Method and apparatus for casting lead into plastic for side terminal batteries

A method for casting a lead-alloy battery terminal connector through an aperture in a plastic battery case, comprising the steps of:

• (a) providing a battery case having an aperture in a wall of said case;
• (b) positioning a plurality of mold means to surround said aperture, a first of said mold means having an opening through which molten lead is subsequently injected;
• (c) disposing a heater at least partially within said opening to prevent solidification of lead within said opening;
• and
• (d) injecting molten lead at a preselected pressure around portions of said heater and through said opening to form said terminal connector.

A method for casting a lead-alloy battery terminal connector through an aperture in a plastic battery case, comprising the steps of:

• (a) providing a battery case having an aperture in a side wall thereof;
• (b) positioning a plurality of mold means to surround said aperture, a first of said mold means having an opening through which molten lead is subsequently injected;
• (c) providing a reservoir of molten lead at a preselected temperature;
• (d) providing a head in fluid communication with said reservoir and said opening;
• (e) heating substantially the entire length of said head to a temperature higher than said preselected temperature in said reservoir;
• and
• (f) injecting molten lead at a preselected pressure through said head and said opening in said mold means.

An apparatus for casting a lead-alloy battery terminal connector through an aperture in a wall of a plastic battery case, comprising:

• (a) a plurality of mold means positioned to surround said aperture, a first of said mold means having an opening through which molten lead is subsequently injected;
• (b) a reservoir of molten lead which is maintained at a preselected temperature;
• (c) a head in fluid communication with said reservoir and said opening;
• (d) means for heating substantially the entire length of said head to a temperature higher than said preselected temperature in said reservoir;
• and
• (e) means for injecting molten lead at a preselected pressure through said head and said opening in said mold means.