and plates where such molten lead is permitted to cool and solidify; and, m. retracting the barrels from the spacers upon cooling and solidification of the molten lead.

Claim 24

An improved method for assembling lead battery plates in a group of positive plates interleaved with and separated from a group of negative plates comprising the steps of: a. positioning a first battery plate on a supporting work surface on a work axis; b. positioning a first lead spacer having an upstanding lead collar on top of the first plate with the lead collar coaxial with the work axis; c. positioning a first separator on the first plate; d. positioning a second battery plate having a polarity opposite the first plate on the first separator; e. positioning a second lead spacer having an upstanding lead collar on top of the second plate and on a second work axis spaced from the first work axis; f. positioning a first bonding head having a ram and a coaxial barrel adjacent the first spacer with the ram disposed on the first work axis; g. positioning a second bonding head having a ram and a coaxial barrel adjacent the second spacer with the ram disposed on the second work axis; h. moving the rams and barrels of the first and second bonding heads into engagement with respective different ones of the first and second spacers with the barrels surrounding the locating collars thereon; i. heating the rams to a temperature sufficient to convert the lead components in the paths of ram movement to the molten state; j. moving the first and second heated rams through their respective barrels and, respectively, axially through the first and second spacers and into and at least partially through the first and second plates with the rams displacing the molten lead thus formed upwardly into the barrels in surrounding relation with the rams; k. retracting the rams from engagement with the unmelted portions of the lead spacers and plates and from the molten lead; l. returning the molten lead theretofore displaced into the barrels back to the areas of ram penetration into the spacers and plates where such molten lead is permitted to cool and solidify; and, m. retracting the barrels from the spacers upon cooling and solidification of the molten lead.

Claim 25

The product produced by the process of claim 13.

Claim 26

A method as sEt forth in claim 13 comprising the further steps of: n. positioning a third separator on the second plate; o. positioning a third battery plate, having a polarity the same as that of the first plate, on the third separator; p. positioning a third lead spacer having an upstanding lead collar on top of the third plate on the first work axis; q. positioning a fourth separator on the third plate; r. positioning a fourth battery plate, having a polarity the same as that of the second plate, on the fourth separator; s. positioning a fourth lead spacer having an upstanding lead collar on top of the fourth plate on the second work axis; and, t. again advancing and retracting the barrels and rams of the first and second bonding heads in the manner set forth in steps h) through m) to bond the third plate and third spacer to one another and to the first plate and first spacer, and to simultaneously bond the fourth plate and fourth spacer to one another and to the second plate and second spacer.

Claim 27

The product produced by the process of claim 15.

Claim 28

A method as set forth in claim 13 wherein said battery plates have a round configuration, and said first work axis passes coaxially through said round plates and a plurality of said second work axes pass vertically through the peripheral portions of round positive plates whereby said first bonding head serves to create molecular fusion bonds between negative plates and spacers on the axis of the round plates and a plurality of said second bonding heads form molecular fusion bonds between positive plates and spacers about the peripheral portions of the positive plates and outboard of the peripheral edges of the interleaved negative plates and separator elements.

Claim 29

The product produced by the process of claim 17.

Claim 30

An improved method for molecular fusion bonding to form a through-the-wall connection in a lead-acid battery comprising the steps of: a. positioning the battery with a first lead connector component disposed on one side of a wall in coaxial relation to an opening formed in said wall; b. positioning a second lead connector component on the opposite side of the wall and in coaxial relation to the wall opening; c. positioning a bonding head having a ram and a coaxial barrel adjacent the first connector component with the ram disposed on the work axis; d. moving the ram and barrel into engagement with the first connector component while supporting the second connector component on a stationary work surface; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially through the first connector component and into and at least partially through the second component with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted portions of the lead components and the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the first and second connector components where such molten lead is permitted to cool and solidify; and, i. retracting the barrel from the first connector component upon cooling and solidification of the molten lead.

