Field of Invention
The present invention generally relates to the forming of battery components
and in particular, but not exclusively, to such apparatus for use in manufacturing cast
on straps during the manufacture of batteries. More specifically the invention relates
to a mould for forming battery components, a cast on strap machine for moulding
battery components and a lead delivery apparatus for a cast on strap machine.
Background of Invention
In the manufacture of batteries, particularly for example lead acid batteries, it is
known to cast connectors known as "straps" and other formations onto the "lugs" (or
"tabs") of battery plates. For example, straps are formed to provide a connection
between a set of plates within a cell of the battery. Straps are generally cast using a
"cast on strap machine" in which a mould cavity is filed with molten metal (normally
molten lead) before the lugs of a group of battery plates are dipped into the cavity prior
to the cooling of the lead. The mould for forming such straps general comprises a
plurality of cavities each configured to form a separate strap across a "pack" or "group"
comprising a plurality of battery plates. The mould may for example include a series of
generally paired cavities spaced along the length of the mould such that each pair of
cavities can form a positive and negative strap for a single group of batteries (and with
the mould, therefore, forming a plurality of groups spaced along the length in a single
process).
Typically, the mould cavities are filled by allowing lead to flow into channels at
the sides of the cavities and spill over a weir into the mould. An example of such a
moulding apparatus is shown in the Applicant's earlier published PCT Application
W094/16466. In order to ensure a good connection between the lugs and casting, the
lead must remain hot until the lugs are in position. However, in order to minimise cycle
time in production, the lead must be cooled as quickly as possible once the plates are in
position.
It is important that the volume of lead is carefully controlled during strap
casting as excess lead (for example as a result of mould features such as weirs) will
have an impact on both the cost and weight of the final battery produced.
As such, the Applicants have recently proposed a new battery moulding
apparatus in published UK Patent Application GB2507485. In this arrangement a
reciprocating sliding block is used to provide an accurately measured volume of lead for
each cavity of a mould.
Embodiments of the invention seek to provide further improvements over the
arrangement proposed in GB2507485 which may for example, further reduce the cycle
time and/or further improve consistent measuring of lead and/or provide delivery of
lead with minimal cooling during transit to the mould and/or provide improved ease of
maintenance or usage of the apparatus.
Summary of Invention
According to the first aspect of the present invention there is provided a mould
for forming battery components (which may for example be cast on straps) the mould
comprising a first mould body comprising a first plurality of mould cavities; a second
mould body comprising a second plurality of mould cavities; wherein said first mould
body and said second mould bodies are configured to be moveable between: a
moulding position in which the first plurality and second plurality of mould cavities are
aligned; and a fill position in which the first plurality and second plurality of mould
cavities are displaced from the aligned position and are proximal to a molten metal
feed.
The applicants have recognised that by providing mould portions which may be
separately moved they can be positioned proximal to a molten metal feed such that the
run of molten metal into the mould cavity may be minimised. For example, the molten
metal may be poured directly into the cavity. Equally, by moving the mould portions
back to an aligned position (which may for example be fixed relative to a
predetermined datum) a group of battery plates may be aligned relative to the mould
cavities without being impeded by the metal feed. Thus embodiments of the invention
may reduce or mitigate issues related to cooling of the metal prior to forming of the
straps and may, for example, avoid the need to provide additional heated channels or
passageways between the lead supply and the cavities.
In the aligned position the first and second mould bodies may be arranged to
provide a single moulding apparatus. The first and second mould bodies may, for
example, abut in the aligned position.
Typically, the mould may be an elongate mould and may define a series of
mould cavities spaced along a longitudinal direction of the mould. The first mould body
and the second mould body may each comprise a longitudinal half of the elongate
mould. Thus, in the aligned position the first mould body and second mould body may
generally abut along a longitudinal centreline of the mould.
The first plurality of mould cavities and the second plurality of mould cavities
may jointly define a plurality of pairs of mould cavities spaced along the longitudinal
direction of the mould. Thus, for example it will be appreciated that, in use, each pair
of cavities may be used for casting a pair of straps for a single group of battery plates.
