U.S. patent application number 15/096500 was filed with the patent office on 2016-11-10 for terminal portion for storage batteries, plastic encapsulated terminal for storage batteries, method for producing the same, storage battery provided with terminal portion, and automobile equipped with storage battery.
This patent application is currently assigned to GS Yuasa International Ltd.. The applicant listed for this patent is Aya Harada, Eiji Hojo, Yasuhide Nakayama, Katsuya Noguchi, Hiroshi Okumura, Shin Osaki. Invention is credited to Aya Harada, Eiji Hojo, Yasuhide Nakayama, Katsuya Noguchi, Hiroshi Okumura, Shin Osaki.
Application Number | 20160329548 15/096500 |
Document ID | / |
Family ID | 47423947 |
Filed Date | 2016-11-10 |
United States Patent
Application |
20160329548 |
Kind Code |
A1 |
Harada; Aya ; et
al. |
November 10, 2016 |
TERMINAL PORTION FOR STORAGE BATTERIES, PLASTIC ENCAPSULATED
TERMINAL FOR STORAGE BATTERIES, METHOD FOR PRODUCING THE SAME,
STORAGE BATTERY PROVIDED WITH TERMINAL PORTION, AND AUTOMOBILE
EQUIPPED WITH STORAGE BATTERY
Abstract
A storage battery includes a terminal portion for storage
batteries having a plurality of bolt insertion holes bored in one
or a plurality of directions, a nut insertion opening through which
a nut is inserted, a hollow in communication with the bolt
insertion holes and the nut insertion opening and the nut having at
least one screw hole threaded in a direction coincident with at
least one or the plurality of directions. A fixation portion is
formed to fix the nut by deforming the terminal portion with the
nut being inserted through the nut insertion opening into the
hollow and the at least one screw hole of the nut being in
communication respectively with the at least one of the plurality
of bolt insertion holes.
Inventors: |
Harada; Aya; (Kyoto, JP)
; Hojo; Eiji; (Kyoto, JP) ; Nakayama;
Yasuhide; (Kyoto, JP) ; Osaki; Shin; (Kyoto,
JP) ; Okumura; Hiroshi; (Kyoto, JP) ; Noguchi;
Katsuya; (Kyoto, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Harada; Aya
Hojo; Eiji
Nakayama; Yasuhide
Osaki; Shin
Okumura; Hiroshi
Noguchi; Katsuya |
Kyoto
Kyoto
Kyoto
Kyoto
Kyoto
Kyoto |
|
JP
JP
JP
JP
JP
JP |
|
|
Assignee: |
GS Yuasa International Ltd.
Kyoto
JP
|
Family ID: |
47423947 |
Appl. No.: |
15/096500 |
Filed: |
April 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14128246 |
Dec 20, 2013 |
9368781 |
|
|
PCT/JP2012/065455 |
Jun 18, 2012 |
|
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15096500 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 2/30 20130101; Y10T
29/49208 20150115; H01M 2/0242 20130101; H01R 43/00 20130101; H01M
2/305 20130101; H01M 2220/20 20130101; Y02E 60/10 20130101 |
International
Class: |
H01M 2/30 20060101
H01M002/30; H01M 2/02 20060101 H01M002/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 27, 2011 |
JP |
2011-141434 |
Jun 27, 2011 |
JP |
2011-141436 |
Jun 29, 2011 |
JP |
2011-144195 |
Jul 6, 2011 |
JP |
2011-149699 |
May 11, 2012 |
JP |
2012-109045 |
Claims
1-15. (canceled)
16. A storage battery comprising: a terminal portion for storage
batteries having a plurality of bolt insertion holes bored in one
or a plurality of directions, a nut insertion opening through which
a nut is inserted, and a hollow in communication with the bolt
insertion holes and the nut insertion opening; and the nut having
at least one screw hole threaded in a direction coincident with the
at least one or a plurality of directions, wherein the terminal
portion further comprising a fixation portion formed to fix the
nut.
17. The storage battery according to claim 16, wherein the fixation
portion is a projecting portion projecting in the hollow direction
in a part, facing the hollow, on an inner surface of the terminal
portion.
18. The storage battery according to claim 16, wherein the fixation
portion is a part of the nut insertion opening that is narrowed
after the nut is inserted into the hollow of the terminal
portion.
19. The storage battery according to claim 18, wherein the hollow
of the terminal portion is elongated in a direction in which the
nut is inserted, and the nut is arranged at a position on the back
side, as seen from the nut insertion opening of the hollow of the
terminal portion.
20. The storage battery according to claim 16, wherein the fixation
portion is a part of a sidewall or ceiling of the terminal portion
in which a recess is provided after the nut is inserted into the
hollow of the terminal portion.
21. The storage battery according to claim 16, wherein the
plurality of bolt insertion holes are bored at such positions as
not to intersect each other within the hollow of the terminal
portion, and the plurality of screw holes of the nut are formed at
such positions as not to intersect each other.
22. The storage battery according to claim 16, wherein the
plurality of bolt insertion holes are bored at such positions as to
intersect each other within the hollow of the terminal portion, and
the plurality of screw holes of the nut are formed at such
positions as to intersect each other.
23. The storage battery according to claim 16, wherein the hollow
of the terminal portion has a large width at the nut insertion
opening and a reduced width on the back side.
24. The storage battery according to claim 16, wherein the storage
battery comprises a plastic encapsulated terminal for storage
batteries comprising: the terminal portion; a pole portion coupled
to a lower end of the terminal portion; and a plastic portion
surrounding a circumferential surface of the pole portion.
25. The storage battery according to claim 16, wherein the nut is
fixed to the terminal portion by a friction force.
26. The storage battery according to claim 16, wherein a bottom of
the terminal portion is formed so as to have a part with a reduced
thickness.
27. The storage battery according to claim 26, wherein a hole is
provided at the bottom of the terminal portion.
28. The storage battery according to claim 27, wherein the bottom
of the terminal portion is deformed by a plastic injected through
the hole.
29. The storage battery according to claim 16, further comprising:
a battery case inside of which is partitioned by partition walls
into a plurality of cells and in which an electrode assembly is
housed in each of the cells; and a cover lying over the battery
case from above, wherein the cover comprises the terminal
portion.
30. An automobile equipped with the storage battery according to
claim 29.
31. A terminal portion for storage batteries comprising: a
plurality of bolt insertion holes bored in one or a plurality of
directions; a nut insertion opening through which a nut is
inserted; a hollow in communication with the bolt insertion holes
and the nut insertion opening; and a fixation portion formed to fix
the nut.
Description
FIELD
[0001] The present invention relates to a terminal portion for
storage batteries, a plastic encapsulated terminal for storage
batteries, a method for producing the same, a storage battery
provided with the terminal portion, and an automobile equipped with
the storage battery.
BACKGROUND
[0002] A plastic encapsulated terminal is often used in a terminal
structure of lead-acid storage batteries for motorcycles.
[0003] A plastic encapsulated terminal as shown in FIG. 14 is
conventionally known to the public (see Patent Literature 1). In
FIG. 14, 11 denotes a terminal portion composed of a rectangular
cube, 12 denotes a circular cylindrical pole portion, 13 denotes a
base in the form a plate, and 14 denotes a plastic portion composed
of polypropylene, polyethylene, or the like. The terminal portion
11 has a lower end integrally coupled to an upper end of the pole
portion 12, and the pole portion 12 has a lower end integrally
coupled to an upper end of the base 13. The terminal portion 11 has
a nut insertion hole 11a bored therethrough from a side surface on
the front side to a side surface on the back side in FIG. 14, and
bolt insertion holes 11b and 11c bored respectively from a top
surface and a left side surface toward the hole 11a. The pole
portion 12 has a circular deburring flange 12a formed around its
circumferential surfaces at the uppermost part, and three ribs of
flanges 12b, 12c, and 12d, formed below the deburring flange 12a at
intervals, each having a radius smaller than that of the deburring
flange 12a. The deburring flange 12a has a circumferential surface
projecting in the horizontal direction from the circumferences at
the lower end of the terminal portion 11. The plastic portion 14 is
formed in the surroundings of the pole portion 12 so as to wrap the
deburring flange 12a and the flanges 12b, 12c, and 12d, then
slightly extends outward from the upper end of the flange 12a, and
rises upward so as to cover the circumferential surfaces in the
lower part of the terminal portion 11 via a groove 15.
