JPS5947430B2 - Leak-free connection methods and devices - Google Patents

Description

[Detailed Description of the Invention] This invention relates to an intermediate cell (Int) of a lead battery (storage battery).
er-Cell), in particular, extrude a part of the inter-cell connection member of two lead alloy battery plates through the opening of the partition wall between adjacent cells of the battery, and form the extruded inter-cell connection. contacting portions of the member, applying a melting current to the member, heating it to a melting temperature, and applying a force to the molten portion to fill the opening with molten intercell connection member metal; The present invention relates to a method and apparatus for forming a connection that forms a reliable mechanical and electrical connection between the intercell connection members after cooling.

In carrying out such a method, the plate-cell connecting member is pressed by a tight clamping device against the intermediate cell partition having one opening, and the two melting electrodes (extruders) The metal of the inter-cell connecting member is pushed out from the inter-cell connecting member into the opening and comes into contact with each other through the hole of the clamp body, and then a melting current is supplied to the extruded metal. Due to the continuous force of the electrode (extruder), the molten part flows into the gap in the opening, and at the same time more metal flows from the intercell connecting member into the opening. The molten metal is extruded until it is filled with the metal of the inter-cell connection member, and then the molten metal is cooled and solidified under the application of the extrusion force of the clamper and electrode (extruder).

The problem with implementing such methods in general manufacturing processes is that they provide simple quality control techniques to ensure consistency of the melt over long manufacturing runs and to monitor melt conditions and product. be.

Normal non-destructive tests like air leaks and IR drops are
It is not effective enough to detect poor melting parts and alert the operator that the melting conditions require correction.
In air leakage, it is detected whether the partition wall opening is sealed, but it is not detected whether the quality of the melted part is good or not.In addition, in IR drop, experience shows that many poor melted parts are not detected. . "Dissolution conditions" mainly include clamping force, extrusion force and response of the electrode (extruder) (ie, fluoro-mel), dissolution current, and dissolution time. Another problem in the general manufacturing operation of the above method is that
To minimize the variables that affect this operation, to be able to control other variables, namely melting conditions, and to have a wide operating range that allows the process to be carried out continuously for long periods of time, often without correction and adjustment. It is to be.

The present invention aims to solve the above-mentioned problems). First, the intercell connecting member of the electrode plate to be melted is cast from a hypoeutectic lead-antimony alloy containing at least 2% by weight of antimony. The inter-cell connecting member is then extruded into contact with the opening in the intermediate cell partition of the battery, the contact surface having an area of 15 to 75% of the area of the opening, and the inter-cell connecting member extruded portion is gradually heated through a softening process, an antimony-rich one-phase (antimony-rich phase) melting process, and an antimony-poor one-phase (antimony-lean phase) melting process. This fast-responsive electrode (extruder) is preferably an elastic urethane pad that is compressed as the electrodes (extruder) approach each other and the force exerted by the electrode (extruder) exerts an opposing force. to reduce the net force, the softened extrudate is first reshaped before melting, and then the antimony-rich phase of the alloy is forced out of the melting region and the antimony-poor phase is substantially melted. The cavity of the opening is filled before the opening.

The melt zone thus formed is dense, i.e. void-free, with an antimony-rich ring forming adjacent to the aperture wall, and an indicating core formed by the antimony-poor monophase junction after fracture. This is used to evaluate the melt formed and to monitor the stability of the method and equipment used to form the intermediate cell connections. Preferably, the lead-antimony-alloy used herein contains 2 to 4.5% by weight antimony, at least 0.03% but not more than 0.3% tin, and not less than 0.001% sulfur. An alloy of such composition has improved reliability as seen from the indicator core.

According to the leak-free connection method of the present invention, a gradually increasing current is applied to the extruded part of the intercell connection member cast from a lead-antimony monoeutectic alloy, while rapidly responding to physical changes therein. By pressing with permanent energy from the rear of the responsive inter-cell connecting member, an antimony-rich lump can be formed around the antimony-poor central portion. BRIEF DESCRIPTION OF THE DRAWINGS While the scope of the invention is limited by the claims, the invention and its method will be described in detail below with reference to the drawings. A battery-intermediate cell connection portion is formed by extruding the inter-cell connection member of the battery one-polar plate through the opening of the battery-intermediate cell partition wall and bringing the melted body of the inter-cell connection member into contact with each other via the extruded portion. b. In this invention, cold extrusion is utilized to provide a contact area of oppositely extruded intercell connecting members of 15-75% of the area of the aperture, and a rapidly responsive electrode (extruder) is utilized in conjunction with a specific melting schedule, which consists of gradually increasing the melting current to produce three physical changes in the intercell connector extrusion as follows: (1) softening and reshaping, (2) antimony-rich one-phase melting, and (3) antimony-poor one-phase melting.