Each pair of mould cavities may include a cavity in each mould body.
The mould may be used with a modified cast on strap machine which includes a
mould positioner. Thus, according to a further aspect of the invention there is provided
a cast on strap machine for moulding battery components, the machine comprising: a
molten metal delivery apparatus; a battery plate positioning device; and a mould
comprising a first mould body comprising a first plurality of mould cavities and a second
mould body comprising a second plurality of mould cavities; and wherein the machine
further comprises: a mould positioner configured to move the first mould body and
said second mould body between: a moulding position in which the first plurality and
second plurality of mould cavities are aligned relative to the battery plate positioning
device; and a fill position in which the first plurality and second plurality of mould
cavities are displaced from the aligned position and are proximal to an outlet of the
metal delivery apparatus.
The molten metal delivery apparatus may be arranged for delivering a
predetermined volume of lead to the mould. Typically, the molten metal may be
molten lead. The metal delivery apparatus may, for example, be arranged to measure
and supply a predetermined volume of lead substantially in the manner described in UK
Patent Application GB2507485.
The battery plate positioning device may for example be arranged to hold and
position groups of battery plates relative to the mould. For example, the battery plate
positioning device may be a jig box. It will be appreciated that the battery plate
positioning device is generally arranged to position a group of battery plates relative to
the mould during casting such that the tabs of a group of battery plates can be moved
into the mould cavities and the lead can solidify so as to form straps connecting the
tabs. Advantageously, as the mould bodies are moveable between the fill position and
the moulding position the positioning of the battery plates may be unimpeded by the
metal delivery apparatus or other metal delivery features when the mould bodies are in
the moulding position.
The molten metal delivery apparatus may comprise first and second molten
metal delivery apparatuses associated respectively with the first and second mould
bodies. For example, a molten metal delivery apparatus may be provided adjacent to
each of the first and second mould bodies. The first and second molten metal delivery
apparatuses may be positioned on opposing sides of the cast on strap machine with the
mould provided between the metal delivery apparatuses.
The first and second molten metal delivery apparatuses may be fed from a
common lead supply.
The first and second molten metal delivery apparatuses may each comprise a
plurality of outlets. One outlet may, for example, be associated with each of the mould
cavities. The, or each, outlet may comprise a through-cavity formed in a slideably
mounted block and arranged to receive lead into the upper end of the through cavity
when the block is in a first position and release lead from the lower end of the through
cavity when the block is in a second position. The, or each, outlet may be associated
with a local metal reservoir.
The, or each, outlet is arranged to dispense lead directly into a mould cavity
when the mould bodies are in the fill position.
The mould positioner is arranged to move said first mould body and said second
mould body linearly. For example, the mould positioner may slide the first and said
second mould bodies outwardly away from a nominal longitudinal centre line of the
mould when moving from the moulding position to the fill position (and moving the
bodies towards the nominal centre line when moving to the moulding position).
The mould positioner may be arranged to reciprocate the first mould body and
second mould body between the moulding and fill positions in use. The mould
positioner may include a crank mechanism connected to the first and second mould
bodies. A single drive may be provided with opposing out of phase crank arms for
moving the first and second mould bodies. Advantageously, a crank mechanism may
progressively decelerate the mould bodies as they approach the end positions of the
motion (i.e. the fill and moulding positions) which is particular important when the
mould is being moved with the cavities filled with molten metal.
The molten metal delivery apparatus may be configured such that when the
first and second mould bodies are in the fill position the mould bodies are heated by
heat transfer from the delivery apparatus. For example, the mould bodies may be
positioned adjacent to a hot surface of the molten metal delivery apparatus such that it
is heated by radiant or conductive heat transfer. Advantageously such an arrangement
may remove the need to provide any direct heating to the mould bodies.
The cast on strap machine may further be provided with a mould loading
apparatus.
Thus, according to a further aspect of the invention, there is provided a cast on
strap machine comprising a molten metal delivery apparatus; a battery plate
positioning device; a mould comprising a plurality of mould cavities; and a mould
loading apparatus arranged to move the mould between an in use configuration and a
configuration in which the mould is external to the cast on strap machine to allow
access to the mould.