[0004] Conventionally, in the terminal portion 11 of such a plastic
encapsulated terminal for lead-acid storage batteries as mentioned
above, an end user inserts a rectangular cuboid nut into the nut
insertion hole 11a and thereafter inserts a bolt into one of bolt
insertion holes 11b and 11c formed respectively through the top
surface and the left side surface, so as to allow the bolt to be
threadedly engaged. Therefore, in attempts to insert the nut into a
small hollow in the terminal portion, the end user may sometimes
drop the nut, which has been a problem.
[0005] Further, such a nut as disclosed in Patent Literature 1 has
one screw hole, and thus the bolt can be inserted into only either
one of the bolt insertion holes 11b and 11c formed respectively
through the top surface and the left side surface. Therefore, it
has been impossible to connect an external lead wire at each of two
points at the same time, and thus it has been necessary to adjust
the direction of the nut each time so that the bolt insertion hole
and the screw hole of the nut that are selected for connection of
the external lead wire should be coincident.
[0006] Meanwhile, as a lead-acid storage battery in which a nut is
pre-fixed to a terminal, an invention of "a lead-acid storage
battery characterized by including: a lead-acid storage battery
body; a hollow box terminal, fixed to the lead-acid storage battery
body, having one surface through which a nut insertion opening is
opened and at least one other surface than the one surface through
which a bolt insertion through hole is opened; a nut, having outer
dimensions slightly smaller than the inner dimensions of the box
terminal, having an internal thread hole facing the bolt insertion
through hole, and housed within the box terminal through the nut
insertion opening in a posture such that the internal thread hole
and the bolt insertion through hole face each other, and a nut
latch provided on a cover of the lead-acid storage battery body so
as to close at least part of the nut insertion opening" is publicly
known (see Patent Literature 2). However, this invention has a
problem of the need for separately providing a means for closing
the part of the nut insertion opening to fix the nut to the
terminal.
[0007] Further, Patent Literature 2 discloses, "The bolt insertion
through hole 9 provided in the box terminal 4 may be provided not
only through the aforementioned end surface on the front side but
also through the upper surface or the back surface of the box
terminal 4 in a plural number. This allows the lead wire that is
connected to each of the terminal portions 3a and 3b to be attached
in a plurality of directions depending on the shape of the box
terminal 4, which is one type, and the direction in which the nut 6
is housed within the box terminal 4" (paragraph [0023]); however,
since the nut 6 has only one internal thread hole 10, the lead wire
cannot be attached thereto at each of two points at the same time,
as shown in FIG. 2.
[0008] Further, a registered design of "a terminal fitting for
storage batteries" (see Non Patent Literature 1) is publicly known.
The article according to this design is described as: "The article
according to the design of the subject application is a terminal
fitting for storage batteries, which is characterized by having a
configuration in which two circular through holes are provided at
positions offset from each other respectively through an upper
surface and a front surface of a substantially rectangular cuboid
terminal portion, and a substantially U-shaped projection is
provided on a bottom surface".
[0009] Non Patent Literature 2 suggests that a nut is fixed within
a hollow of such a storage battery terminal as mentioned above in
which two circular through holes (holes) are provided at positions
offset from each other respectively through the upper surface and
the front surface of the substantially rectangular cuboid terminal
portion. It reads, "In order to improve convenience and
functionality of the terminal, it is made possible to attach a
harness at each of two points respectively on the upper surface and
the front surface of the terminal at the same time. For achieving
this, a lead bushing terminal shape as shown in FIG. 3 is employed,
and the positions of holes in the nut are designed to be compatible
with existing batteries. Further, the terminal is designed so as to
have a width larger than that of existing batteries by 3.5 mm or
4.5 mm, and the axes of the holes respectively through the upper
surface and the front surface are offset from each other by 6.5 mm,
so that the harness can be fixed at each of two points at the same
time, as shown in FIG. 4, without the two holes intersecting each
other within the terminal" (line 2 to line 11 in the right column
of page 43), and "The nut is inserted into a special lead bushing
terminal that has been newly developed in order to fix the nut to
the terminal in the battery production process. Thus, a technique
for fixing the nut to the terminal at the time of plastic molding
of the cover has been established. This prevents, in a GYZ20HL
battery, the nut from falling from the terminal, even if the
battery is turned over on its side so that the nut insertion
opening in the terminal faces downward (see FIG. 6)" (line 6 to
line 11 in the left column of page 45). However, a specific method
for fixing the nut is not disclosed therein.
CITATION LIST
Patent Literature
[0010] Patent Literature 1: JP 11-154503 A
[0011] Patent Literature 2: JP 2001-283825 A
Non Patent Literature
[0012] Non Patent Literature 1: Japanese Design Registration No.
1396609
[0013] Non Patent Literature 2: "GS Yuasa Technical Report",
December 2009, Vol. 6, No. 2, page 39 to page 46
SUMMARY
Technical Problem
[0014] The present invention aims to solve the problems as
mentioned above, and an object thereof is to provide a terminal
portion for storage batteries that enables a nut to be fixed easily
and reliably so that the nut does not fall therefrom, and a
terminal portion for storage batteries that enables a bolt to be
inserted into the nut by selecting either one point through the
upper surface or the front surface, or two or more points
therethrough at the same time, even if the nut is fixed to the
terminal portion when connecting an external lead wire to a storage
battery. It is another object of the present invention to provide a
storage battery including such a terminal portion for storage
batteries.