A "fast-responsive" electrode (pusher) refers to an electrode (pusher) that can instantaneously and forcefully follow an intercell connection member as it changes its physical properties. The fast-responsive electrode (extruder) preferably gradually applies the force (as the lead alloy softens and melts).
It has an electrode (extruder) that reduces the extrusion pressure (extrusion pressure) and an elastic clamping means that gradually increases the clamping force (clamping pressure). Note that it is also possible to extrude the inter-cell connecting member into the partition wall opening by using an extruder, and to apply electricity to the extruder by using an electrode separate from the extruder. The intercell connection member, which is cast from a hypoeutectic lead-antimony alloy containing at least 2% antimony, is tightly clamped to the wall of the partition in the melting station, and the intercell connection member is The parts are cold extruded into contact with each other within the opening of the septum (see Figure 5), forming an initial contact area of 15-75% of the area of the opening. The dimensions of the contact area affect the initial contact resistance, which in turn affects the amount of thermal energy initially dissipated in the melt. do. After the part has made contact within the aperture, the melting current is switched on and gradually increased to its maximum value. This technique of gradually increasing the melting current is known as "resistance welding (melting) technology".
This technique is known as ``up sloping''. The initial and final current levels can be varied to provide an almost stepless current rise pattern.
Combinations of ``up-slope and maintenance'' or ``up-slope and down-slope'' are available, but they do not seem to offer any particular benefit in the case of up-slope alone, and do not require much control. It becomes necessary. For constant upslope conditions with AC power, the dissolution time is at least 3 cycles and 11
cycle or less is preferred. If it is less than 3 cycles, the effect of the up slope is lost, and if it is longer than 11 cycles, thermal changes in the partition wall (made of plastic) will occur.

A dissolution time of 5 to 7 cycles is most preferred.

As a result of upslope dissolution current, between cells::〒′
:． $'I, 27':''.:◆22*藩;. The inter-cell connecting member is flowed into the opening and enlarged to completely fill the opening just before melting begins (see Figure 6). .at the same time,
The area of the connection between the extruded parts of the intercell connection member increases,
This reduces the contact resistance of the screw connections. A certain amount of air gap remains within the opening, in particular in the form of a ring surrounding the connection, adjacent to the opening wall. The current continues to rise, thereby imparting more heat to the extrusion and the temperature at the connection increases until it exceeds the melting point of the antimony-rich monophase of the lead-antimony mono alloy. The microparticles of the antimony-rich monophase melt rapidly, and under the continuous force applied by the rapidly responsive electrode (extruder), the liquefied antimony-rich monophase flows from the dissolution region into the remaining voids. It flows (see Figure 7). Rapid response electrode (extruder) allows
Before substantial melting of the high-melting antimony-poor phase occurs, the voids are filled with a low-temperature melt zone. Eventually, the temperature near the center of the melting region reaches the melting point of the antimony-poor phase remaining there, which also begins to melt, and the extrusion of the inter-cell connection member is completely joined. . The alloy composition of the intercell connectors is important, with a sufficient amount of the low melting point phase to force the applied force to fill the void remaining in the opening before substantial melting of the antimony monophase occurs. (i.e., a phase of wealth and antimony). However, the alloy required to produce this effect must maintain a hardness of the lead alloy that allows the initial contact area (i.e., 15-75% of the open area) to be formed cold. At least 2% to achieve this hardness
It shall have an antimony content of 1. It is also preferred that the antimony content be approximately 4.5% higher in order to provide the hardness that provides this initial contact area, as well as more complete antimony richness. When the antimony content is about 2 to 4.5%, the results are somewhat reliable, but not necessarily complete.
Therefore, in alloys having such antimony properties, it is preferable to include controlled amounts of tin and sulfur within the alloy. The tin content is kept below 0.03-0.3% by weight (preferably about 0.2% by weight (f)). The sulfur content is sufficient to provide a good surface finish after casting, but must be less than 0.001% by weight. The remainder of the alloy is ``primarily lead'', which includes not only pure lead but also combinations with other components known to alter the properties of lead-antimony alloys used in battery production. Including matching. It typically contains copper, iron, nickel, silver bismuth, zinc and cadmium, usually in small amounts (such as 0.1% by weight), as well as up to about 0.30% arsenic. Because the up slope melts the intercell connecting member extrusions in stages, high liquid pressures are not created within the openings as would be the case if they were melted substantially simultaneously. As a result, there is less tendency for metal to eject (flow) from the opening under the force necessary to form a leak-free, void-free connection. Electrodes with reduced force application during melting (
By using an extruder, as described in more detail below, the tendency for molten metal to flow out of the openings in the septum is further reduced. When the cast inter-cell connection member cools, the alloy is segregated as a good structure.
This consists of a high-melting point-poor antimony phase (i.e., an antimony solid solution) that makes up the majority and a low-melting-point rich antimony phase (eutectic or It consists of a mixture of alpha and beta solid solutions in an approximately eutectic state.

