Method of forming weldless battery using cover as mold to cast plate

Abstract

An improved battery design which utilizes the cover of the container as a mold to simultaneously create a plurality of solid cast electrical circuits, including external terminals, all without welded connections. The battery cover includes a plurality of plate strap mold wells or mold wells which receive molten lead. Adjacent plate strap mold wells are separated by a partition wall. An aperture is formed in the partition wall which allows molten lead to flow between adjacent plate strap mold wells and connect thereof. Terminal mold wells have terminal apertures through which molten lead flows to form an external terminal with the aid of a external terminal mold. A meltable sealant material is pre-applied to the plurality of mold wells and which becomes fluid upon introduction of molten lead. Upon cooling, the sealant material prevents migration of electrolyte between mold wells. The sealant material also prevents electrolyte and gasses from leaking out of the juncture between the external terminals and the battery cover. The sealant material further has the advantage of flowing into the fusion junctures between the plate lugs and the plate straps. The plate lugs may also be pre-coated when bright metal clean with a flux laden sealant to prevent oxidation of the lugs and enhance fusion of the lugs to the plate straps. The sealant retaining the flux inhibits oxidation of the plate lugs. With this innovative method of battery manufacture, the battery is assembled and completely sealed in a matter of seconds.