Solution to Problem
[0015] In order to solve the above-mentioned problems, the present
invention employs the following means: [0016] (1) A terminal
portion for storage batteries, including: a plurality of bolt
insertion holes bored in a plurality of the same and/or different
directions; a nut insertion opening through which a nut having at
least one screw hole threaded in a direction coincident with at
least one of the plurality of the same and/or different directions
is inserted; a hollow in communication with the bolt insertion
holes and the nut insertion opening; and a fixation portion
configured to fix the nut by deforming the terminal portion with
the nut being inserted through the nut insertion opening into the
hollow and the at least one screw hole of the nut being in
communication respectively with the at least one of the plurality
of bolt insertion holes; [0017] (2) The terminal portion for
storage batteries according to (1), wherein the fixation portion is
a projecting portion projecting in the hollow direction in a part,
facing the hollow, on an inner surface of the terminal portion;
[0018] (3) The terminal portion for storage batteries according to
(1) or (2), wherein the fixation portion is a part of the nut
insertion opening that is narrowed after the nut is inserted into
the hollow of the terminal portion; [0019] (4) The terminal portion
for storage batteries according to (3), wherein the hollow of the
terminal portion is elongated in a direction in which the nut is
inserted, and the nut is arranged at a position on the back side,
as seen from the nut insertion opening of the hollow of the
terminal portion; [0020] (5) The terminal portion for storage
batteries according to (1) or (2), wherein the fixation portion is
a part of a sidewall or ceiling of the terminal portion in which a
recess is provided after the nut is inserted into the hollow of the
terminal portion; [0021] (6) The terminal portion for storage
batteries according to any one of (1) to (5), wherein the plurality
of bolt insertion holes are bored at such positions as not to
intersect each other within the hollow of the terminal portion, and
the plurality of screw holes of the nut are formed at such
positions as not to intersect each other; [0022] (7) The terminal
portion for storage batteries according to any one of (1) to (5),
wherein the plurality of bolt insertion holes are bored at such
positions as to intersect each other within the hollow of the
terminal portion, and the plurality of screw holes of the nut are
formed at such positions as to intersect each other; [0023] (8) The
terminal portion for storage batteries according to any one of (1)
to (7), wherein the hollow of the terminal portion has a large
width at the nut insertion opening and a reduced width on the back
side; [0024] (9) A plastic encapsulated terminal for storage
batteries, including: a terminal portion; a pole portion coupled to
a lower end of the terminal portion; and a plastic portion
surrounding a circumferential surface of the pole portion, wherein
the terminal portion is the terminal portion according to any one
of (1) to (8); [0025] (10) A method for producing a plastic
encapsulated terminal for storage batteries, the terminal
including: a terminal portion having a plurality of bolt insertion
holes bored in a plurality of the same and/or different directions,
a nut insertion opening through which a nut having at least one
screw hole threaded in a direction coincident with at least one of
the plurality of the same and/or different directions is inserted,
and a hollow in communication with the bolt insertion holes and the
nut insertion opening; a pole portion coupled to a lower end of the
terminal portion; and a plastic portion surrounding a
circumferential surface of the pole portion, the method including a
step of fixing the nut by deforming the terminal portion with the
nut being inserted through the nut insertion opening into the
hollow and the at least one screw hole of the nut being in
communication respectively with the at least one of the plurality
of bolt insertion holes; [0026] (11) The method for producing a
plastic encapsulated terminal for storage batteries according to
(10), wherein the nut is fixed, after the nut is inserted into the
hollow, by narrowing the nut insertion opening through application
of a pressure, or providing a recess on a sidewall or ceiling of
the terminal portion; [0027] (12) The method for producing a
plastic encapsulated terminal for storage batteries according to
(10), wherein the nut is fixed, after the nut is inserted into the
hollow, by deforming the terminal portion by heating; [0028] (13)
The method for producing a plastic encapsulated terminal for
storage batteries according to (10), wherein the nut is fixed,
after the nut is inserted into the hollow of the terminal portion,
by placing the terminal portion into a plastic mold for plastic
molding and applying a pressure to a wall of the terminal portion
using a pressing pin provided in the plastic mold for plastic
molding, thereby providing a recess on the wall; [0029] (14) A
storage battery including: a battery case inside of which is
partitioned by partition walls into a plurality of cells and in
which an electrode assembly is housed in each of the cells; and a
cover lying over the battery case from above, wherein the cover
includes the terminal portion according to any one of (1) to (8);
and [0030] (15) An automobile equipped with the storage battery
according to (14).
[0031] In a commonly employed nut or rectangular cuboid terminal
portion, the "different directions", for example, are a direction
from "the upper surface to the lower surface" and a direction from
"the front surface to the back surface". The "same direction", for
example, is either one of the above-mentioned directions. Further,
"a plurality of bolt insertion holes bored in a plurality of the
same and/or different directions", for example, mean: one bolt
insertion hole bored in a direction from "the upper surface to the
lower surface" and at least one bolt insertion hole bored in a
direction from "the front surface to the back surface"; at least
one bolt insertion hole bored in a direction from "the upper
surface to the lower surface" and one bolt insertion hole bored in
a direction from "the front surface to the back surface"; at least
two bolt insertion holes bored in each of a direction from "the
upper surface to the lower surface" and a direction from "the front
surface to the back surface"; or at least two bolt insertion holes
bored in a direction from "the upper surface to the lower surface"
or a direction from "the front surface to the back surface". The
"nut having at least one screw hole threaded in a direction
coincident with at least one of the plurality of the same and/or
different directions", for example, means a nut having: at least
one screw hole in a direction from "the upper surface to the lower
surface" (none in a direction from "the front surface to the back
surface"); at least one screw hole in a direction from "the front
surface to the back surface" (none in a direction from "the upper
surface to the lower surface"); or at least one screw hole in each
of a direction from "the upper surface to the lower surface" and a
direction from "the front surface to the back surface". The
"plurality of the same or different directions" are not limited to
the above-mentioned directions, and includes a direction from "the
right (left) side surface to the left (right) side surface".
Further, the "plurality" does not mean "many", and the number is
generally 2 to 10, preferably 2 to 4. The "at least one" means a
number that corresponds to one or the above-mentioned "plural"
number, and is preferably at least two.
[0032] In the description of the present application, the "upper
surface" and "lower surface" are not limited to the horizontal
surfaces, and the "front surface" and "back surface" are not
limited to the vertical surfaces. They include inclined or
positionally offset surfaces.
[0033] Further, the shape of the terminal portion or the nut is not
limited to the above-mentioned rectangular cuboid shape, and they
may be triangular prism, triangular pyramid, pentagonal prism, or
the like. That is, there is no dependence on their shape as long as
the bolt can be fastened in two or more directions.
[0034] In the present invention, the state where "the nut is fixed"
means that the nut does not fall even if the nut insertion opening
of the terminal portion faces downward, and includes not only the
case where the nut is fixed to the terminal portion in a static
state, but also the case where the nut is fixed thereto in a
movable state relative to the terminal portion due to a gap formed
between the nut and the terminal portion. It further includes the
case where the nut is fixed to the terminal portion by a friction
force so that the nut is easily detached therefrom by applying an
external force exceeding the friction force.
Advantageous Effects of Invention
[0035] Use of the terminal portion for storage batteries of the
present invention enables the nut to be fixed to the terminal
portion easily and reliably. In this way, the problem that the end
user drops the nut can be solved by pre-fixing the nut.
[0036] Further, connection of an external lead wire to the storage
battery at each of two or more points at the same time is made
possible by using such a terminal portion in which a plurality of
bolt insertion holes are bored at such positions as not to
intersect each other within the hollow of the terminal portion, and
a plurality of screw holes of the nut are formed at such positions
as not to intersect each other. In contrast, in the case of a
terminal portion in which two bolt insertion holes are bored at
such positions as to intersect each other within the hollow of the
terminal portion, and two screw holes of the nut are formed at such
positions as to intersect each other, either one of the screw holes
is selected and a bolt is inserted thereinto for connecting the
external lead wire to the storage battery, which exerts an effect
of allowing the nut to be compact and the terminal portion to be
compact as well. Furthermore, when the two bolt insertion holes and
the two screw holes are provided at two or more points, connection
at two or more points at the same time is enabled.
[0037] Use of a terminal with a pre-fixed nut dramatically
increases the working efficiency of attaching a storage battery to
an automobile body. This effect is outstanding in mass production
of automobiles. This effect is further outstanding in production of
motorcycles. This is because a delay in assembly work caused by
dropping a nut is more problematic since two-wheeled vehicles have
an attachment space for storage batteries or surrounding working
spaces that are smaller than those in four-wheeled vehicles.
BRIEF DESCRIPTION OF DRAWINGS
[0038] FIG. 1A is a perspective view (as seen from one side)
showing Embodiment 1 of a terminal portion for storage batteries
according to the present invention.
[0039] FIG. 1B is a perspective view (as seen from the other side)
showing Embodiment 1 of the terminal portion for storage batteries
according to the present invention.
[0040] FIG. 2A is a perspective view (as seen from the one side)
showing Embodiment 2 of the terminal portion for storage batteries
according to the present invention.
[0041] FIG. 2B is a perspective view (as seen from the other side)
showing Embodiment 2 of the terminal portion for storage batteries
according to the present invention.
[0042] FIG. 3 is a perspective view of a nut used for the terminal
portion in Embodiment 2.
[0043] FIG. 4A is a perspective view (as seen from the one side)
showing Embodiment 3 of the terminal portion for storage batteries
according to the present invention.
[0044] FIG. 4B is a perspective view (as seen from the other side)
showing Embodiment 3 of the terminal portion for storage batteries
according to the present invention.
[0045] FIG. 5A is a perspective view (as seen from the one side)
showing Embodiment 4 of the terminal portion for storage batteries
according to the present invention.
