Патент USA US2111107код для вставки
' BATTERY cABLE AND CONNECTER ‘ Filed July 25, 1936 ' . 2 sneaks-sheet 1 Eu // l!) ` * AIl i ~ Mar¢h15,1938. ’ ' _ - ~ AHM/11.51; - „ 2,111,101 `BATTERY CABLE AND CONNECTER Filed Juiy 25, 195e îïè-flë ¿à 50» 55 ' > _ ' 2 sheets-sheet 2 E112-¿16:35 5 e IN VEN TOR. l7 ' Patented Mar. ` 2,111,101 19138 A -' UNITED STATE s Pri‘r‘sri're oI-‘Flcls> 2,111,107 ‘ . BATTERY. CABLE AND' commenta Philadelphia, Pa., assignor, by I assignments, of one-third to and one Arnold Berman, Philadelphia, Pa., third to Carrie E. Hohl, Upper Darby, Philadel phia, Pa. Albert H. Walde, ‘ direct and mesne Application July 25, 1936, Serial Nb.- 92,650 - f (Cl. 173-259) ‘1 Claim. „n shape which' they assume when embedded with My invention relates broadly to battery cables in the cable terminal; Fig. 2 is a similar view ‘and connecters andmore particularly to a con with vlow melting point metallic form retaining struction of improved- battery cable and lcon bands vapplied to the ends of the strands to _con- . =‘ necter having a high degree of strength and high ' line and substantially align the strands during 5 _electrical conductivity. l l the process of casting; Fig. 3 is a side elevation thereof; Fig. 4 is a top plan view of the cable ' One of the objects of my invention is to provide a construction of battery cable and connecter in which _ the stranded wires of the cable are em- terminal with the terminal connecter shown in _' dotted lin‘es; Fig. 5 is a similar view showingv the Vbedded in the ’material forming the’jaws of the _ 10 connecter which embrace thestorage battery post strands embedded within the cable connecter,~ the low melting point Ametallic bands encircling the ends of the strands having melted and be come an integral part of the molded battery and low electrical resistivity. ` Another object of my invention is to provide a ' terminal casting; Fig.‘6 is -a view similar to Fig. construction of non-corrosive battery cable and 5 showing the bifurcated 'ends of the terminal 15 connecter having a minimum number> of parts " drilled to receive the securing bolt; Fig. 7 is a substantially free from detrimental edects of cor S similar view showing the battery `terminal pro _rosion and eliminating the necessity of establish vided with the clamping bolt and fastened to a ing a separate connection between the connecter conventional storage battery post; Fig. 8 vis a sectional view taken substantially on line 't--t and the cable. n , oi Fig. 7'; Fig. 9 is a transverse vertical section 20 -Still another; object _of vmy invention is to pro vide a construction of connecter for storage bat taken on line 9--9 oi Fig. 3; Fig. 101s a trans for imparting a high degree of tensile strength » tery posts in which the metal forming the con verse vertical section taken on line Iii-_iii of Fig. 3; Fig. 1l is a transverse vertical section taken on . line H-ii of Fig. ‘7; Fig. 12 is a _similar View. necter may be cast directly around _the stranded ends of a cable having the ends thereof spread and shaped to conform with the contour of they Y taken on line i2----i2 of Fig. 7; Fig. 13 is a top 25 storage battery post with which the connecter plan view showing the cable provided with 'an is designed to cooperate. oiïset connecter, substantially at right angles to. the cable; Fig. 14 is asimilar view showing the ' A further.. object of my invention is to provide a construction of connecter for storage battery »posts in-whlch the stranded ends of a cable are preformed to conform with the shape of the stor age battery post with which the connecter is de connecter in horizontal sectiomFlg. l5 is a sec tional view showing a plurality oi cables clamped within the halves of a mold ready to receive the signed to coact and non-corrosive metal cast directly around the cable so that the stranded 35 portions of the cable form the c_ore of the jaws of the connecter thereby imparting a high degree of tensile strength and relative resilience to. the jaws facilitating the insertion and removal of molten metal; Fig.I 16 is a tran erse vertical section taken on line it--lt of Fl . 