Lead acid storage battery and method of bonding battery cell terminal posts and bushings

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post made of lead alloy material, providing a cover having a bushing supported therein made of a material having a melting point at least about 100 degrees F. less than the melting point of the lead alloy material of said post, and heating the terminal post and bushing to a temperature above the melting point of said bushing but below the melting point of the post to bond the bushing to the post with a secure leak free joint.

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post made of lead alloy material, providing a cover having a bushing supported therein made of a solder alloy material having a melting point below the melting point of the material of said terminal post, and heating the terminal post and bushing to a temperature above the melting point of said bushing but below the melting point of the post to bond the bushing to the post with a secure leak free joint.

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post, providing a battery cover having a bushing supported therein and an integral upstanding mold section of the cover completely surrounding the bushing, positioning the cover on the battery case with said terminal post extending upwardly through said bushing, locating the battery case with the cover mold section in predetermined relation to an induction heating coil by engaging said mold section with said coil, energizing said induction heating coil to induce current flow through said post and bushing to melt at least a portion of the bushing and secure the bushing to the post with the mold section retaining melted material of the bushing.

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post, providing a battery cover having a bushing supported therein and an integral upstanding mold section of the cover completely surrounding the bushing, positioning the cover on the battery case with said terminal post extending upwardly through said bushing, locating the battery case with the cover mold section in predetermined relation to an induction heating coil by positioning said mold section within said coil, energizing said induction heating coil to induce current flow through said post and bushing to melt at least a portion of the bushing and secure the bushing to the post with the mold section retaining melted material of the bushing.

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post, providing a battery cover having a bushing supported therein and an integral upstanding mold section of the cover completely surrounding the bushing, positioning the cover on the battery case with said terminal post extending upwardly through said bushing, locating the battery case with the cover mold section in predetermined relation to an induction heating coil, energizing said induction heating coil to induce current flow through said post and bushing to heat said busing to a temperature above the melting point of the material of the busing but below the melting point of the material of the post so as to melt at least a portion of the bushing and secure the bushing to the post with the mold section retaining melted material of the bushing.

A method of making a lead acid storage battery comprising providing a battery case with a plurality of battery cells having at least one terminal post, providing a battery cover having a bushing supported therein and an integral upstanding mold section of the cover completely surrounding the bushing, positioning the cover on the battery case with said terminal post extending upwardly through said bushing, locating the battery case with the cover mold section in predetermined relation to an induction heating coil, energizing said induction heating coil to induce current flow through said post and bushing to melt at least a portion of the bushing and secure the bushing to the post with the mold section retaining melted material of the bushing, positioning an outer cover on said case in vertically spaced relation above the cover within which said bushing is supported following bonding of said bushing and said post, and bonding said outer cover to the top of said mold section.