[0046] FIG. 5B is a perspective view (as seen from the other side)
showing Embodiment 4 of the terminal portion for storage batteries
according to the present invention.
[0047] FIG. 6A is a perspective view (as seen from the one side)
showing Embodiment 5 of the terminal portion for storage batteries
according to the present invention.
[0048] FIG. 6B is a perspective view (as seen from the other side)
showing Embodiment 5 of the terminal portion for storage batteries
according to the present invention.
[0049] FIG. 7A is a perspective view (as seen from the one side)
showing Embodiment 6 of the terminal portion for storage batteries
according to the present invention.
[0050] FIG. 7B is a perspective view (as seen from the other side)
showing Embodiment 6 of the terminal portion for storage batteries
according to the present invention.
[0051] FIG. 8 is a partial sectional view (where a pole portion 2
and a base 3 are not depicted as a cross section) showing a method
for forming a plastic portion of a plastic encapsulated terminal of
Embodiment 1 according to the present invention.
[0052] FIG. 9 is a partial sectional view (where the pole portion 2
and the base 3 are not depicted as a cross section) showing a
method for forming a plastic portion of a plastic encapsulated
terminal of Embodiment 2 according to the present invention.
[0053] FIG. 10A, FIG. 10B, FIG. 10C, FIG. 10D, and FIG. 10E are
flow diagrams showing an example of a method for producing the
plastic encapsulated terminal of the present invention.
[0054] FIG. 11 is a partial sectional view (where the pole portion
2 and the base 3 are not depicted as a cross section) of a
lead-acid storage battery including the plastic encapsulated
terminal of Embodiment 1 according to the present invention.
[0055] FIG. 12 is a partial sectional view (where the pole portion
2 and the base 3 are not depicted as a cross section) of a
lead-acid storage battery including the plastic encapsulated
terminal of Embodiment 2 according to the present invention.
[0056] FIG. 13 is a view showing a state where a storage battery
having the terminal of the present invention is mounted on a
motorcycle.
[0057] FIG. 14 is a partial sectional view (where a pole portion 12
and a base 13 are not depicted as a cross section) of a
conventional plastic encapsulated terminal.
DESCRIPTION OF EMBODIMENTS
[0058] FIG. 1A and FIG. 1B show Embodiment 1 of a terminal portion
for storage batteries of the present invention (example when used
in a plastic encapsulated terminal 7).
[0059] A rectangular cuboid terminal portion 1 for storage
batteries has a hollow 1a and an insertion opening 1b into which a
nut 6 is inserted. The hollow 1a into which the nut 6 is inserted
is bored through the terminal portion 1 from the insertion opening
1b on the right side surface toward the left side surface in FIG.
1A. However, the wall on the side opposite to the insertion opening
1b is preferably left so that the nut 6 is prevented from passing
therethrough, as shown in FIG. 1B. Further, a bolt insertion hole
1c and a bolt insertion hole 1d are bored respectively from the
upper surface and the front surface toward the hollow 1a.
[0060] In Embodiment 1, in order to connect an external lead wire
at each of two or more points at the same time, the bolt insertion
hole 1c on the upper surface and the bolt insertion hole 1d on the
front surface are formed at such positions as not to intersect each
other within the hollow 1a, that is, a position where the bolt
insertion hole 1c is offset to the left or right on the upper
surface, and a position where the bolt insertion hole 1d is offset
to the right or left on the front surface.
[0061] The nut 6 is inserted into the hollow 1a through the
insertion opening 1b of the terminal portion 1 and fixed therein.
In order to enable both of the bolt insertion hole 1c on the upper
surface and the bolt insertion hole 1d on the front surface of the
terminal portion 1 to be selected at the same time for inserting a
bolt into the nut 6 when connecting an external lead wire to a
storage battery with the nut 6 pre-fixed to the terminal portion 1,
a screw hole 6a threaded from the upper surface toward the lower
surface and a screw hole 6b threaded from the front surface toward
the back surface of the rectangular cuboid nut 6 are formed at such
positions as not to intersect each other, that is, a position where
the screw hole 6a is offset to the left or right on the upper
surface (lower surface), and a position where the screw hole 6b is
offset to the right or left on the front surface (back
surface).
[0062] The nut 6 is fixed by being inserted into the hollow 1a
through the insertion opening 1b of the terminal portion 1 so that
the screw hole 6a threaded from the upper surface toward the lower
surface of the nut 6 is brought into communication with the bolt
insertion hole 1c bored through the upper surface of the terminal
portion 1, and the screw hole 6b threaded from the front surface
toward the back surface of the nut 6 is brought into communication
with the bolt insertion hole 1d bored through the front surface of
the terminal portion 1. Accordingly, a bolt (not shown in the
figure) is inserted through each of the bolt insertion hole 1c on
the upper surface and the bolt insertion hole 1d on the front
surface, thereby allowing the tip of each bolt to threadedly engage
with the nut. Then, an external lead wire (not shown, such as a
wire capable of being connected to electronic components) is fixed
by being interposed between each bolt and the nut 6. In this way,
an external lead wire is connected to a storage battery at each of
two points at the same time in Embodiment 1.
[0063] Further, as a modification of Embodiment 1, it is made
possible to connect an external lead wire to the storage battery at
each of two or more points, for example, three points, or four
points at the same time by employing the nut 6 in which two or more
bolt insertion holes 1c on the upper surface and/or two or more
bolt insertion holes 1d on the front surface of the terminal
portion 1 in FIG. 1A are provided (in the case of "or", the number
of bolt insertion holes on the other surface is zero or one), and
two or more screw holes 6a threaded from the upper surface toward
the lower surface and/or two or more screw holes 6b threaded from
the front surface toward the back surface are provided
corresponding to the bolt insertion holes.
[0064] FIG. 2A and FIG. 2B show Embodiment 2 of the terminal
portion for storage batteries of the present invention (example
when used in the plastic encapsulated terminal 7).
[0065] A rectangular cuboid terminal portion 1 for storage
batteries has a hollow 1a and an insertion opening 1b into which a
nut 6 is inserted. The hollow 1a into which the nut 6 is inserted
is bored through the terminal portion 1 from the insertion opening
1b on a right side surface toward a left side surface in FIG. 2B.
However, the wall on the side opposite to the insertion opening 1b
is preferably left so that the nut 6 is prevented from passing
therethrough, as shown in FIG. 2A. Further, a bolt insertion hole
1c and a bolt insertion hole 1d are bored respectively from the
upper surface and the front surface toward the hollow 1a.
[0066] In Embodiment 2, the nut 6 is inserted into the hollow 1a
through the insertion opening 1b of the terminal portion 1 and
fixed therein, as shown in FIG. 2B. In order to enable either one
of the bolt insertion hole 1c on the upper surface and the bolt
insertion hole 1d on the front surface of the terminal portion 1 to
be selected, as needed, for inserting a bolt into the nut 6 when
connecting an external lead wire to a storage battery with the nut
6 pre-fixed to the terminal portion 1, a nut in which a screw hole
6a threaded from the upper surface toward the lower surface and a
screw hole 6b threaded from the front surface toward the back
surface of the rectangular cuboid nut 6 intersect each other is
employed, as shown in FIG. 3. The screw hole 6a threaded from the
upper surface toward the lower surface and the screw hole 6b
threaded from the front surface toward the back surface preferably
intersect each other at the center of the nut in order to use these
two efficiently. However, they also may be configured to intersect
each other at a position slightly offset from the center.
[0067] Also in Embodiment 2, the method for inserting the nut and
the method for inserting the bolt are the same as in Embodiment 1.
However, there is an effect of capable of selecting either one of
the upper surface and the front surface, as needed, even if the nut
6 is fixed when connecting an external lead wire to the storage
battery, since a bolt is inserted into the nut 6 by selecting
either one of the bolt insertion hole 1c on the upper surface or
the bolt insertion hole 1d on the front surface of the terminal
portion 1.