15; Fig. 17 is is a horizontal section taken substantially on line /l'l--il or Fig. 15; Fig. 18 is a horizontal section taken on line lt-it -ofÍ Fig. l5; and Fig. 19 shows y a modiñed form of terminal embodying my in. vention. the connecter from the storage battery post. . A still furtherv object-oi my iiviventionv is to provide a method oi making a connecter, having stranded wire cored jaws, for storage' battery \ ` My invention is directed to an improved con struction of cable connecter for storage battery terminals. l` provide a special construction of stranded »flexible cable which is substantially iiat and substantially rectangular >in cross section. posts in which a multiplicity of connecters may be made simultaneously by process of casting in ` Therectangular structure of cable is covered by expensively on a quantity production basis. insulation material which substantially conforms .Other andv further objects of my .invention in contour to the structure of the cable: The reside in the process of making electrical con relatively nat stranded conductor constituting necters and the improved construction thereof as the Vcable is >separated into two substantially set forth more fully in the specification herein 50 after following by reference to the accompany ing‘drawings in which: . l ' ’ ’ y Figure lpis a top plan .View of a portion of a equal portions which are spread to substantially conform with the shape of the coacting jaws'of the'tlnished terminal connecter. - For purposes of maintaining the form of the the strands comprising thel cable' f separated 'portions of the _stranded conductor, I " _ being spaced apart to form the stranded core of provide an encircling band of metal having low 55 the ¿lawsv of the connecter in >substantially the battery cable. a. >melting point adapted to normally em'brace 2.111,10? are cast into the‘jaws of the terminal, are of material having a relatively low melting point. Under the .intense heat developed in the mold ing process, these 'clips lose their -identity and iiow into the material constituting the molded and ' conñne the strands in separated portions. The ’ cable thus prepared is laid in position inv a mold. 'I'he mold may be' of 'a variety of forms as the method of my invention is .adapted for die cast ing as well as permanent mold casting and poured jaws ofthe terminal. ' ' ‘ mold operations. 'I'he construction of the mold The molded embedded wire terminal construc- is such that preformed recesses are provided in ‘ tion of my invention is Íadapted both to the ì Y opposite coacting portions 'of the Amold for shap-r' 10 'ing the battery terminal. The coacting portions elbow type terminal and the straight type ter minal as well as to various forms of angularly 10 disposed lug and strap type terminal connecters. v of the mold, defining .the shape of\thel terminal by means of the aligned recesses, is adapted to receive-the prepared battery cable. The sepa rated portions of the stranded wire forming- the ~ 'I'he important consideration in~ all of these forms _is that the portions of the stranded con ductors shall extend substantially the entire ’length of the terminal and around the jaws' which clamp the terminal to the storage bat 15 cable are of such length as to extend substan >muy the entire length/of the finished battery terminal.- 'I'he separated stranded portions of tery post. i . _ - the cable, each confined in-position by the band - ¿Referring to the drawings in more detail, ref wrappers of low melting point metal, extend erence character l designates the ñexible strand 20 around the centralportion of the .coacting re ed electrical conductor constituting the storage cesses in the aligned parts of the mold and upon battery cable. 'I'he iiexible conductor I ,is formed opposite sides of that portion of the terminal, by a plurality of separate strands. Each strand which -ultimately forms the central aperture is formed by a multiplicity of twisted relatively . which receives the storage battery post. The in »line wire j conductors. The strands constituting 25 sulation covering the stranded cable extends to the cable are grouped in substantially. rectangu 25 a position substantially within the limits of the lar cross-section. The substantially rectangularv coacting recesses in the aligned parts of themold. cross-section cable is covered by flexible insu Accordingly, when the metal is flowed in, the lation material indicated at_2. 