The fine-particle rich antimony phase hardens the solid alloy so that the area of the initial cold extrusion is 75 times the area of the aperture.
% and melts rapidly once the melting point is reached during dissolution. Connection of the intercell connections is preferably made after a short time of casting and before age hardening of the alloy has occurred, since age hardening introduces additional variables that must be adjusted. The dimensions of the high-melting antimony-poor monophase or the loosely formed joint in the center of the connection are used as an indicator of the quality of the formed melt zone and the stability of the melt conditions.

The dimensions of this joint are determined by first fixing one inter-cell connecting member and rotating the other inter-cell connecting member within the plane of the partition wall until the connecting portion of the intermediate cell is broken. It can be observed after twisting (No. 8)
figure). Since the antimony-poor one-phase junction is weaker than the antimony-rich one-phase junction, failure occurs virtually unchanged through the weak junction, which is exposed in the fracture plane. The exposed and fractured weak joints appear as isolated islands on the surface of the fractured joint. This fractured, weakly bonded island of alloy will hereinafter be referred to as the "indicator core." The d-Kg (I
n. -D). ) number indicates the strength of the melt. A large indicator core is formed by cold melting (i.e. when there is insufficient thermal energy). Such connections are typically 10
．． 2n (0.41n) diameter opening/connection, 57
．． 6cm-Kf (501n.-D). It has a small strength and the core diameter is 7.6T1r111 (0.31n.
) That's it. Melting sections with indicator cores as small as 7.6 m (0.31 n.) in diameter are acceptable. If the core is not present, the melt zone is either overheated, meaning that molten metal can begin to flow out of the septum opening, or the electrode (extruder) is insufficiently driven and the perforation tend to form sexual dissolution areas. Porous dissolution means that when the fractured specimen is vacuum saturated with fluorescent oil (i.e., ZyglOZL-15 water wash penetrant sold by Ma Yuba1wcC0rp) and observed with a black light, the dissolution area is visible. means that substantially no oil has penetrated into the surface. Porous melts tend to form joints that corrode over time when the battery is constantly exposed to electrolyte. From the point of view of controlling this work, 2.5
An indicator core of diameter t1wL (0.11n.) is selected as a reference point and the deflection from it determines the stability of the work. In other words, this task is 2.51
m (0.11 n.) and the amount of deflection from it is used to determine how to deflect this work during this melting operation and the direction of correction. . 2.5? (0.11 n.) diameter core, approximately 86.5 cm-Kf (
751n. tb. ) has a strength of

This, of course, will vary depending on the composition of the alloy utilized to form the connection and the amount of age hardening of the alloy that occurs after melting. If the core size is within the control range of 2.5 to 7.6 m (
0.1-0.31n. ), one or more of the dissolution conditions will need to be adjusted. Obviously, 2
．． It is possible to still form a good melting zone with a core smaller than 5wL (0.11n) in diameter, but this means that this process requires melting under high heat conditions or slow electrode response time. Many batteries are of substandard quality and must be corrected before they are assembled. Since the melting and clamping machines are mostly integrated into the machine and cumbersome to adjust, the core size is controlled only by varying the amount of electrical current. For example, by simply increasing the maximum current, the core can greatly reduce the dimensions (i.e. 7.6 m (0.31 n)
), or the dimensions can be reduced slightly to increase the initial current. At the same time, the core size can be made much larger by reducing the maximum current and slightly larger by reducing the minimum current. - It has been discovered that most lead-antimony alloys having greater than about 4.5% antimony can form useful cores.

It has also been discovered that for antimony contents of about 2-4.5%, useful indicator cores are formed when the tin and sulfur contents are controlled within the ranges previously described. At this connection, the core formed in the extrusion-melt melt is not only influenced by the melting conditions, but is also strongly influenced by the composition of the alloy. For example, 2-4.5% Pb-S
If the sulfur and tin content of the b-alloy is not controlled, the core dimensions will change regardless of melt conditions, thus rendering core evaluation techniques worthless in terms of melt condition indicating effects. The melting conditions are related to controlling the sulfur and tin content within certain narrow ranges and subjecting the pieces to the aforementioned "up-sloping" current application and dissolution through a rapid response electrode (extruder); Thus, an indicator core is formed that provides a reliable reference for determining the stability of the dissolution conditions. In addition to the flowability advantage, tin gives a precise amount of hardening to repeatedly produce melt extrudates of nearly identical dimensions and contact resistance between extrudates, and sulfur mainly contributes to improving particle size. It seems so. Tin and sulfur are commonly found in most lead-antimony alloys used in battery production, but not in controlled amounts as described here.