The mould loading apparatus may be arranged to automate the removal and
insertion of the mould into the cast on strap machine. For example, the mould loading
apparatus may be utilised to service or interchange the mould during use.
The mould loading apparatus may comprises an elevator arranged t o
raise/lower the mould between a first height corresponding to the plane of the in use
position of the mould and a second height where the mould is positioned out of the in
use plane. By moving the mould out of the plane of the in use position it may be raised
above or below the lead delivery apparatus such that it can be conveniently be moved
into or out of the cast on strap machine. For example, the elevator may be arranged to
lower the mould below the plane of a base member of the operational section of the
cast on strap machine.
The mould loading apparatus may further comprise a lateral positioning
member. The lateral position arrangement may be arranged to move the mould
between an internal position, in alignment with the in use configuration, and an
external position in which the mould is positioned to a side of the cast on strap
machine. The lateral positioning arrangement may move the elevator.
The lateral positioning arrangement may comprise a fixed support frame and a
moveable frame slidable mounted theretto. The lateral positioning arrangement may
be below the working area of the cast on lead machine.
The mould loading apparatus may comprise a cradle for supporting the mould.
The cradle may, for example, be provided on the elevator. An ejection device may be
provided for removing the mould from the cradle when the mould is in the in use
configuration.
According to a further aspect of the invention there is provided a lead delivery
apparatus for a cast on strap machine arranged to deliver a predetermined volume of
molten lead to a mould, comprising: a housing defining a lead reservoir having a lead
outlet defined in its base and in communication with the reservoir; a runway beneath
the base, spaced from the base and substantially parallel thereto; a block slideably
mounted between the base and the runway, the block having a through cavity defining
the predetermined volume for receiving lead from the outlet of the reservoir in a first
position and for releasing the lead in a second position; and a mechanism for
reciprocating the block between the first and second positions; and characterised in
that the apparatus further comprises a clamp arranged to selectively secure an upper
portion of the housing such that the housing and/or block may be removable.
The clamp may comprise a pivotable clamping member. The clamping member
may be pivotally connected to the apparatus at, or proximal to, a first end of fastener
for securing the clamping member in a closed configuration. The fastener may
comprise quick release mechanism. The fastener may engage at, or proximal to, a free
end of the clamping member.
The clamp and reservoir housing may be provided with interconnecting features
which fix the housing relative to the clamp (and therefore relative to the housing) when
the clamp is in a closed configuration. The interconnecting features may comprise a
projection on one of the housing or clamp and a corresponding aperture defined by the
other of the clamp or housing. The clamp may be configured such that the projection is
retained in the aperture when the clamp is in the closed configuration. For example,
the aperture may be defined by a notch or recess in the clamp. The notch or recess
may be defined in the pivotable clamping member or in an opposing surface thereof, or
jointly defined by the profile of such opposing surfaces. For example the clamping
member and opposing surface (which may for example be a fixed member of the clamp
from which the clamping member is pivoted) may have stepped profiles which in the
closed position jointly define the aperture.
The clamp may further comprise a reservoir cover. The reservoir cover may
close an upper portion of the reservoir when the clamp is in a closed configuration.
The reservoir cover may be pivotally connected to the clamp (such that it may self-align
with the reservoir housing).
According to a further aspect of the invention there is provided a method of
moulding battery components comprising the steps of: providing a two part mould,
each mould part comprising a plurality of mould cavities; separating the mould parts
and providing a supply of molten metal to each of the plurality of mould cavities with
the mould parts at spaced apart locations; and moving the filled mould parts to an
aligned position to form the battery components.
The method may further comprising the step of: providing a plurality of aligned
battery plates (which may for example be arranged in one or more groups); and, after
the step of moving the filed mould parts into an aligned position, positioning the
plurality of battery plates relative to the mould such that a portion of the plurality of
battery plates lie within the mould cavities; and allowing the molten metal to solidify so
as to form a connection between the plurality of battery plates.
The method may further comprises moving the plurality of battery plates away
from the away from the mould to eject the moulded battery components from the
mould. After ejection of the moulded battery components the step of separating the
mould parts (and the subsequent steps) may be repeated to start a further moulding
cycle.