'The insulation cable 4connecter is formed directly around the material 2 is cut away adjacent the end o_f the separated stranded portions of the cable con cable, leaving the ilexible strands forming' the 30 ductor and directly around the end of 'the insu cable bare. The ñexible strands are separated lation forming a permanent unitary construction ._ into equal portions represented at 3 and 4. 'I'he of high electrical conductivity and low resistivity. separate portions of the ñex‘ible cable are shaped 'I'he cylindrical bore inthe j'aws of thestorage to conform substantially with the contour of the battery connecter through which the securing jaws of the connecter vwhen iinally completed. 35 bolt is adapted to extend is drilled through the That is to say, the strands 3 and 4 are separated aligned jaws. The drill, cuts through not only in spaced relation to (form a substantially solid the molded metal of the terminal but also vertical wall or core structure. In order to main through the stranded'conductors of the cable. Y tain the form of the spread and separated por 40 There is thus obtained substantial electrical con tions of the cable at 3- and 4, I provide metallic» ductivity, substantially the entire length of the bands having the characteristic of low melting terminal connecter. This construction imparts point, which bands encircle the core formed by not only good electrical conductivity to the ter the conductors at 3 and 4. The metallic bands j minal but also mechanical strength and a high> are> shown in Figs. Í2, 3, 4, 9, 15, 16 and 18 at 45 degree of resiliency. _Thus the jaws of the ter' -5_ and 6. The metallic band 5 embraces the 45 minal may be clamped with respect to the~stor-` strands 3 and has sufficient rigidity to maintain age battery post when securing _the cable in 'strands 3 in a substantially "vertical plane con position and spread when removing the cable stituting a wallor core structure. The band 6 from the storagebattery post._ which encircles the iìexible conductors 4 simi 50 Because of the resiliency imparted to <the jaws larly maintains the conductors 4 in'a vertical of the terminal‘by the embedded stranded con plane symmetrically spaced vfrom the. plane of « ductors of the cable, I depend much less upon the inherent resiliency of the cast metal form ing the terminal. ' In somehinstances, however, I 55 employ a composition material of antirnony, tin, copper and lead which in itself provides> a mate rial of relatively h_ighA resiliency. A wall struc the jaws of the'storage battery connecter indi l ture substantially the height of the terminal is formed on either side of the recess through cated in dotted lines in Fig. 4 at 1. 'I'hat is to 60 which the storage vbattery post projects by the separated portions of the ñexible cable ,conduc tor. _The_spreadportions of the ilexible'cable Yconductor thus impart substantialstrength to , the terminal. 65 the conductors 3 on opposite sides of a central axis through the cable 2. The substantially ver tical wall 0r core structure formed lby the sepa rated portions of the flexible cable 3 and 4 is 55 ñrst shaped to conform with the ñnal shape of -I eliminate connecting- devicesV between the end of the cable and the terminal by- directly forming the terminal on the spread portions of ' the cable thus eliminating undesirable corrosive ac_tion so prevalent in storage battery terminals. 70 A loose connection cannot develop between they cable and the terminal because the cable -becomes an intimate part of the terminal in the struc~ say, each of the groups of strands 3 and 4 are shaped as in Fig. 4v by imparting an outwardly -60 extending convex curvature -as represnted at 3a and 4a in an intermediate positionl between the Vextremities of the conductors and the end of _the insulation material at 2. 'I'he extreme outer y ends of the conductors at 3 and 4 remain in 65 parallel spacial relation' clamped by the low melting point metallic clips shown at 5 and 6. ' ' The shaped end ofthe cable is, now »ready-for the mold. 