Therefore, tin is added to the battery-grid casting alloy up to 1 (!l), which increases the fluidity of the melt and
This is to reduce cast pot scum by oxidizing to a wet thick-walled rich tin oxide that floats on top of the melt and prevents pot oxidation. Similarly, sulfur is often found in lead batteries and is commonly referred to as a brittle impurity. This is 0.0 in lead
0.001%, above which there is a tendency to form grain-forming sulfide nuclei. Sulfur, like tin, improves the fluidity of the melt and forms an oxide barrier in the cast pot. A lead-antimony alloy containing the aforementioned proportions of tin and sulfur offers particular advantages for the cast-on-strap version in foundry operations (i.e. when the strap is cast directly onto the plate). All strap casting operations utilize a holding container with a central holding pot and a dispensing bob or metering valve for directing the precise amount of lead to the melt manifold or strap casting mold.

This accuracy provides a good thermal balance of the screw device and allows for good welding of the casting strap to the grid ears without melting of the plate cell interface members. The problem with such lead metering equipment is that it undergoes corrosion from molten lead, causing metal oxides to coat or form on the delivery pieces, orifices, causing dimensional changes in the surface, and A rough surface is formed, which affects the accuracy of the amount of dissolved solution to be discharged. Mixtures of tin and sulfur contribute to poor delivery accuracy and, when containing amounts of tin and sulfur used in the normal battery industry, form a reactive scale that seals the casting pot. Although convenient, it exacerbates the problems associated with metering devices. Sulfur content up to 0.001%
(preferably from 0.0003 to 0.0007%) the formation of oxides on the distributing portion is minimized. Similarly, if the tin content is kept at a maximum of 0.3%, lead will hardly corrode the valve material, and sticky tin oxides will accumulate on the metering device and spoil its accurate operation. Never. By upslope melting of a mono-antimony alloy containing at least about 2% Sb, in combination with the use of a rapidly responding electrode (extruder),
High strength with virtually no voids (i.e. approx.
-Kg (501n.-Tb.) or more) is formed. This is apparently due to the redistribution of antimony within the aperture that occurs during dissolution. As mentioned above, the antimony-rich monolead having a low melting point moves to the outside of the melting region at the same time as it melts, where it forms a metal ring that is stronger than the antimony-poor center. Not only is this ring constructed of strong metal, but it occupies a substantial portion of the cross-sectional area of the weld zone, and in particular this part experiences the most stress during use. In addition, the antimony-poor center has a higher melting point (than the antimony-rich outer ring) and therefore solidifies radially outward from the center of the melt, and if there is no antimony redistribution. The opposite happens. Due to this directional solidification, the intermediate cell connections formed in this operation are void-free, with shrinkage cracks or No voids are formed. A further advantage is that only the low melting point antimony-rich metal contacts the aperture walls, resulting in less thermal deformation of said walls during melting. This is particularly advantageous when the electrode and aperture are tightly misaligned so that the tendency for plastic to eject into the aperture is reduced.
Finally, the low melting point rich antimony ring has less tendency to dissolve metal from the intercell interconnect at the edges of the opening, allowing molten lead to escape from the septum opening along the interface between the septum and the intercell interconnect. The tendency for outflow is reduced. Electrode (extruder)
and the method of applying force to the intercell connection members vary widely in the method of this invention. The intercell connecting member undergoes several physical changes, namely softening, melting in the first stage, and melting in the second stage.
Force must be applied instantaneously and constantly, depending on the fluidity of the lead as it passes through the stages of melting.

