Resistive electrode

In a welding apparatus for welding a battery terminal post to a battery bushing, the battery terminal post being electrically connected to a battery plate disposed within a battery case and the battery bushing being secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case,

• the welding apparatus comprising a bushing mold for location on the battery bushing for connecting the bushing to a first connector of a power source and a resistive electrode connected to a second connector of the power source;
• the resistive electrode being generally cylindrical and extending longitudinally between a base end and a tip end with the base end being secured to the second connector of the power source, a first bore being defined in the base end for receiving a cooling fluid for cooling the resistive electrode, a second bore being defined in the tip end for providing an annular tip surface for engaging with the battery bushing to enable the flow of electric power between the resistive electrode and the mold bushing to heat the resistive electrode for welding the battery terminal post to the battery bushing,
• the improvement comprising:
• the first bore distance extending approximately seventy percent of the longitudinal distance between the base end and the tip end of the resistive electrode;
• a copper conductive sleeve disposed in the first bore and engaging a sidewall of the first bore, said copper conductive sleeve enhancing the flow of electrical current from the base end to the tip end of the resistive electrode and concentrating the resistive heat proximate to the tip end of the resistive electrode;
• and
• said conductive sleeve facilitating the transfer of heat from the resistive electrode to the cooling fluid.