'The mold is shown more particularly‘in Figs. 15-18 as comprising a pair .of coacting sec 70 tions `8 and 9. The coacting sections of the mold are hingedly connected as indicated ’at l0 and are adapted to be closed with respect to each other .to provide aligned metal -receiving portions 'in 75 of theseparated portions of the cable, and which._ di'cated at Il and I2. The aligned metal receiv 75 ^ ture of my invention. The conñning means or clips around the ends 3 9,111,101 to the -con ing portions of themold are shaped tour o! the connecter which is 'finally produced. ing bolt 21 has a head 28 on one end and is screw threaded at 29 on the opposite end to receive nut 30. By turning nut 30 tapered cylindrical I5 adapted to be' `aligned with each other when I4 andllä are each tapered so as to provide the required tapered >bore in the connecter which a ing bolt 21 extends through the transverse pas sage’ 24 in the jaws ofthe terminal. yThe clamp It will be seen that the coacting sections of the' mold l9 andi!) carry central core portions 'I4 and 4 the mold sections are closed. 'I'he core portions ' side walls 26 ofthe jaws of the terminal are brought into more intimate engagement with the tapered side walls of the storage battery post 25. Becausev of -the yieldablev character of the _core structure provided by portions ofthe cable .-3 and 4 Vembedded inthe jaws of the terminal the material of the jaws is sufñcientiy resilient to facilitate clamping of the terminal on the post and the removal of the terminal from the fits around the storage battery post. The co-acting core` portions I4 and l5 are connected ` with the coa'ctìng parts of the mold through webs I3 and I1 which ~provide means in the mold for forming the gap between the ends of the jaws of the connecter. The coacting parts of the mold post by spreading of the jaws. _ f each have a semi-cylindrical recess in the aligned As heretofore illustrated, the terminal of my indicated at I8 andIS , invention is constructed in straight form. It will interior faces thereof as to` allow the insulation 2 of the cable to be be understood that the principles of my inven-, clamped between the coacting parts of the mold. , tion are equally applicable to other forms of The cable is so located in the mold that the in terminals, one o! vwhich I have illustrated in 20 sulation 2 projects interiorlyv into the mold so Figs. 13 and 14. In this arrangement the ter that when the metal flows into the-mold, the minal indicatedat 3| is provided with an angu metal will ñow wholly around `the insulation sheathing 2 of the cable forming a protection larly disposed connecting' portion 3_2 through which the stranded portions of the cable 33 ex for the end of. the insulation on the cable. tend as illustrated in lï‘ig.~1‘i=.Í The >stranded 25' It will be seen thatv the end of the cable pre- , cable 33 has .the strands thereof divided into two 25 formed as in Fig. 4 is inserted in position in the multiple mold as shown, for example, in Fig. 15. The portions of the cable at 3 and 4 are sep arated to extend substantially through a central 30 zone in' each 'of the recesses in the coacting parts of the mold with the low melting point metallic portions 34 and 35 which form cores for the co acting jaws of the terminal. The cable' 33 hasv the insulation 36 thereof extending into the molded structure of the'V connecter 32 thereby pre 30 venting corrosive attack of -acid upon the con clips 5 and 6 maintaining the shape ofthe strands of the cable projecting into the mold. When the ends of the cable are positioned in the mold, as 35 shown in Fig. 15, for example, the non-corrosive metal from which the connecter is formed is the cable at 34 and 35 extend entirely around central aperture 31 of the connecter and sub stantiallyto the ends of the jaws 38_through 35 _ ready to be poured intothe molds through suit able gates which I have indicated at 20, individual to each of the molds. 40 , , ‘_ ' The parts 8 and 9'of the mold are maintained ductors ofthe cable. Th'e separated portions of ' `which the clamping bolt 39 extends. AIn some instances, I construct thei terminal in a manner which eliminates the necessity of drilling the transverse passages 24 by casting thel metal of the terminal directly around a trans 40 verse core member. A terminal constructed in in closed kaligned position by means ofv a suit - this manner is shown in Fig. 19. It will be seenable clamp device which I have indicated at 2l. that the strandsA 3 and 4 of the conductor are The molten iluid metal flows around the core allowed to terminate short' of the transverse portions 3 and 4 of the cable and fills the space passages 24 invthis construction-and thus avoid 45 on