Without this, the antimony-rich alloy will not move rapidly toward the walls of the septum before the antimony-poor material dissolves.
The application of this necessary instantaneous force cannot be obtained by conventional pneumatic or hydraulic cylinders alone, in which case electrode (pusher) movement in response to deformation of the intercell connections;
There will be a momentary delay between the pressure generated in the cylinder and the pressure generated within the cylinder. If these physical changes occur within a few cycles (60 cycles/sec), even momentarily, the electrode (
If the force of the extruder is lost, a poor quality melt will be formed. By placing a spring, such as a Belleville spring (or urethane bud), between the hydraulic cylinder and the melting electrode (extruder), the required rapid response electrode (extruder) can be achieved.
The following is brought about. From now on, use a spring like this.
A force-driven through spring (force-driven spring). The use of Belleville springs is because they have a flat spring rate for the distances involved. The exact amount of force required for each operation will vary depending on the composition and aging of the lead, the dimensions of the aperture, the dimensions of the extruder electrode, and the amount of current and upslope used. . In general, too little force will create holes or voids that allow electrolyte to migrate from one cell to the next, or too much force will damage parts and equipment. When using this equipment to form connections, the equipment “
'locked' and all clamp bodies and electrodes (
The force applied to the extruder is provided by a force-through spring that is compressed during locking. In the preferred embodiment shown, the clamping member is a urethane pad surrounding the electrode (extruder);
This locks the device and the resulting electrode (extruder)
is compressed during the follow-through of the
This creates a reaction force against the flow through spring, which increases as said spring expands. The real effect is that the clamp force increases and the force of the electrodes (pushes) decreases as they move rapidly relative to each other as the extrusion changes physically. This applies a high clamp force to the ear,
The fluid forces on the molten metal are reduced, thereby reducing the tendency for the molten metal to flow or blow out of the bulkhead opening. During melting, the force acting on the piece comes from two sources: the force applied by the force spring and the clamping device. In a preferred form of apparatus for carrying out the invention, the clamping device is fixed to the electrode (extruder) holder and is itself a spring-biased member surrounding the melting electrode (extruder). In most preferred forms of the device, the clamping device is a compressible, high density polyurethane block or pad. The clamper need only be sufficient to prevent the flow or expulsion of molten lead from the septum opening at a given current. Generally, the required force increases as the melting current increases. Foos Fooroichi Through
In a preferred device having a compressible clamp spring surrounding the spring and the electrode (extruder), the strength of the former spring is sufficient to overcome the reaction force created by the clamp spring, so that the force of the clamp spring is must be exceeded. In this case, the force-through spring must be able to generate at least four times, preferably at least six times, the force of the clamper, measured in the closed or locked state of the melting gun. It has been found that high fluorocarbon sulfur increases porosity (ie, leakable voids). Furthermore, it has been found that melting with high fluoro-sulka requires more electrical energy than melting with low fluoro-sulka in order to obtain melts of comparable quality. In the most preferred device having a urethane pad as the clamping device, the relationship between the electrode (pusher) dimensions and the aperture dimensions is important in minimizing twisting or deformation of the case.

This relationship also affects the quality of the melt zone; if the ratio of electrode (extruder) diameter to hole diameter is less than approximately 0.62 or greater than 0.78, unacceptable septum deformation may occur. or a poor weld may be formed. The drawings show a preferred apparatus (tool) for carrying out the method of the invention and some of the steps involved.

Figure 1 shows a battery having groups of plates in separate cells of the battery, and an intermediate cell connection that electrically connects one group of positive plates to an adjacent group of negative plates via a partition between them. Section 4 is shown. Figures 2, 3, 10 and 11 show a preferred apparatus for carrying out the method of the invention, in which a toggle for forming one intermediate cell connection is shown.
A gun welder (TOgglegun welding equipment) is shown. However, in reality some or all (12
Separate equipment can be arranged for simultaneously melting (welding) the intermediate cell connections (five in the case of one battery). As shown in Figure 2, opposing electrodes (extruder)
is fixed to a copper electrode (extruder) holder 8, which is fixed to a slide 10 which slides horizontally in a guide 12 (FIG. 12). Electrical energy is supplied to the electrode (extruder) 6 from a suitable source via the connection 7. An electrical insulator 14, such as cloth reinforced phenolic resin, is optionally provided to insulate the retainer 8 from the slide 10 and other parts of the device. The electrode (pusher) holders 8 move toward and away from each other when the slide 10 moves in response to the action of a lever arm, said arm 16 being fixed to a part 19 of the frame 21 of the device. The pin 18 swings in rotation D, causing the sliding body 10 to cam back and forth. Lever arm 16 is driven by a two-piece actuation arm 20 connected thereto by a pivot pin 22;
The actuating arms 20 are connected to each other at a toggle joint 23 at the output shaft 24 of a fluid cylinder (not shown). An inverted U-shaped coupling 25 connects the output shaft 24 to the toggle joint 23. The outer end 21 of the pin of the toggle joint 23 is held within a bronze bearing 29 (FIG. 11), which slides upwardly and downwardly within a guide 31. Forth
A spring 26 is positioned between each of the two parts of the actuating arm 20 as shown, the spring 26 is centered by a guide pin 28, and its compressive force is applied to the washer. One lump sum 30
It is adjusted. A high-density polyurethane pad 32 is provided around each electrode (extruder) 6, which is used to attach the intercell connection member 33 of the battery monopolar plate to the wall of the intermediate cell partition during the extrusion, melting and cooling steps of the melting operation. It has the effect of tightly clamping (fixing).