Whilst the invention has been described above, it extends to any inventive
combination of features set out above or in the following description or drawings.
Brief Description of the Drawings
Specific embodiments of the invention will now be described in detail by way of
example only and with reference to the accompanying drawings in which:
Figure 1 to 5 are schematic cross-sectional views of a cast on strap machine
according to an embodiment of the invention showing the sequence of operation;
Figure 6 to 10 are schematic views of a cast on strap machine according to an
embodiment including a mould loading apparatus and showing the loading sequence;
Figure 11 is a schematic side view of the lead delivery apparatus for use in a cast
on strap machine.
Description of an Embodiment
A cast on strap machine 1 in accordance with an embodiment of the invention is
arranged to provide liquid lead into the mould cavities 51, 53 of a mould 50 before tabs
81, 82lugs of a set of battery plates 80 are moved into position by a jig box 70 with the
lugs 81, 82 within the mould cavities 51, 53 and the lead can solidify so as to form
straps connecting the lugs. As will be explained in further detail below, the mould 50 is
formed of two mould bodies 50, 52 which each comprise a plurality of mould cavities
51, 53.
A lead delivery apparatus 5 is provided for delivering a predetermined volume
of lead to the mould 50. The basic operating principle of the lead delivery apparatus
shown in the embodiment is as described in the applicants earlier UK Patent
Application GB2507485. It will, however, be appreciated that other lead delivery
arrangements could be used in embodiments of the invention. The illustrated lead
delivery apparatus 5 generally comprises a housing 2, which defines an inlet reservoir 4,
a block 10 and a runway 30 on which the block 10 is slideably mounted. The delivery
apparatus would further comprise a drive arrangement (not shown for clarity) arranged
to reciprocate the block 10 as shown in the sequential diagrams. The lead delivery
apparatus 5 is connected to a lead supply 60. It will be noted that in the illustrated
embodiment a pair of identical lead delivery apparatus 5a, 5b are provided at opposing
sides of the mould 50 and arranged to deliver to the opposing mould bodies 50 and 52.
It will also be appreciated that the lead delivery apparatus 5 will typically have a
plurality of outlets 6 along its length (each corresponding to a separate cavity). Such
outlets may be formed in a plurality of separate blocks and/or blocks with a plurality of
cavities and it will be appreciated that this will depend upon the type of mould to be
formed and therefore the invention may be used in a single or multiple arrangements.
The housing 2 defines a lead reservoir 4 in its interior and is generally arranged
to have an open upper surface such that dross which accumulates maybe easily
skimmed from the lead in the reservoir 4. An inlet 8 is provided for the supply of lead
and an outlet 6 is provided in the base of the reservoir. It will be appreciated that the
cross sections shown in figures 1 to 5 show only a section through a single cavity pair
and associated lead delivery apparatus but typically a series of such arrangements will
be repeated along the length of the apparatus.
The housing 2 may further be provided with a cover 3 which encloses the
reservoir 4 but which is spaced apart from the lead fill level of the reservoir 4. A gas/air
inlet 9 is provided at the rear of the housing 4 which extends into the ullage 4b over the
reservoir. The housing 2 is further provided with a bleed opening 7 which (as described
in below) is arranged to be aligned with the through cavity 12 when the block 10 is in
the second position. The bleed opening 7 is in fluid communication with the ullage 4b
of the housing 2.
Spaced apart from, and below, the housing 2 is a runway 30 which is arranged
parallel to the lower surface of the housing 2 and defines a slot therebetween which is
shaped and sized to receive a block 10. The runway 30 is provided with a through hole
34 aligned with the inlet 8 on the housing 2.
The block 10 is provided with a through cavity 12 and a through hole 18. In the
non-displaced position of the block 10 the through hole 18 is aligned with the inlet 8
and through hole 34 to form the inlet path to the lead reservoir 4. In the same
position, the through cavity 12 is aligned with the outlet 6 of the lead reservoir 4 and
the blind hole 36 of the runway 30 such that lead from the reservoir will enter the blind
hole 36 and cavity 12.