[0068] Further, as a modification of Embodiment 2, it is made
possible to select points, when connecting an external lead wire to
the storage battery, from two points on the upper surface, two
points on the front surface, and one point on each of the upper
surface and the front surface of the terminal portion 1 in FIG. 2A,
as needed, by employing the nut 6 in which two bolt insertion holes
1c on the upper surface and two bolt insertion holes 1d on the
front surface are provided, and two screw holes 6a threaded from
the upper surface toward the lower surface and two screw holes 6b
threaded from the front surface toward the back surface are
provided corresponding to the bolt insertion holes.
[0069] Furthermore, in Embodiment 2, the nut 6 is exposed on the
side opposite to the insertion opening 1b, as shown in FIG. 2A and
FIG. 2B, which serves to allow the nut 6 that has been fixed as
described later to be forced out by hammering. In the case of the
absence of such an exposed surface for forcing out the nut 6, it is
also possible to employ the nut 6 in which a bolt insertion hole is
provided on the side opposite to the insertion opening 1b, and a
screw hole threaded from the side surface opposite to the insertion
opening 1b toward the insertion opening 1b is provided instead of
the screw hole 6b threaded from the front surface toward the back
surface.
[0070] In Embodiments 1 and 2 described above, the outer shape of
the nut 6 is rectangular cuboid to match the hollow 1a of the
rectangular cuboid terminal portion 1.
[0071] The nut 6 preferably has a rectangular cuboid shape with an
upper surface (lower surface) and a front surface (back surface) in
a laterally elongated substantially rectangular shape, and both
side surfaces in a substantially square shape, in order to form the
screw hole 6a at a position offset to the left or right on the
upper surface (lower surface) and the screw hole 6b at a position
offset to the right or left on the front surface (back
surface).
[0072] The hollow 1a of the terminal portion 1 has a shape matching
the outer shape of the nut. The outer shape of the terminal portion
1 may be cuboid or laterally elongated rectangular cuboid. The
length to width ratio of the terminal portion 1 is about 1:1 to
1:1.5. The terminal portion 1 is made of a lead alloy, and is
generally formed with a thick bottom in a plastic encapsulated
terminal. Therefore, there may be the case where the terminal
portion 1 including the bottom has a vertically long rectangular
cuboid shape.
[0073] Further, all the corners of the nut 6 may be right angled.
However, it is preferable to chamfer some of the corners, so that
one end of the nut 6 has an outer shape matching one end of the
hollow 1a, and the other end of the nut 6 has an outer shape not
matching the end of the hollow 1a. Processing into such shapes can
prevent misinsertion of the nut 6. For example, supposing that the
nut 6 has a shape in cross section as shown in FIG. 8, when the nut
6 is inserted into the hollow 1a of the terminal portion 1 in the
correct direction, the nut 6 is arranged at such a position as to
have a surface at the other end flush with the insertion opening
1b, whereas when the nut 6 is inserted thereinto in the wrong
direction, the nut 6 is arranged at such a position as to have a
surface at the other end projecting outwardly from the insertion
opening 1b. As a result, misinsertion can be detected easily. This
is particularly effective when a plurality of bolt insertion holes
and a plurality of screw holes (1c, 1d, 6a, 6b) are provided
respectively in the terminal portion 1 and the nut 6, where
insertion of the nut in the wrong direction may cause the screw
holes in the nut and the bolt insertion holes in the terminal
portion to deviate from each other. In the above-mentioned example
shown in FIG. 8, one end of the nut 6 is chamfered. Other than
that, as examples deforming the end of the nut, the corner can be
rounded, or a projection or a recess can be provided thereon. In
the case where a projection is provided at one end of the nut, a
recess capable of accommodating the projection is provided at a
corresponding end of the hollow 1a. In the case where a recess is
provided at one end of the nut, a projection capable of being
accommodated in the recess is provided at a corresponding end of
the hollow 1a. In either case, the other end of the nut preferably
has an outer shape not matching that of the end of the hollow 1a in
the case of misinsertion.
[0074] In the present invention, shapes including a cuboid shape, a
shape with a deformed end as mentioned above, a shape provided with
a recess to be mentioned later are collectively referred to as a
"rectangular cuboid shape".
[0075] Further, the shape of the terminal portion 1 and the nut 6
is not limited to a rectangular cuboid shape, and they may be
triangular prism, triangular pyramid, pentagonal prism, or the
like. That is, there is no dependence on their shape as long as the
bolt can be fastened in two or more directions.
[0076] In the present invention, a projecting portion that projects
in the hollow direction is provided in a part, facing the hollow,
on an inner surface of the terminal portion, in order to fix the
nut to the terminal portion. Fixation with this structure is
achieved by the friction between the projecting portion and the
nut, and thus allows the nut to be detached easily by applying an
external force exceeding the friction force (for example, the
surface of the nut exposed on the side opposite to the insertion
opening is hammered so that the nut is forced out). Further, in the
case where no hole for forcing out the nut is provided on the side
opposite to the insertion opening, it is also possible to provide a
projection (handle) on the nut so that the nut is taken out by
pulling the projection. The projecting portion can be formed, after
the nut is inserted into the terminal portion, by narrowing the
insertion opening through application of a pressure, or by
providing a recess on a sidewall or ceiling.
[0077] As a specific method for fixing the nut 6, it is possible to
employ a method in which the nut 6 is fixed, after being inserted
into the hollow 1a of the terminal portion 1, by providing a recess
if in the terminal portion 1 on a sidewall 1e (sidewall on the back
surface side opposite to the front surface on which the bolt
insertion hole 1d is bored), on a sidewall at a point where the
bolt insertion hole 1d is not bored, or on a ceiling at a point
where the bolt insertion hole 1c is not bored. The nut 6 is fixed
by pressing a part of the sidewall 1e of the terminal portion 1
using a punch or the like, thereby providing the recess 1f, as
shown in FIG. 1B and FIG. 2B.
[0078] Further, in the case of a conventional nut having one screw
hole threaded from the upper surface toward the lower surface, or
from the front surface toward the back surface, the nut may be
fixed, after being inserted into the hollow 1a of the terminal
portion 1 so that the screw hole is brought into communication with
the bolt insertion hole on the upper surface or the bolt insertion
hole on the front surface of the terminal portion 1, by pressing a
part of the sidewall 1e of the terminal portion 1 using a punch or
the like, in the same manner as above, thereby providing the recess
1f, as shown in FIG. 2B.
[0079] The projecting portion formed by machining is preferably
provided on the sidewall 1e except the ceiling of the terminal
portion. This makes it possible to avoid a problem of careless
deformation of the pole portion 2 or a plastic portion 4 of the
terminal portion 1 during formation of the projecting portion (the
recess 1f) as shown in FIG. 1B and FIG. 2B.
[0080] In the case where the recess if is provided by pressing the
sidewall 1e opposite to the sidewall through which the bolt
insertion hole is provided, it is preferable to press a point on
the back surface side corresponding to the bolt insertion hole 1d.
In this case, it is further preferable to provide the screw hole 6b
passing through the nut 6 from one side to the other side. This
allows the recess (projecting portion that projects in the hollow
direction) 1f provided on the sidewall 1e to be arranged at a
position so as to be fitted into the screw hole 6b of the nut 6.
Use of such arrangement suppresses careless deformation of the
terminal portion 1 since there is a space in which the projecting
portion (recess) 1f projecting in the hollow direction is formed.
When providing the recess if on the sidewall 1e, the shape of the
projection with an optimal size for deforming the wall is
selected.
[0081] Furthermore, recesses may be provided respectively on both
of a pair of sidewalls of the terminal portion by pinching the pair
of sidewalls with a tool. Further, it is also possible to fix the
nut by pressing a corner of the terminal portion using a punch or
the like, thereby providing a recess over two sidewalls that form
the corner.