The end of the electrode (extruder) 6 should be slightly (approximately 0.0
．． 25 m (0.011 n.), and therefore, before the clamping action of the pad 32, the inter-cell connecting member 33
It stings a little. This results in 1 hard butt 3 during melting.
The force required to further compress 2 can be reduced to some extent. For soft pads 32, the electrodes (pushers) 6 may be placed in the same plane as the surface of the pad 32, or below said plane depending on the balance of forces throughout the device. A groove 34 is provided on each side of each butt 32, which is connected to the intercell connecting member 3 as shown in FIG.
It substantially conforms to the shape of No. 3. the width and depth of the groove 34;
The degree of compression of the urethane butt 32 and the force applied thereto can be adjusted depending on the degree of proximity of the groove 34 to the periphery of the intercell connection member 33. This groove is a localized stress that occurs within the butt. Reduces power and greatly increases its lifespan. The clamping surface of the urethane pad 32 has the same angle as the draft angle of the intercell connection member 33, thereby applying a uniform clamping force, but in the preferred form the clamping surface angle is the same as the draft angle of the intercell connection member 33. In order to apply a larger force to the top of the connecting member than to its base, the draft angle of the inter-cell connecting member must be adjusted to l! )2゜～
Increased by 6° (4° is preferred). Electrode (extruder) coolant enters the electrode (extruder) 6 via fitting 35 and flows through suitable channels (not shown) within the electrode (extruder) 6. A particular advantage of utilizing a urethane pad 32 is that its hardness can be changed simply by changing the temperature and/or flow rate of the electrode (extruder) coolant without having to go through the trouble of replacing the pad. and thereby provide further means for making fine adjustments to the force device if necessary. For operation, the battery is connected to its electrode plate cell connection member 33.
is positioned between the electrodes (pushers) 6 as shown in FIG. 4, and the fluid cylinder is then actuated and its output shaft 24 is driven fully downward until it contacts the stop 36.

The spring 26 then compresses and completely ``bottoms out'' the surrounding pad, thereby ``locking'' the apparatus and completing the initial cold extrusion as shown in FIG. In this case, the extruded portion 38 of the inter-cell connecting member is extruded from the inter-cell connecting member 33 and meets within the opening 40 of the intermediate cell partition. The flattened contact area 39 formed between the extrusions 38 constitutes 15-75% of the area of the opening 40. The compressed spring 26 is now ready to provide the necessary rapid flow through the device. Next, a dissolution current is applied and gradually increased to a maximum level. The extruded portion 38 of the inter-cell connection member is heated and softened, and the spring 26
The force applied causes some flow to more completely fill the aperture 40 with soft but solid metal as shown in FIG. At this point, a void volume in the form of an annular body 42 is left within the aperture adjacent to the wall of the aperture around the extrusion of the intercell connecting member.

Immediately after the metal of the inter-cell connecting member softens, the extruded portion 38 of the inter-cell connecting member is exposed to its contact surface (interface) due to the increasing current.
At 39 the temperature rises to the melting point of the rich antimony-rich alloy, which melts. Due to the melting and the instantaneous force applied by spring 26), the antimony-rich alloy flows out of the melt region into the annular cavity 42 before any antimony-poor alloy has substantially melted. As a result, the previously formed void 42
An antimony-rich circular part b (Fig. 7) and an antimony-poor central part a (Fig. T) are formed. In the remaining portion of the melting cycle, the antimony-poor central portion a is heated to its melting point, and the central portion finally melts. The antimony-poor region a) of FIG. 7 is weaker than the antimony-rich region b because it is the last to melt; the size and/or degree of melting is an indicator for making energy adjustments to the device. To monitor this process, a battery is periodically removed from the line and its connections are twisted to break, as shown in FIG.