Figure 1 shows the apparatus in an initial position in which the mould blocks 50,
52 are in a fill position adjacent the lead delivery apparatus 5a and 5b. The block 10 is
aligned such that the through cavity 12 is below the outlet 6 of the lead reservoir 4 and
the through hole 18 is aligned with the inlet 8 of the lead reservoir 4. Thus, lead will
flow through the supply 60 (which includes supply pipes 66a and 66b provided in a
heated block), for example from a constant head lead supply (not shown) 60, and hole
34 in the runway 30 into the reservoir 4. The reservoir 4 will be maintained at a fill
level. As the through cavity 12 is in fluid communication with the lead reservoir 4, a
predetermined volume of lead will fill the cavity 12 and an additional volume of lead
will enter the blind hole 36 so as to provide a sump below the cavity 12.
It will be noted that in this step, the moulds 50, 52 are already positioned
adjacent to the lead delivery apparatus 5a, 5b at the inner side of, and immediately
below the end of the runway 32. In other words, the moulds 50, 52 are in the "fill
position". The supply 60 immediately adjacent to the moulds 50, 52 is heated (to
maintain lead flow in the supply pipes 66a and 66b). A small air gap exists between the
moulds 50, 52 and the supply 60 and, therefore, in this position the moulds 50, 52 are
heated by radiant heat transfer.
To commence filling of the mould, the mechanism is actuated to slide block 10
relative to the housing 2 and runway 30, as shown by the arrows A in Figure 2. The
block 10 slides inwardly towards the mould 50, 52 until it reaches its second position
(as shown in Figure 2) in which the delivery port 16 of the through cavity 12 is inward of
the end 32 of the runway 30. In this position the through cavity 12 is directly overlying
the cavity 51, 53 of the mould. In this position the bleed opening 7 provided in the
housing 2 is in fluid communication with the inlet of the through cavity 12 such that gas
may be drawn into the upper portion of the through cavity 12. This arrangement helps
to avoid any vacuum effect which may hinder the release of the lead from within the
through cavity 12.
Once the lead pouring has been completed, the block 10 returns to its first
position in which the through cavity is aligned with the outlet 6 of lead reservoir 4
(moving in the direction of arrows B shown in Figure 3). In this position the reservoir 4
is again in fluid communication with the lead supply 60 such that the level of the
reservoir will be replenished and the through cavity 12 will be refilled. At the same
time, the drive mould mechanism 20 translates the moulds 50, 52 inwardly, as shown
by arrows C, toward one another via the crank arms 24, 26. As such the mould parts
50, 52 are moved to the moulding position, shown in Figure 3, in which the two halves
5a, 5b are abutting (or closely aligned) along a longitudinal centreline.
Subsequently, as shown in Figure 4, the battery plates 80 are brought into
position above the mould 50 by a downward motion (in the direction of arrow D) until
the lugs 81, 82 of the plates lie within the mould cavity (which now contains molten but
cooling lead).
Finally, as shown in Figure 5, the battery plates 80 are moved away from the
mould 50 by the jig box 70 (in the direction of arrow E) and eject the formed straps
with the lugs 81, 82. The forming procedure may then recommence by the mould
bodies 50, 52 being moved back to the fill position by the drive 20.
In some embodiments the cast on strap machine may further include a mould
loading apparatus 100 as shown in Figure 6. The mould loading apparatus 100 may
automate the process of moving a mould between an internal, in use, position within
the cast on strap machine and an external position in which the mould may be serviced,
replaced or maintained. The mould loading apparatus 100 generally comprises a cradle
110, an elevator 120, a lateral position arrangement 130 and an ejection arrangement
140. The components of the loading apparatus 100 may be powered by suitable
pneumatic cylinders (for example cylinder 136 for the lateral positioner and cylinder
122 for the elevator).
Figure 6 shows an initial position in which the mould 50 is external to the cast
on strap machine. The mould 50 has been loaded into and is supported by the mould
cradle 110 on the elevator 120 (which is in a raised position for ease of access). The
elevator 120 (and therefore the cradle 110 and mould 50) is external to the working
area of the cast on strap machine due to the lateral position arrangement 130 being in
an extended configuration with the sliding frame 134 displaced relative to the fixed
frame 132.