either side of the cable and between the side' obstruction to the transverse core member. lOther walls ofthe mold andthe wall formed by the' , strands of the conductor may extend beyond, portions of the cable 3 and 4- and between the above and/or below, _the passages 24, as in the central coacting core portions I4 and I5. The other forms of my invention. -‘ intense heat of the ñuid metal melts the metallic Inasmuc-h as fthe 'copper wire, forming the 50 I50 bands 5 and E so that the metallic bands 5 and 3 d strands ,of the cable forms a relatively large por losel their identity and rlow into the material. constituting the molded jaws of /the te inal. The condition of the casting just after -the mold ing process is illustrated in Fig. 5 in which the 55 portions of the cable at 3 and 4 are illustrated as forming an extended core for the coacting jaws of the terminal 22 substantially the entire length of the terminal. The terminal 22 is shown hav ing parallel extending spaced faces on either ` 60 side of. the central axis ‘of the terminal. The terminal 22 is now ready for boring and as V illustrated in Fig. 6 a transverse passage is drilled through the jaws of the terminal at 24. This operation actually cuts through some of the con 65 ductors of the portions 3 andr 4 of the cable as indicated at 3b and 4b in Fig.' 6. Nevertheless, tion of the jaws of the connecter, the compo-sition of the terminal of my invention, though „l including an alloy poured in the proportion of ' approximately 34% lead, 2% copper, 5% tin 55 and 9% antimony, actually consists, when in cast , form, of approximately 15% lead, 5% tin_and antimony and 80% copper. The presence of such a large amount of copper throughout the 60 jaws of the connecter greatly increases the elec trical conductivity of the connecter and reduces resistivity thereby yincreasing the emciency of the cable. It will be understood 'that the copper Wire does not enter into ~the alloy forming the 65 cast, but is considered included in the 80% cop per noted inthe completed terminal- on a simple quantitative lbasis only; that is, the 80% noted suñicient core structure formed by the” portions - includes the large amount of free copper in the 3 and 4 of the cable remains to impart strength to the jaws ofi the terminal substantially to the 70 extreme limits. of the ends thereof. - »The terminal 22 is adapted to be lengaged over the "storage .battery post as indicated in Figs. ‘1, 8 and 11 at 25. The storage battery post 25 is tapered and the coacting- aperture molded in ,75, terminal 22 is correspondingly tapered. A clamp wires and- the small percentage contained in th'e 70 ‘ alloy. As the free copperconstitutes a large por-_ tion of the completed terminal, theA quantity of_ alloy,- and the proportions of its components, are relatively reduced. _ ' ' ` I have found' the construction of the cable and connecter of my invention ~highly practical for 4 2,111,107 smated'stmded cable. dividing tnevstrvanded ends _ inexpensive manufacture on a quantity produc tion basis. I realize that other modlñcations in the construction and arrangement may be made and I do not intend that my invention herein be limited to the particular forms of cable and con necter and method- of making the same as herein described and I desire that it be understood that ~ modiñcations may be made and’that no limita tions upon my invention are intended other than V10 may be imposed by the scope of the appended claim. I What I claim as new and desire to secure by -Letters Patent of the UnitedStates is as fol lows: _ . t The method of making a storage battery ter .15 - minal which comprises baring the ends of an in of the' cable into’ two symmetrlcalportions dis-` posed in substantially parallel planes on oppo- « site sides of a central axis extending through the ' cable. coniìning the strands of the cable form ing the said symmetrical portions by metallic Hands of low melting I int characteristic',y shaD-' lng the symmetrical portions of the strands to substantially conform withthe contour of a stor- _ age battery post, centering the preformed cable 10 in a shaped mold, pouring molten metal into the shaped mold and around the preformed cable for melting the low temperature bands and form inga terminal directly around the strands of >the cable. -15 l ALBERT H.. WALDE.