Temperature controlled, auto timed, variable amperage cascading-water furmation method for use with high antimony and maintenance free lead-acid batteries

Claim 1

A method for producing batteries having plastic cases comprising the steps of: (a) separating a plurality of batteries into a plurality of sets, said separating comprising sorting batteries which are at a similar stage of formation into a single set, said separating further comprising the step of sorting a plurality of unformed batteries of a preselected cranking capacity immediately into sets after filling with "one shot" formation electrolyte; (b) providing a plurality of container means for holding a plurality of battery sets; (c) placing said sets of batteries into said container means, one set for each container means and electrically interconnecting said batteries in each set for connection to a separate rectifying means for each set; (d) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor; (e) connecting each set of said batteries to said separate rectifying means for charging said plurality of batteries in each set; (f) continuously providing cooling fluid to maintain each of said plurality of container means at a predetermined level, and to circulate said cooling fluid therethrough by causing said cooling fluid to overflow from said container means; and (g) forming said sets with said rectifying means while maintaining said cooling fluid within each of said container means at a temperature of between 100° to 125° F., said step of maintaining said cooling fluid at said temperature further comprising the steps of: (i) conveying said overflow cooling fluid from said container means to a heat removing means for removing heat from said cooling fluid; and (ii) returning said cooling fluid from said heat removing means to said container means.

Claim 2

A method for producing batteries having plastic cases comprising the steps of: (a) separating a plurality of batteries into a plurality of sets, said separating comprising sorting batteries which are at a similar stage of formation into a single set, said separating further comprising the step of sorting a plurality of unformed batteries of a preselected cranking capacity immediately into sets after filling with "one shot" formation electrolyte; (b) providing a plurality of container means for holding a plurality of battery sets; (c) placing said sets of batteries into said container means, one set for each container means and electrically interconnecting said batteries in each set for connection to a separate rectifying means for each set; (d) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor; (e) connecting each set of said batteries to said separate rectifying means for charging said plurality of batteries in each set; (f) continuously providing cooling fluid to maintain each of said plurality of container means at a predetermined level, and to circulate said cooling fluid therethrough by causing said cooling fluid to overflow from said container means; and (g) forming said sets with said rectifying means while maintaining said cooling fluid within each of said container means at a temperature of between 100° to 125° F., said step of maintaining said cooling fluid at said temperature further comprising the steps of: (i) conveying said overflow cooling fluid from said container means to a heat removing means for removing heat from said cooling fluid; and (ii) returning said cooling fluid from said heat removing means to said container means.