Initially, the elevator 120 is moved to its lowered position as shown in Figure 7,
such that it is below the plane of the base of the working section of the cast on strap
machine (which is defined by a base below the lead delivery apparatus). The lateral
positioner 130 is then used to move the elevator 120, cradle 110 and mould 50
inwardly into horizontal alignment with its operational position as shown in Figure 8.
The elevator 110 is then activated as shown in Figure 9, to raise the mould 50 to its
working position. An ejection arrangement 140 may then be activated to disengage the
mould 50 from the cradle 110 (and may provide a support for the mould in use).
In order to provide ease of maintenance and/or interchanging of the sliding
block 30 (for example to provide different volume measuring openings), embodiments
may further include a clamping arrangement 200 as shown in Figure 11 which
comprises a clamp 200 arranged to selectively secure an upper portion of the housing 2
such that the housing 2 and/or block 10 may be removable.
The clamp 200, can be formed of a lower fixed clamp member 210, rigidly
attached to the frame of the machine and an upper moveable clamp member 220
which is connected to fixed member 210 via a pivot 230. Thus, the moveable member
220 may be rotated between an open position shown in figure 11A and a closed
position shown in figure 11B.
A fastener 240 in the form of a rotatable latch having a handle 244 is provided
adjacent to an end of the moveable clamp member 220 which is distal to the pivot 230.
The fastener 240 includes a latch member 242 which engages and retains a
corresponding recess feature 224 formed on an upper surface of the moveable clamp
member 220. . It may also be noted that a notch or cut out is provided in the lower
fixed clamp 210 to receive for the latch member 242 n the open position (of Figure
11A). This helps ensures that the fastener 240 does not impede access to the sliding
block 30.
As best seen in Figure 11A, the clamping arrangement 200 is substantially
aligned with the housing 2 of the reservoir 4 (and the sliding block 10 is, in the view of
Figure 11, concealed behind the lower, fixed arm of the clamp). The housing 2 is
provided with a projection 250 on the side of its outer body for engagement by the
clamp 200. With upper moveable clamp member 220 rotated into the open position,
the sliding block 10 may be positioned within the lead delivery apparatus followed by
the reservoir housing 2 being placed over the sliding block 10. The reservoir 4 may be
aligned correctly by positioning the projection 250 against a step feature 212 formed in
the upper edge of the fixed clamping member 210. When the upper moveable clamp
member 220 is rotated downwardly into the clamped position of Figure 11B, it will be
noted that a corresponding step feature 222, formed in the lower edge of the
moveable clamping member 220 is brought into alignment with the projection 250.
Thus, it will be seen that the clamp opposing step features 212, 222 jointly form an
aperture for fixably retaining the projection 250 when the clamp 200 is in the closed
configuration. The clamp 200 will, therefore, fix the housing 2 relative to the clamp,
and the body of the delivery apparatus
It may also be noted that the clamp 200 also carries the reservoir cover 3, which
is rotatably connected to the upper moveable clamping member 220 via a pivot. Thus,
as the clamp 200 is closed, the reservoir cover 3 may self-align with the upper portion
of the reservoir housing 2 and close the upper end thereof.
Although the invention has been described above with reference to one or
more preferred embodiments, it will be appreciated that various changes or
modifications may be made without departing from the scope of the invention as
defined in the appended claims.
For example, the skilled person will appreciate that while the embodiment
above has been primarily described in relation to the forming of straps, other
formations may also be cast onto the lugs of battery plates (for example posts) and that
a cast on strap machine may be used for the formation of any such formations without
departing from the scope of the invention.
In some embodiments it may be advantageous to provide a plurality of cavities
12 arranged to deliver lead to a single mould cavity. For example, this may be desirable
for relatively large mould cavities. The plurality of cavities could be in multiple blocks
or in single multiple cavity block. For example, each cavity may measure a separate
volume of lead and the total volume of the cavities may provide the volume require for
the particular mould cavity. The cavities may for example deliver to different areas of a
single mould cavity to ensure an even distribution of lead.