Claim 31

An improved method for molecular fusion bonding to form a through-the-wall connection in a lead-acid battery comprising the steps of: a. positioning the battery with a first lead connector component disposed on one side of a wall in coaxial relation to an opening formed in said wall; b. positioning a second lead connector component on the opposite side of the wall and in coaxial relation to the wall opening; c. positioning a bonding head having a ram and a coaxial barrel adjacent the first connector component with the ram disposed on the work axis; d. moving the ram and barrel into engagement with the first connector component while supporting the second connector component on a stationary work surface; e. heating the ram to a temperature sufficient to convert the lead components in the path of ram movement to the molten state; f. moving the heated ram through the barrel and axially through the first connector component and into and at least partially through the second component with the ram positively displacing the molten lead thus formed upwardly into the barrel in surrounding relation with the ram; g. retracting the ram from engagement with the unmelted portions of the lead components and the molten lead; h. returning the molten lead theretofore displaced into the barrel back to the area of ram penetration into the first and second connector components where such molten lead is permitted to cool and solidify; and, i. retracting the barrel from the first connector component upon cooling and solidification of the molten lead.

Claim 32

The product produced by the process of claim 19.

Claim 33

The product as set forth in claim 20 in which said first and second connector components include annular upraised integral ridges surrounding and in coaxial relation to the opening passing through said wall for biting into the wall during a bonding operation and creating a seal between the bonded parts and the wall.

Claim 34

The product as set forth in claim 20 in which deformable sealing means are interposed between both of said first and second connector components and said wall.

Claim 35

The product as set forth in claim 22 in which said wAll comprises a plastic battery cover, said first connector component comprises an intercell connector, said second connector component comprises a battery post passing through the opening in said cover, and said deformable sealing means comprises first and second O-ring seals positioning in recesses formed in said plastic cover between said cover and said connector and said cover and said post respectively.

Claim 36

The product as set forth in claim 20 wherein at least one of said first and second connector components includes a portion passing through the opening in said wall.

Claim 37

The product as set forth in claim 20 wherein both of said first and second connector components include portions projecting through the opening in said wall.

Claim 38

The product as set forth in claim 25 in which one of said first and second connector components includes a tubular flange passing throuth the opening in said wall and the other of said first and second connector components includes a projecting portion extending into said tubular flange.

Claim 39

The product as set forth in claim 26 in which the tubular flange includes a tapered bore and said projecting portion of said other connector component has a greater diameter than the minimum diameter of said tapered bore so that when said first and second components are brought together in telescoping relationship, the tubular flange on said first connector component is expanded outwardly into intimate sealing engagement with the wall.

Claim 40

The product as set forth in claim 27 in which a sealing gasket is interposed between said tubular bore and said wall.

Claim 41

The product as set forth in claim 20 further characterized in that deformable sealing means are interposed between at least one of said connector components and said wall.

Claim 42

The product as set forth in claim 29 further characterized in that said wall comprises a plastic battery cover, said first connector component comprises an intercell connector, and said second connector component comprises an upstanding battery post, and wherein said deformable sealing means comprises an O-ring seal disposed in an annular groove formed in said cover and interposed between said cover and said battery post.

Claim 43

The product as set forth in claim 30 further characterized in that said cover includes an annular recess in its outer surface coaxial with the opening passing therethrough and wherein lead collar defining means are seated in said recess beneath said intercell connector.

Claim 44

The product as set forth in claim 31 wherein said lead collar defining means are integral with said intercell connector.

Claim 45

The product as set forth in claim 29 further characterized in that said wall comprises a plastic battery cover, said first connector component comprises an intercell connector, said second connector component comprises a battery post passing through said opening in said cover, and further including a lead bushing passing through said opening in said cover in coaxial surrounding relation to said post, and wherein said deformable sealing means comprises an O-ring seal positioned within a groove formed in said bushing between said bushing and said battery post.