Apparatus and method for cold forming an L-shaped lead alloy battery terminal

A method for manufacturing an L-shaped lead battery terminal in a cold forming process, the method comprising the steps of:

• stamping a lead slug in a forming station having a split die to cold form a semi-finished L-shaped lead battery terminal including a head having a radial ring, a base, a tower extending from the base and offset from the head, and a recess extending from the head toward a top surface of the base terminating in a blank wall;
• transferring the semi-finished L-shaped battery terminal to a through punch station;
• and
• punching the semi-finished L-shaped battery terminal in the through punch station forming an L-shaped battery terminal having a through hole.

A method for manufacturing L-shaped lead battery terminals in a cold forming process, the method comprising the steps of:

• stamping a lead slug in a first cold forming station forming a partial-finished L-shaped lead battery terminal including
• a head having a substantially uniform outer diameter,
• a flange,
• a base,
• a tower extending from the base and offset from the head, and
• a recess extending from the head into the base and terminating in a blank wall;
• transferring the partial-finished L-shaped battery terminal to a through punch station;
• punching the partial-finished L-shaped battery terminal in the through punch station forming a near-finished L-shaped battery terminal having a through hole;
• transferring the near-finished L-shaped battery terminal to a rolling station;
• and
• engaging a ring forming head on the head of the near-finished battery terminal in the third rolling station forming a rolled battery terminal having a head including an annular ring.

A press for cold forming a non-symmetric battery pole from a piece of lead, the battery pole including a cylindrical head having a central axis and a tower formed with the head and offset from the central axis, the press comprising:

• a first die defining a tower-shaped cavity within which the tower is formed;
• a second die defining a cylindrical cavity having a central axis within which the head is formed;
• a press frame, the first and second dies being supported by the press frame to move into and out of engagement with the tower-shaped cavity being offset from the central axis, wherein the first and second dies form a closed cavity having a surface which generally defines the shape of the non-symmetric battery pole when the dies are substantially engaged;
• and
• a punch supported by the press frame to move within the closed cavity to force lead within the closed cavity into engagement with the surface.