Further, whilst the described embodiment utilises a mould which is split into
two, elongate, longitudinal halves it will be appreciated that the particular arrangement
may depend upon the particular configuration of the mould which is being cast. For
example, in some embodiments it may be possible to divide the mould into more than
two mould bodies (at the expense of potential increased complexity).

Claims
1. A mould for forming battery components comprising:
a first mould body comprising a first plurality of mould cavities;
a second mould body comprising a second plurality of mould cavities;
and
wherein said first mould body and said second mould bodies are
configured to be moveable between:
a moulding position in which the first plurality and second
plurality of mould cavities are aligned; and
a fill position in which the first plurality and second plurality of
mould cavities are displaced from the aligned position and are proximal
to a molten metal feed.
2. A mould as claimed in claim 1, wherein in the aligned position the first and
second mould bodies form a single moulding apparatus.
3. A mould as claimed in claim 1 or 2, wherein the mould is an elongate mould
defining a series of mould cavities spaced along a longitudinal direction of the
mould and wherein the first mould body and the second mould body each
comprise a longitudinal half of the elongate mould.
4. A mould as claimed in claim 3, wherein the first plurality of mould cavities and
the second plurality of mould cavities jointly define a plurality of pairs of mould
cavities spaced along the longitudinal direction of the mould.
A cast on strap machine for moulding battery components, the machine
comprising:
a molten metal delivery apparatus;
a battery plate positioning device; and
a mould comprising a first mould body comprising a first plurality of
mould cavities and a second mould body comprising a second plurality of mould
cavities; and wherein the machine further comprises
a mould positioner configured to move the first mould body and said
second mould bodies between:
a moulding position in which the first plurality and second plurality of
mould cavities are aligned relative to the battery plate positioning device; and
a fill position in which the first plurality and second plurality of mould
cavities are displaced from the aligned position and are proximal to an outlet of
the metal delivery apparatus.
6. A cast on strap machine as claimed in claim 5, wherein the molten metal
delivery apparatus comprises first and second molten metal delivery
apparatuses associated respectively with the first and second mould bodies.
7. A cast on strap machine as claimed in claim 6, wherein the first and second
molten metal delivery apparatuses are fed from a common lead supply.
8. A cast on strap machine as claimed in claim 6 or 7, wherein the first and second
molten metal delivery apparatuses each comprise a plurality of outlets with one
outlet associated with each of the mould cavities.
9. A cast on strap machine as claimed in claim 8, wherein each of the plurality of
outlets is associated with a local molten metal reservoir.
10. A cast on strap machine as claimed in any of claims 5 to 9, wherein the, or each,
outlet comprises a through cavity formed in a slidably mounted block and
arranged to receive lead into the upper end of the through cavity when the
block is in a first position and to release lead from the lower end of the through
cavity when the block is in a second position.
11. A cast on strap machine as claims in any of claims 5 to 10, wherein the, or each,
outlet is arranged to dispense lead directly into a mould cavity when the mould
bodies are in the fill position.
12. A cast on strap machine as claimed in any preceding claim wherein the mould
positioner is arranged to slide said first mould body and said second mould body
linearly outwardly away from a nominal longitudinal centre line of the mould
apparatus when moving from the moulding position to the fill position.
13. A cast on strap machine as claimed in claim 12, wherein the mould position
includes a crank mechanism connected to the first and second mould bodies.
14. A cast on strap machine as claimed in any of claims 5 to 13, wherein the molten
metal delivery apparatus is configured such that when the first and second
mould bodies are in the fill position the mould bodies are heated by radiant
heat transfer from the delivery apparatus.
15. A cast on strap machine as claimed in any preceding claim, further comprising a
mould loading apparatus.
16. A cast on strap machine comprising
a molten metal delivery apparatus;
a battery plate positioning device;
a mould comprising a plurality of mould cavities; and
a mould loading apparatus arranged to move the mould between an in
use configuration and a configuration in which the mould is external to the cast
on strap machine to allow access to the mould.