[0082] In Embodiment 3, the nut 6 is fixed, after being inserted
into the hollow 1a of the terminal portion 1, by narrowing the
insertion opening 1b through application of a pressure by pinching
with a tool.
[0083] In order to facilitate deformation of the insertion opening
1b when the nut 6 is fixed by narrowing the insertion opening 1b
through application of a pressure, the nut 6 is arranged at a
position on the back side, as seen from the insertion opening 1b of
the hollow of the terminal portion 1, as shown in FIG. 4A.
Furthermore, the hollow 1a of the terminal portion 1 preferably has
a large width at the nut insertion opening 1b and a reduced width
on the back side. Such a configuration facilitates insertion of the
nut 6 through the insertion opening 1b and application of a
pressure to the insertion opening 1b or the sidewall 1e in the
vicinity of the insertion opening 1b, thereby enabling the nut 6 to
be fixed easily.
[0084] In the case of narrowing the insertion opening 1b through
application of a pressure by pinching with a tool as mentioned
above, it is also possible to narrow the insertion opening 1b by
pinching the sidewalls 1e on the left and right of the terminal
portion 1 with a tool so as to form recesses 1f, or by pinching the
upper part and lower part (ceiling and bottom) of the terminal
portion 1 with a tool so as to form the recesses 1f. Further, these
two may be combined as shown in FIG. 4A and FIG. 4B.
[0085] Instead of forming the recesses 1f, it is also possible to
deform the insertion opening 1b to be uniformly narrowed
entirely.
[0086] Furthermore, in order to further facilitate deformation of
the insertion opening 1b, a recess is preferably provided in a part
on the surface of the nut 6 corresponding to the part where the
insertion opening 1b is narrowed.
[0087] In Embodiment 4 shown in FIG. 5A and FIG. 5B, the nut 6 is
fixed, after being arranged at a position on the back side, as seen
from the insertion opening 1b of the hollow 1a of the terminal
portion 1, so that the screw hole 6a threaded from the upper
surface toward the lower surface is brought into communication with
the bolt insertion hole 1c on the upper surface of the terminal
portion 1, and the screw hole 6b threaded from the front surface
toward the back surface is brought into communication with the bolt
insertion hole 1d on the front surface of the terminal portion 1,
by narrowing the insertion opening 1b of the terminal portion 1
through application of a pressure (for example, by forming the
recesses 1f).
[0088] Further, in the case of a conventional nut having one screw
hole threaded from the upper surface toward the lower surface or
from the front surface toward the back surface, the nut may be
fixed, after being arranged at a position on the back side, as seen
from the insertion opening 1b of the hollow 1a of the terminal
portion 1, so that the screw hole is brought into communication
with the bolt insertion hole on the upper surface or the bolt
insertion hole on the front surface of the terminal portion 1, by
narrowing the insertion opening 1b of the terminal portion 1
through application of a pressure.
[0089] In Embodiment 5, a method for fixing the nut to the terminal
portion by deforming, after the nut is inserted into the hollow of
the terminal portion, the terminal portion by heating is employed.
A projecting portion projecting in the hollow direction is provided
in a part, facing the hollow, on an inner surface of the terminal
portion by deforming the terminal portion by heating. Fixation by
this structure is also achieved by the friction between the
projecting portion and the nut, and thus allows the nut to be
detached easily by applying an external force exceeding the
friction force.
[0090] As a method for deforming the terminal portion by heating, a
method of holding a heat source close to an outer surface of the
terminal portion can be used. In use of this method, various
welders can be used as a heat source. Examples thereof include a
gas welder, a TIG welder, a plasma arc welder, and a laser welder.
Among these, the gas welder is preferable because of its low cost
of installation.
[0091] As an example of the specific method for fixing the nut 6,
the nut 6 is fixed, after being inserted into the hollow 1a of the
terminal portion 1, by deforming the terminal portion 1 by heating,
thereby providing the recess if (projecting portion projecting in
the hollow direction) on a ceiling 1g, as shown in FIG. 6A and FIG.
6B.
[0092] In the case where the point to be deformed is made on the
ceiling 1g of the terminal portion, as mentioned above, the gravity
acts to cause the deformation. Therefore, only a heating step is
required, and there is no need for additional operations such as
punching.
[0093] It is also possible to deform a point on a sidewall of the
terminal portion. In such a case, it is possible to deform a target
point with a small force by applying a pressure using a punch or
the like, since the metal composing the terminal portion is
softened by heating.
[0094] Further, the hollow 1a of the terminal portion 1 preferably
has a large width at the nut insertion opening 1b and a reduced
width on the back side. Such a configuration facilitates insertion
of the nut 6 through the insertion opening 1b and deformation of
the vicinity of the insertion opening 1b by heating, thereby
enabling the nut 6 to be fixed easily.
[0095] Furthermore, in order to further facilitate deformation of
the target point of the terminal portion, a recess is preferably
provided at a point on the surface of the nut 6 corresponding to
the point to be heated in the terminal portion.
[0096] In Embodiment 6 shown in FIG. 7A and FIG. 7B, the nut 6 is
fixed, after being inserted into the hollow 1a of the terminal
portion 1, so that the screw hole 6a threaded from the upper
surface toward the lower surface is brought into communication with
the bolt insertion hole 1c on the upper surface of the terminal
portion 1, and the screw hole 6b threaded from the front surface
toward the back surface is brought into communication with the bolt
insertion hole 1d on the front surface of the terminal portion 1,
by deforming the terminal portion 1 by heating, thereby providing
the recess 1f (projecting portion projecting in the hollow
direction) on the ceiling 1g.
[0097] In the case of such a rectangular cuboid terminal portion as
shown in FIG. 7A and FIG. 7B in which bolt insertion holes bored
respectively through the upper surface and the front surface of the
terminal portion 1 are formed at such positions as to intersect
each other in the hollow 1a, the ceiling 1g is narrow, and
therefore the nut 6 is preferably fixed by narrowing the insertion
opening 1b by deforming the vicinity of the insertion opening 1 on
the ceiling 1g of the terminal portion 1 by heating. It is also
possible to deform the vicinity of the insertion opening 1 on
surfaces other than the ceiling 1g by heating.
[0098] Further, in the case of a conventional nut having one screw
hole threaded from the upper surface toward the lower surface, or
from the front surface toward the back surface, the nut may be
fixed, after being inserted into the hollow 1a of the terminal
portion 1, so that the screw hole is brought into communication
with the bolt insertion hole on the upper surface or the bolt
insertion hole on the front surface of the terminal portion 1, by
deforming the terminal portion 1 by heating, in the same manner as
above.
[0099] The plastic encapsulated terminal of the present invention
is described with reference to FIG. 1A and FIG. 1B.
[0100] In the plastic encapsulated terminal 7, 1 denotes a
rectangular cuboid terminal portion, 2 denotes a circular cylinder
pole portion, 3 denotes a base in the form a plate, and 4 denotes a
plastic portion composed of polypropylene, polyethylene, or the
like. The terminal portion 1 has a lower end integrally coupled to
the upper end of the pole portion 2, and the pole portion 2 has a
lower end integrally coupled to the upper end of the base 3. As
shown in FIG. 8, the pole portion 2 has a rectangular (shape almost
similar to the bottom surface of the terminal portion) deburring
flange 2a formed around its circumferential surfaces at the
uppermost part, and three ribs of flanges 2b, 2c, and 2d, formed
below the deburring flange 2a at intervals, each having a diameter
smaller than the length of one side of the deburring flange 2a. The
deburring flange 2a has a circumferential surface projecting in the
horizontal direction from the circumferences at the lower end of
the terminal portion 1. The plastic portion 4 is formed in the
surroundings of the pole portion 2 so as to wrap the deburring
flange 2a and the flanges 2b, 2c, and 2d, then slightly extends
outward from the upper end of the flange 2a, and rises upward so as
to cover the circumferential surfaces in the lower part of the
terminal portion 1 via a groove 5.
