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Патент USA US2111107

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‘ Filed July 25, 1936
2 sneaks-sheet 1
Filed Juiy 25, 195e
îïè-flë ¿à
55 '
> _
2 sheets-sheet 2
E112-¿16:35 5
Patented Mar.
` 2,111,101
Pri‘r‘sri're oI-‘Flcls>
Pa., assignor, by
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
(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
_electrical conductivity.
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.
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:
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.
>melting point adapted to normally em'brace
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.
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
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.
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
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
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. _
each have a semi-cylindrical recess in the aligned
As heretofore illustrated, the terminal of my
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
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.
' 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
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
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
What I claim as new and desire to secure by
-Letters Patent of the UnitedStates is as fol
The method of making a storage battery ter
- 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
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.
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