Gnb Batteries Inc.

Edward G Schaumburg

Anthony Sabatino

Peter A Recht

Eugene F Stanefski

Mark R Frich

Alby H Wolf

Douglas J Olszewski

Richard T Strait

Cory D Benson

Ronald N Romanchuk

Michael G Zais

A system for assembling, processing and transferring battery cell elements including a plurality of element assemblers and an exit conveyor having a plurality of element conveying lanes. Each element assembler includes element transfer and processing apparatus comprising an endless chain conveyor having a plurality of longitudinally spaced element carriers adapted to successively engage an element at a loading station, carry the engaged element through a plurality of process stations, and release the element at a discharge station. In the illustrated apparatus, the carriers each engage a loosely assembled element at the loading station, compress the element to final size, and carry the element through an inspection and manual unload station, a plate alignment station, a plate lug brushing station, a plate alignment after brushing station, and a series of tape applicator stations which bind the element in assembled and processed condition. The discharge station of each element assembler includes a transfer mechanism adapted to transfer assembled elements onto a selected one of a plurality of exit conveyor lanes in a manner that enables a uniform supply of elements for subsequent use in an automated battery production line.

Apparatus and method for processing and transferring battery cell

A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold. The apparatus includes a master controller that controls operation of the plurality of table and operating stations and maintains optimum casting conditions in each mold and the molten metal dispensed therein at the time of casting.

Apparatus and method for casting straps on battery cell elements

A method and apparatus for providing a compound (22) in each of the cell spaces of a multicell battery case (10). The compound comprises a bituminous material delivered to a plurality of the cell spaces concurrently through a plurality of nozzles (25) of a dispensing head (24). The battery case (10) is accurately positioned against a back stop (45) and a forward stop (36). A sensor (49) determines the accurate alignment of the battery case (10) in the fill position and cooperates with a controller (81) for controlling operation of the automatic dispenser (23). In the dispensing operation, the nozzles (25) are moved along a first plurality of cells. The nozzles are then retracted and moved lengthwise of the case to be aligned with a second group of cells. The nozzles are then moved along the case cells while dispensing compound to the second group of cells. A drip shield (62) is automatically positioned under the nozzles when they are being moved between cells and during movement of the battery case to and from the delivery position. Microswitches (69,70,90,91) are provided for accurately sensing the position of the dispenser head and adjustable control rods (71,72,75,76) are provided for permitting adjustment of the operation of the microswitches to accommodate the dispensing operation to different size battery cases. Structure is provided for maintaining the compound hot prior to its delivery into the battery case. Control of the dispensing operation is coordinated with other process steps in the manufacture of the battery by way of the controller (81).

Compound dispensing method and apparatus

An apparatus and method for assembling battery cell elements having a plurality of electrode plates of alternating polarity separated by a continuous interleaved insulating sheet. The apparatus includes a separator sheet supply station; a creaser for forming transverse creases in a length of separator sheet at longitudinally spaced fold points; a first plate loader for positioning a first set of electrode plates of common polarity onto a pre-fold mechanism; a sheet transfer mechanism for transferring a cut and creased length of separator sheet from the creaser onto the first set of plates; a second plate loader for positioning a second set of electrode plates of common polarity opposite to that of the first set onto the separator sheet at locations directly above the plates of the first set; the pre-fold mechanism including a collapsible pre-fold paddle assembly for folding the separator sheet into relatively loose accordian folds with the plates of the first and second sets occupying alternate folds on opposite sides of the separator sheet; an intermediate fold mechanism for engaging the pre-folded element, positioning the plates thereof into relatively precise alignment, and compressing the element into a tighter intermediate folded assembly; and a final fold mechanism for engaging the intermediate folded assembly, compressing the assembly into final element form, transporting the element through a series of tape applicators to secure it in its final form and then to a discharge station. The apparatus includes a master controller that controls operation of the plurality of mechanisms to permit automatic and continuous high volume production of such battery cell elements.

Apparatus and method for assembling battery cell elements

A method and apparatus for assembling battery components including a battery case (10) having a plurality of divider walls (32) defining a plurality of side-by-side cell spaces (26,27,28,29,30,31) opening through a top portion of the case. A plurality of intermediate cell elements (34,35,36,37) are provided in the cell spaces intermediate the end cell spaces (26,31) and end cell elements (38,39) having terminal post portions (101) are inserted in the end cell spaces (26,31). The apparatus effects an automatic pickup of the cell elements at one or more insert stations from delivery conveyors (19,20) suitably positions the picked-up cell elements for proper polarity relationship in the inserted disposition within the battery case, and after moving the picked-up cell elements to overlying relationship with the battery case, inserts the cell elements automatically into the proper cell spaces. Control of delivery of the battery cases to the respective insert positions is effected and coordinated with the delivery of the necessary cell elements from apparatus for preforming the cell elements. Apparatus (106) is provided for accurately spacing the end cell elements upon delivery thereof to the pickup position. The pickup structure (50) includes finger devices (59,60) arranged to engage plate connecting straps (45,98,100) provided on the cell elements in effecting positive pickup, transfer and insertion thereof.

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Askov, MN, United States of America

Edward G Schaumburg