This failure always occurs in region a, where the bond is weakest and melting is also the last. Destruction surface 46 (9th
The dimension (i.e. diameter) of this last melting part a indicates whether the melting conditions should be adjusted, as shown in Figure 10).6 The large indicator core a (Figure 9) As shown in FIG. 10, it indicates that energy needs to be increased to reduce core size. If no core is produced, the energy must be reduced so that a core as shown in FIG. 10 is produced, which acts as a "reference" designator to make the correct decision. In a variation of the directed core test, the connections are age hardened for approximately 4 hours until the central core is hardened to a point where it is stronger than the intercell connection metals that do not melt.
) was done. In that case, either a well-melted connection failed along the contact (middle) plane between the unmelted metal and the recrystallized metal, or an incompletely melted metal at low power still failed in the core. The fracture core of the age-hardened product is approximately 5.1
If it exceeds t1!11 (0.21 n.), it is required to increase the power (energy). As one particular example of this invention, the intercell connection member of the electrode plate has a draft angle of 2 degrees with respect to the rear surface L, 5.
3% Sb, . O. 2% Sn,O. OOO5
OL) of SlO. It is cast from an alloy having primarily 2% As and the balance lead. This inter-cell connecting member is located on both sides of the intermediate cell partition wall, and the partition wall is 1.8Wr11t (
0.0701n. ) and a diameter of 10.1m (0.4
1n. ) is made of ethylene-propylene copolymer with openings. Is the melting electrode (extruder) 7.9? (0.31
21n. ) for the electrode (extruder).
It is surrounded by a urethane clamp pad with a 2 m° (0.4021 n.) diameter hole. The clamp pad has a shore "D" hardness of 42-47 and a clamping face angle of 4 degrees (2 degrees is an inappropriate combination for the part).
Made of vacuum gassed polyurethane. The selection of the Belleville spring is such that at the start of melting, a force of approximately 481 kg (1060 tb) acts on the electrode (extruder) and a force of 91 kg (200 tb) acts on the urethane pad, and at the end of melting, , 254kg (560
A). ) is applied to the electrode (pusher), and a force of 163 kf (360 tb.) is applied to the pad, causing the Belleville spring to apply a force of approximately 154 tb.
A net fluoro-sluker of kf (340 tb.) is brought into play. After the initial extrusion, electrical current is gradually applied to the b-piece over a total dissolution period of 6 cycles. The melting device is a 25-unit unit with an open circuit voltage of 8.2
v, with a closed circuit voltage of approximately 1.5-2.5 V, which of course increases throughout the upslope melt cycle. The current is about 4200 amps from the beginning 14
It can be changed up to a maximum value of 000 amps. Under these conditions, during the third and sixth melt cycles, the electrode (extruder) moves rapidly, and then after the current is stopped, the electrode movement subsides during the melt hold cycle.

The melted part formed is about 75C! rl-Kf (651n.
tb. ) torque of approximately 3.8 cm (0.1
51n. ) with an indicated core of dimensions. As described above, according to the present invention, it is possible to provide a melting section with increased strength and substantially no voids, it is possible to connect intercell connecting members without the molten metal flowing out from the partition openings, and it is possible to connect intermediate cells. Thermal deformation of the partition wall can be reduced.

[Brief explanation of the drawing]

Fig. 1 is a partial cross-sectional front view of a battery formed according to the present invention, and Fig. 2 is a cross-sectional elevational view of the apparatus used in this method, showing the position of each part in the first step of the method of the present invention. , FIG. 3 is a sectional view taken along line 3-3 in FIG. 2, FIG. 4 is an enlarged cross-sectional elevational view of a part of the device in FIG. 2 showing the position of each part before the device is operated, and FIG. is an enlarged cross-sectional elevational view of a portion of the apparatus of FIG. 2 showing the condition of the parts after the first cold extrusion step of the method; FIG. Figure 7 is an enlarged cross-sectional elevational view of a portion of the apparatus of the invention showing the condition of the pieces; FIG. A top view, Figure 8 is an elevational view of the fractured piece observed to carry out the work that allows quality control, Figure 9.
The figure is a cold melting indicator core characteristic diagram, Figure 10 is a cutaway diagram of the optimal indicator core, and Figure 11 is a drive link shown at 11-1 in Figure 2.
An enlarged sectional view along line 11, Figure 12 is 12-1 in Figure 2.
FIG. 2 is an enlarged cross-sectional view taken along two lines.