17. A cast on strap machine as claimed in claim 15 or 16, wherein the mould loading
apparatus comprises an elevator arranged to raise/lower the mould between at
least a first height corresponding to the plane of the in use position of the
mould and a second height where the mould is positioned below the plane of a
base member of the machine to allow removal.
18. A cast on strap machine as claimed in claim 17, wherein the mould loading
apparatus further comprises a lateral positioning member arranged to move the
mould between an internal position, in alignment with the in use configuration,
and an external position in which the mould is positioned to a side of the cast
on strap machine.
19. A cast on strap machine as claimed in claim 18, wherein the lateral position
member comprises a fixed support frame and a moveable frame slidable
mounted thereto.
20. A cast on strap machine as claimed in any of claims 16 to 19, wherein the
mould loading apparatus comprises a cradle for supporting the mould.
21. A cast on strap machine as claimed in claim 20, wherein the machine further
comprises an ejection device for removing the mould from the cradle when the
mould is in the in use configuration.
22. A lead delivery apparatus for a cast on strap machine arranged to deliver a
predetermined volume of molten lead to a mould, comprising:
a housing defining a lead reservoir having a lead outlet defined in its
base and in communication with the reservoir;
a runway beneath the base, spaced from the base and substantially
parallel thereto;
a block slideably mounted between the base and the runway, the block
having a through cavity defining the predetermined volume for receiving lead
from the outlet of the reservoir in a first position and for releasing the lead in a
second position; and
a mechanism for reciprocating the block between the first and second
positions; and characterised in that the apparatus further comprises
a clamp arranged to selectively secure an upper portion of the
housing such that the housing and/or block may be removable.
23. A lead delivery apparatus as claimed in claim 22, wherein the clamp comprises a
pivotable clamping member, pivotally connected to the apparatus at, or
proximal to, a first end and a fastener for securing the clamping member in a
closed configuration.
24. A lead delivery apparatus as claimed in claim 23, wherein the fastener
comprises a quick release mechanism which engages at, or proximal to, an
opposing free end of the clamping member.
25. A lead delivery apparatus as claimed in any of claims 22 to 24, wherein the
clamp and reservoir housing are provided with interconnecting features which
fix the housing relative to the clamp when the clamp is in a closed configuration.
26. A lead delivery apparatus as claimed in claim 25, wherein the interconnecting
features comprise a projection on one of the housing or clamp and a
corresponding aperture defined by the other of the clamp or housing, the clamp
being configured such that the projection is retained in the aperture when the
clamp is in the closed configuration.
27. A lead delivery apparatus as claimed in claim 26, wherein the aperture is
defined by a notch or recess in the clamp.
28. A lead delivery apparatus as claimed in any of claims 22 to 27, wherein the
clamp further comprises a reservoir cover, which closes an upper portion of the
reservoir when the clamp is in a closed configuration.
29. A method of moulding battery components comprising the steps of:
providing a mould comprising at least two mould parts, each mould part
comprising a plurality of mould cavities;
separating the mould parts and providing a supply of molten metal to
each of the plurality of mould cavities with the mould parts at spaced apart
locations; and
moving the filled mould parts to an aligned position to form the battery
components.
30. A method of moulding battery components as claimed in claim 29, further
comprising the step of:
providing a plurality of aligned battery plates (may be in groups); and
after the step of moving the filed mould parts into an aligned position,
positioning the plurality of battery plates relative to the mould such that a
portion of the plurality of battery plates lie within the mould cavities; and
allowing the molten metal to solidify so as to form a connection
between the plurality of battery plates.
31. A method of moulding battery components as claimed in claim 30, wherein the
method further comprises moving the plurality of battery plates away from the
mould to eject the moulded battery components from the mould.
32. A method of moulding battery components as claimed in claim 31, wherein,
after ejection of the moulded battery components, the step of separating the
mould parts is repeated to start a further moulding cycle.
33. A mould for forming battery components substantially as described herein with
reference to the drawings.
34. A cast on strap machine substantially as described herein with reference to the
drawings.
35. A lead delivery apparatus substantially as described herein with reference to the
drawings.