[0101] Next, a method for forming a plastic portion of the plastic
encapsulated terminal according to Embodiment 1 of the present
invention is described with reference to FIG. 8.
[0102] When producing a plastic encapsulated terminal, a metal
portion integrally including the terminal portion 1, the pole
portion 2, and the base 3 is first produced by pouring a lead alloy
into a casting mold (not shown in the figure). Since the plastic
encapsulated terminal is required to have a certain hardness,
Pb--Ca--Sn alloys are preferably used.
[0103] Next, this metal portion is placed in a plastic mold
composed of an upper plastic mold 8 and a two-part lower plastic
mold 9a, 9b, as shown in FIG. 8, so that a plastic molding space is
formed within the plastic mold. Subsequently, a plastic such as
polypropylene is poured into the plastic molding space within the
plastic mold. After curing of the plastic, the upper plastic mold 8
and the lower plastic mold 9a, 9b are removed, so that the plastic
encapsulated terminal 7 with the plastic portion 4 formed in the
surroundings of the pole portion 2 is obtained.
[0104] Even if a gap is present between the side surface of the
terminal portion 1 and the side surface of the groove of the upper
plastic mold 8, it is possible to prevent the plastic from entering
this gap by forming the plastic portion 4 with the upper surface of
the deburring flange 2a and the lower surface of a projection 8a of
the upper plastic mold 8 being in tight contact with each other, as
shown in FIG. 8, thus preventing formation of burrs on the side
surfaces of the terminal portion 1.
[0105] A first method for producing a plastic encapsulated terminal
according to the present invention is a method in which a plastic
portion is formed: after the rectangular cuboid nut 6 in which the
screw holes 6a and 6b respectively threaded from the upper surface
toward the lower surface and from the front surface toward the back
surface are formed at such positions as not to intersect each other
is inserted into the hollow 1a of the rectangular cuboid terminal
portion 1 having the bolt insertion holes 1c and 1d bored
respectively through the upper surface and the front surface and
having the other end to which the pole portion 2 is coupled, as
mentioned above, so that the screw holes 6a and 6b are brought into
communication respectively with the bolt insertion holes 1c and 1d;
or after a rectangular cuboid nut having one screw hole is inserted
thereinto, so that the screw hole is brought into communication
with the bolt insertion hole on the upper surface or the bolt
insertion hole on the front surface of the terminal portion, and
fixed therein. According to this production method, the plastic
portion 4 is not yet present during the operation of fixing the nut
6 to the terminal portion 1, and therefore the plastic portion 4 is
suppressed from deforming or deteriorating due to the fixing
operation.
[0106] A second method for producing a plastic encapsulated
terminal according to the present invention is a method in which
the nut 6 is fixed, after the plastic portion 4 is formed, within
the hollow 1a of the terminal portion 1, as mentioned above.
According to this production method, since the plastic portion 4
can be formed before the terminal portion 1 is deformed due to the
operation of fixing the nut 6, it is possible to facilitate the
work of fitting the terminal portion 1 into the later-mentioned
plastic mold (the upper plastic mold 8 and the lower plastic mold
9a, 9b), or to suppress the decrease in dimensional accuracy of the
plastic portion 4 and the degree of contact between the plastic
portion 4 and the terminal portion 1. The terminal portion 1 or the
pole portion 2 may be carelessly deformed in some cases due to
operation of fixing the nut 6. In such a case, it is made
impossible to assemble the plastic mold accurately so as to be
fitted to the surroundings of the terminal portion 1, which has
been a problem. Further, dimensions of the plurality of flanges 2a,
2b, 2c, and 2d of the pole portion 2 are designed with high
accuracy; however, when they are carelessly deformed, it is made
impossible to maintain their dimensional accuracy, which also has
been a problem. Such problems that have been caused by careless
deformation of the terminal portion 1 are improved by performing
the step of forming the plastic portion 4 before the terminal
portion 1 is deformed, thereby enabling the production of terminals
with high productivity and high dimensional accuracy.
[0107] A third method for producing a plastic encapsulated terminal
according to the present invention is a method in which the nut 6
is fixed within the hollow 1a of the terminal portion 1 at the time
of molding the plastic portion 4.
[0108] An example in which this third method is applied to the
plastic encapsulated terminal of Embodiment 2 according to the
present invention is described with reference to FIG. 9.
[0109] That is, it is possible to employ a method in which the nut
6 is pressed to be fixed, after the rectangular cuboid nut 6 in
which the screw holes 6a and 6b threaded respectively from the
upper surface toward the lower surface and from the front surface
toward the back surface intersect each other is inserted into the
hollow 1a of the rectangular cuboid terminal portion 1 which has
the bolt insertion holes 1c and 1d bored respectively through the
upper surface and the front surface and to which the pole portion 2
is coupled at the other end, as mentioned above, so that the screw
holes 6a and 6b are respectively brought into communication with
the bolt insertion holes 1c and 1d, by injecting a plastic through
a plastic injection hole 1i into a bottom 1h of the terminal
portion 1 so as to deform the bottom 1h located below the hollow 1a
at the time of molding the plastic portion 4.
[0110] In this third method, the plastic injection hole 1i is
provided at the bottom 1h of the terminal portion 1, and a plastic
is fed to the bottom 1h of the terminal portion 1 at the time of
molding the plastic portion 4. Then, the bottom 1h located below
the hollow 1a is deformed by the plastic injected through the
plastic injection hole 1i due to the pressure at the time of the
molding, so that the nut 6 is pressed and fixed. It is preferable
that the bottom 1h be formed so as to have a part with a reduced
thickness of lead alloy so that such part is easily deformed due to
the pressure at the time of the molding. According to this method,
the nut 6 can be fixed to the terminal portion 1 at the time of
molding the plastic portion 4, the plastic encapsulated terminal 7
is accomplished simultaneously with the fixation of the nut 6.
[0111] Further, a fourth method for producing a plastic
encapsulated terminal according to the present invention is
described with reference to the flow diagram of FIG. 10.
[0112] This fourth method is characterized in that the nut 6 is
fixed by applying a pressure to the sidewall 1e of the terminal
portion 1 using a pressing pin provided in the plastic mold for
plastic molding, thereby providing the recess if on the sidewall
1e, at the time of plastic molding of the plastic encapsulated
terminal.
[0113] When producing the plastic encapsulated terminal, a lead
alloy is first poured into a mold (not shown in the figure) to
produce a metal portion (terminal) integrally including the
terminal portion 1, the pole portion 2, and the base 3. Then, the
nut 6 is inserted into the terminal portion 1 of this terminal, as
shown in FIG. 10A.
[0114] Next, this terminal is placed in a plastic mold composed of
the upper plastic mold 8 and the two-part lower plastic mold 9a, 9b
as shown in FIG. 10B, and a plastic molding space is formed within
the plastic mold.
[0115] In the fourth method, it is preferable that a pressing pin
10 be threadedly fixed to the lower plastic mold 9a of the plastic
mold in advance, and a pressure be applied to the sidewall 1e of
the terminal portion 1 by screwing the pressing pin 10
simultaneously with operation of fitting the terminal into the
plastic mold (operation of fitting the terminal with the upper
plastic mold 8 to the lower plastic mold 9a, 9b), as shown in FIG.
10B and C. This enables the motion of fitting the terminal into the
plastic mold to be used for applying a pressure to the sidewall 1e
of the terminal portion 1. Further, it is possible to control the
shape of the recess 1f to be formed on the sidewall 1e by varying
the degree of pressing the pressing pin 10 through the degree of
screwing the pressing pin 10, to vary the pressure applied to the
sidewall 1e of the terminal portion 1.
[0116] It is also possible to apply a pressure using the pressing
pin after the terminal has been fitted into the plastic mold,
however, in which a mechanism for moving the pressing pin back and
forth is rendered necessary. Therefore, it is preferable that the
pressure be applied at the time of operation of fitting the
terminal into the plastic mold, in order to achieve an apparatus
with low cost.