Claims (1)

[Claims] 1. Between the electrode plates (for example, 2) of adjacent cells of a lead-acid battery,
an opening (e.g. 40) in a non-conductive partition separating the cells;
In the method for making a leak-free connection via a strap, the electrode plate group is provided with a strap having inter-cell connecting members (for example, 33) facing each other on both sides of the opening (for example, 40), and the inter-cell connecting members are having a wall thickness greater than the partition walls and being cast of a lead-antimony-hypoeutectic alloy containing at least 2% antimony, and an antimony-poor phase forming the majority and an antimony-rich phase forming the majority; distributed throughout the antimony-poor phase to form a portion; then said intercell connecting member is clamped to both sides of said partition wall to cover and seal the opening with the surface of said intercell connecting member; pressurizing the portion of the cell-interconnecting member covering the opening while clamping the inter-cell connecting member, and moving the portion of the inter-cell connecting member covering the opening from each side of the opening into the opening; A lead alloy is extruded using an extruder to form a bridge in the space within the opening, and the bridge is located approximately in the center of the opening between the extruded portions of the inter-cell connecting member, and has an area corresponding to the area of the opening in its plane. forming a contact area (e.g. 39) comprising between 15 and 75%; storing potential energy at the rear of the extrusion which can be dissipated sufficiently rapidly, thereby
As soon as a decrease in the resistance to flow of the extrusion occurs, the extrusion of the ear (e.g. 38) is caused to flow rapidly and forcefully in response and to prevent segregation of the phase at an early stage of melting. while maintaining clamping pressure and extrusion pressure at the intercell connection;
A gradually increasing current is applied by an electrode to the extrusion of the intercell connecting member to cause a physical change in the extrusion, the physical change first softening the extrusion before melting, and then softening the extrusion before melting. melting the antimony-rich phase of the alloy in the contact zone and finally melting the ammonium-poor phase of the alloy in the contact zone, using the stored rapidly dissipable energy while supplying the current. Sufficient pressure is continuously maintained on the extrusion section by releasing the molten ammonia-rich phase from the contact zone before any substantial melting of the ammonia-poor phase occurs. Flow outwards towards the walls of the aperture to form an antimony-rich ring (e.g. b) around the antimony-poor center (e.g. a); then the supply of current is stopped and the molten lead within said aperture is The melted zone formed by the alloy is gradually solidified from its center radially outward toward the walls of the opening, while at the same time maintaining the clamping and extrusion forces on the intercell connecting member to melt the alloy. A method of making a leak-tight connection that keeps the opening filled during solidification. 2 2-4.5% antimony, 0.03% by weight
Liquid leakage according to claim 1, characterized in that the inter-cell connecting member is formed by casting a lead alloy consisting of ~0.3% by weight of tin and less than 0.001% by weight of sulfur. How to make a connection without. 3. A current is supplied to the extruded portion of the inter-cell connection member,
and as the extruded portion of the inter-cell connecting member passes through the softening stage, the antimony-rich melting stage and the antimony-poor melting stage, the clamping force acting on the inter-cell connecting member is increased; A method for making a leak-tight connection according to claim 1, characterized in that the pressure acting on the extrusion is reduced. 4 Between the electrode plates (for example, 2) of adjacent cells of a lead-acid battery,
an opening (e.g. 40) in a non-conductive partition separating the cells;
in a device for making a leak-tight connection through a melting gun, after application to the portion of the intercell connection member covering the opening, the melting gun is directed towards each other to force the alloy of the portion into the opening (e.g. 40). a pair of opposed substantially cylindrical plunger electrodes movable to the extruded portion; compressible intercell connection member clamping means (e.g. 32) surrounding each said plunger electrode and engaging said intercell connection member to hold it during said extrusion and melting; each of the plunger electrodes (for example 6) and the inter-cell connection member clamping means (
A pair of opposing plunger electrode holding devices (e.g. 8) are adapted to be inserted between the adjacent cells and apply pressure to the plunger electrode and intercell connecting member clamping means. compressible means (e.g. 26) A device for making a leak-tight connection, provided with means for exerting a force together on said retaining device. 5. said compressible intercell connection member clamping means having a pad (e.g. 32) of high density polyurethane surrounding each of said plunger electrodes (e.g. 5. Apparatus for making a leak-tight connection as claimed in claim 4, characterized in that it engages and clamps them to said septum during said extrusion and melting. 6 the opposing plunger electrode holding devices (e.g. 8
) has a sliding member (for example 10), which causes the time keeping devices to move linearly toward and away from each other. A device that makes a connection that does not exist. 7. A pair of lever arms (e.g. 16) are engaged at one end with said sliding member (e.g. 10) to effect movement toward and away from each other, and the other end of said arm is connectable to a power source (e.g. 24), said lever being pivotally coupled between its ends to a rigid support frame (e.g. 21), said lever being coupled thereto between said other ends thereof; a toggle connection (e.g. 20, 22, 23), each arm (e.g. 20) of said toggle connection being compressed when a force is applied to said lever by said toggle and being compressed during application of a melting current; 7. The device according to claim 6, further comprising a spring (e.g. 26) adapted to store rapidly dissipable potential energy released into the plunger electrode at the rear of the plunger electrode. A device that makes connections without leakage.