[0117] In the case where the lower plastic mold 9a, 9b is formed
extending up to an upper part of the terminal portion 1, a recess
may be provided on an upper wall of the terminal portion 1 by
arranging the pressing pin 10 in an upper part of the lower plastic
mold 9a, 9b and applying a pressure to the upper wall of the
terminal portion 1.
[0118] Mechanisms surrounding the pressing pin are preferably as
follows.
[0119] The pressing pin 10 has a base with an externally threaded
portion that is threadedly engaged to an internally threaded
portion of the plastic mold. A pressure is applied to the sidewall
1e of the terminal portion 1 by sliding of the plastic mold, as
shown in FIG. 10C. In that case, the projecting length at the tip
of the pressing pin 10 is adjustable by screwing the pin itself,
and can be set arbitrarily. By setting the projecting length before
sliding the plastic mold, it is possible to form the recess 1f with
a desired depth on the sidewall 1e of the terminal portion 1 when
the plastic mold is pressed thereagainst.
[0120] After the nut 6 is fixed to the terminal through application
of a pressure to the sidewall 1e of the terminal portion 1 by the
pressing pin 10 provided in the plastic mold at the time of closing
the plastic mold, a plastic such as polypropylene is poured into
the plastic molding space within the plastic mold, as conventional.
After curing of the plastic, the upper plastic mold 8 and the lower
plastic mold 9a, 9b are removed, and thus the plastic encapsulated
terminal 7 with the plastic portion 4 formed in the surroundings of
the pole portion 2 is obtained, as shown in FIG. 10D and FIG.
10E.
[0121] Even if a gap is present between the side surface of the
terminal portion 1 and the side surface of the groove of the upper
plastic mold 8, it is possible to prevent the plastic from entering
this gap by forming the plastic portion 4 with the upper surface of
the deburring flange 2a and the lower surface of a projection 8a of
the upper plastic mold 8 being in tight contact with each other, as
shown in FIG. 10C, thus preventing formation of burrs on the side
surface of the terminal portion 1.
[0122] The thus produced plastic encapsulated terminal 7 is joined
to a cover of a lead-acid storage battery, as shown in FIG. 11 and
FIG. 12.
[0123] An end of the base 3 forming a part of the plastic
encapsulated terminal 7 and a strap 22 formed integrally with an
electrode assembly 21 in advance, for example, by the COS process
are joined together by welding, thereby forming a weld joint
portion 22a. Further, when a battery case 23 and a cover 24 are
welded together, the upper surface of the plastic portion 4 and a
projection 24a provided on the inner surface of the cover 24 are
joined together, thereby forming a weld bonded portion 24b. The air
tightness and liquid tightness within the plastic encapsulated
terminal 7 are ensured by the welding of the plastic portion 4 to
the projection 24a provided on the lower surface of the cover 24,
the adhesion of the plastic portion 4 to the plurality of flanges
2b, 2c, and 2d formed on the outer circumferential surface of the
pole 2, and the creepage distance thereof.
[0124] Examples of application of the present invention to a
plastic encapsulated terminal and a lead-acid storage battery
provided with a plastic encapsulated terminal have been described
above. However, the present invention also can be applied to a
terminal portion for storage batteries, as disclosed in Non Patent
Literature 2, in which a rectangular cuboid terminal portion having
a hollow and an insertion opening for insertion of a nut and having
bolt insertion holes bored through the upper surface and the front
surface at such positions as not to intersect each other within the
hollow is formed by integral molding so as to be coupled via a
conductive portion to a tubular bushing welded with a pole
extending from an electrode assembly in a battery case being
inserted thereto.
[0125] In such a case, after a nut in which screw holes threaded
from the upper surface toward the lower surface and from the front
surface toward the back surface of the nut are formed at such
positions as not to intersect each other is inserted into the
above-mentioned hollow of the terminal portion, so that the screw
holes are brought into communication with bolt insertion holes of
the terminal portion, the nut may be fixed, for example, by
narrowing the insertion opening of the terminal portion, providing
a recess on a sidewall or ceiling of the terminal portion, or
deforming the terminal portion by heating, in the same manner as in
the case of the plastic encapsulated terminal.
[0126] Further, in production of storage batteries, such a terminal
portion formed by integral molding as mentioned above can be
attached to a cover made of a synthetic resin by insert molding, as
conventional.
[0127] Furthermore, the nut can be fixed also by applying a
pressure to the wall of the terminal portion using a pressing pin
provided in the plastic mold for plastic molding, thereby providing
a recess on the wall, in the same manner as in production of
plastic encapsulated terminals.
[0128] In the case where fixation is achieved by the molding
pressure for the plastic, the nut in which screw holes threaded
respectively from the upper surface toward the lower surface and
from the front surface toward the back surface intersect each other
is fixed, after being inserted into a hollow of a terminal portion
for storage batteries formed by integral molding of; a terminal
portion that has the hollow and an insertion opening for insertion
of the nut and has bolt insertion holes bored respectively through
the upper surface and the front surface at such positions as to
intersect each other within the hollow; a tubular bushing welded
with a pole extending from an electrode assembly in a battery case
being inserted thereinto; and a conductive portion coupling the
two, by insert molding to a cover made of a synthetic resin. The
injection-molding pressure of the synthetic resin in the insert
molding deforms the bottom of the terminal portion, so that the nut
is pressed and fixed to the hollow portion of the terminal
portion.
[0129] FIG. 13 shows a state where a storage battery having the
terminal of the present invention is mounted on a motorcycle.
[0130] As shown in FIG. 13, when mounting the battery on the
motorcycle, it is necessary to place the battery within a very
narrow space. Further, although some motorcycles are equipped with
a center stand, most motorcycles are equipped only with a side
stand. In the latter cases, attachment of the battery is performed
while such a motorcycle is inclined to the ground, and therefore a
nut unfixed to a terminal may be dropped in the attachment in some
cases, which is inconvenient. In the storage battery of the present
invention, the nut 6 is pre-fixed to the terminal portion 1, as
shown in FIG. 13. Therefore, it is possible to provide convenient
storage batteries.
REFERENCE SIGNS LIST
[0131] 1; Terminal Portion
[0132] 1a: Hollow
[0133] 1b: Insertion Opening
[0134] 1c: Bolt Insertion Hole (upper surface)
[0135] 1d: Bolt Insertion Hole (front surface)
[0136] 1e: Sidewall
[0137] 1f: Recess
[0138] 1g: Ceiling
[0139] 1h: Bottom
[0140] 1i: Plastic Injection Hole
[0141] 2: Pole Portion
[0142] 2a: Deburring Flange
[0143] 2b, 2c, 2d: Three Ribs of Flanges (each having a diameter
smaller than the length of one side of 2a)
[0144] 3: Base
[0145] 4: Plastic Portion
[0146] 5: Groove
[0147] 6: Nut
[0148] 6a: Screw Hole (threaded from the upper surface toward the
lower surface)
[0149] 6b: Screw Hole (threaded from the front surface toward the
back surface)
[0150] 7: Plastic Encapsulated Terminal
[0151] 8: Upper Plastic mold
[0152] 8a: Projection (of the upper plastic mold 8)
[0153] 9a, 9b: Two-Part Lower Plastic mold
[0154] 10: Pressing Pin
[0155] 21: Electrode Assembly
[0156] 22: Strap
[0157] 22a: Weld Joint Portion
[0158] 23: Battery Case
[0159] 24: Cover
[0160] 24a: Projection (on the inner surface of the cover 24)
[0161] 24b: Weld Bonded Portion
INDUSTRIAL APPLICABILITY
[0162] A storage battery provided with the terminal portion of the
present invention includes a nut pre-fixed to the terminal portion,
and is therefore useful as a storage battery for motorcycles in
which the attachment space for the storage battery and the
surrounding working space are small.
* * * * *