Mold assemblies including removable inserts and associated methods of use and manufacture

Abstract

Mold assemblies and associated methods and components for forming battery grids for lead acid batteries are disclosed herein. In one embodiment, a battery grid mold assembly includes a first die block that is movable relative to a second die block between an assembled position and an unassembled position spaced apart from the second die block. The mold assembly also includes a first insert plate having a first side that is removably coupled to the first die block and a second side opposite the first side. The second side of the first insert plate includes a first recess. The mold assembly further includes a second insert plate having a third side removably coupled to the second die block and a fourth side opposite the third side. The fourth side includes a second recess. When the first and second die blocks are in the assembled positions, the first and second recesses at least partially define a grid cavity that is configured to receive a flowable material for forming a battery grid.

1 . A mold assembly for forming a battery grid for a lead acid battery, the mold assembly comprising:
 a first subassembly comprising—
 a first die block; and 
 a first insert plate removably coupled to the first die block adjacent to the first fill plate, wherein the first insert plate includes a first recess; and 
   a second subassembly configured to be removably coupled to the first subassembly, the second subassembly comprising—
 a second die block; and 
 a second insert plate removably coupled to the second die block adjacent to the second fill plate, wherein the second insert plate includes a second recess, and wherein the first insert plate contacts the second insert plate and the first and second recesses at least partially define a grid cavity configured to receive a flowable material for forming a battery grid when the first subassembly is coupled to the second subassembly. 
   
     
     
         2 . The assembly of  claim 1 , further comprising:
 a first fill plate removably coupled to the first die block; and   a second fill plate removably coupled to the second die block, wherein the first fill plate contacts the second fill plate when the first subassembly is coupled to the second subassembly.   
     
     
         3 . The assembly of  claim 1  wherein:
 the first die block includes a first ejector opening; 
 the first insert plate includes a second ejector opening that is aligned with the first ejector opening when the first insert plate is coupled to the first die block; and 
 the assembly further comprises an ejector that is movable through the first and second ejector openings to eject a finished battery grid from the first recess. 
 
     
     
         4 . The assembly of  claim 1 , further comprising at least one biasing member positioned between the first die block and the first insert plate when the first insert plate is coupled to the first die block, wherein the biasing member urges the first insert plate away from the first die block to facilitate separation thereof. 
     
     
         5 . The assembly of  claim 1  wherein:
 the first recess includes a peripheral frame portion and multiple grid channels extending within the peripheral frame portion; and 
 the first insert plate includes multiple grid features positioned between adjacent grid channels. 
 
     
     
         6 . The assembly of  claim 5  wherein the first insert plate includes multiple vent holes passing through corresponding grid features, and wherein the individual vent holes are configured to allow gas to escape from the cavity as the flowable material fills the cavity. 
     
     
         7 . The assembly of  claim 6  wherein the first insert plate includes a first surface that contacts the first die block and a second surface opposite the first surface that contacts the second insert plate in the assembled position, and wherein the first surface includes one or more vent channels extending at least partially therethrough, wherein the one or more vent channels are aligned with one or more corresponding vent holes. 
     
     
         8 . The assembly of  claim 7  wherein individual vent channels have a width that is approximately the same as a cross-sectional dimension of the corresponding one or more vent holes. 
     
     
         9 . The assembly of  claim 1  wherein:
 the first die block includes an alignment features extending away therefrom; and 
 the first insert plate includes an alignment opening that receives the alignment feature when the first insert plate is coupled to the first die block. 
 
     
     
         10 . The assembly of  claim 1  where in the first fill plate comprises:
 a body; and 
 a fluid channel extending through at least a portion of the body and configured to receive a fluid different than the flowable material for transferring heat to or from the body. 
 
     
     
         11 . A battery grid manufacturing assembly comprising:
 a first die block;   a second die block movable relative to the first die block between a first position at least proximate to the first die block and a second position spaced apart from the first die block;   a first insert plate having a first side removably coupled to the first die block and a second side opposite the first side, wherein the second side includes a first recess; and   a second insert plate having a third side removably coupled to the second die block and a fourth side opposite the third side, wherein the fourth side includes a second recess, and wherein when the second die block is in the first position the first and second recesses define a grid cavity for forming a battery grid.   
     
     
         12 . The assembly of  claim 11 , further comprising:
 a first fill plate removably coupled to the first die block adjacent to the first insert plate; and   a second fill plate removably coupled to the second die block adjacent to the second insert plate, and wherein the second die block is in the first position the first and second fill plates are positioned to receive a flowable material and introduce the flowable material into the grid cavity.   
     
     
         13 . The assembly of  claim 11  wherein:
 each of the first and second recesses includes a plurality of grid channels; and 
 each of the first and second insert plates includes a plurality of grid features extending between adjacent grid channels in the corresponding first and second recesses. 
 
     
     
         14 . The assembly of  claim 13  wherein at least one of the first and second insert plates includes a plurality of vent holes aligned with individual corresponding grid features. 
     
     
         15 . The assembly of  claim 14  wherein the at least one of the first and second insert plates includes a plurality of vent channels in the first side, and wherein individual vent channels are aligned with corresponding vent holes in the grid features of the first insert plate. 
     
     
         16 . The assembly of  claim 11 , further comprising:
 a first alignment feature extending from the first die block and through at least a portion of the first insert plate when the first insert plate is coupled to the first die block; and   a second alignment feature extending from the second die block and through at least a portion of the second insert plate when the second insert plate is coupled to the second die block.   
     
     
         17 . The assembly of  claim 11  wherein when the second die block is in the second position the second die block is spaced apart from the first die block by a distance that is approximately equal to a combined thickness of the first and second insert plates. 
     
     
         18 . A method of making a battery grid, the method comprising:
 releasably securing a first insert plate to a first die block, the first insert plate having a first recess in a first surface opposite the first die block;   releasably securing a second insert plate to a second die block, the second insert plate having a second recess in a second surface opposite the second die block;   coupling the first die block at least proximate to the second die block in a molding position, wherein in the molding position the first surface of the first insert plate mates with the second surface of the second insert plate and the first and second recesses at least partially define a battery grid cavity;   introducing a casting material into the battery grid cavity; and   allowing the battery grid material to at least partially solidify in the battery grid cavity.   
     
     
         19 . The method of  claim 18 , further comprising:
 removably securing a first fill plate to the first die block adjacent to the first insert plate;   removably securing a second fill plate to the second die block adjacent to the second insert plate, wherein in the molding position the first fill plate mates with the second fill plate and the first and second fill plates at least partially define a fluid opening; and   wherein introducing the casting material comprises introducing the casting material into the grid cavity via the fluid opening.   
     
     
         20 . The method of  claim 18  wherein after allowing the battery grid material to at least partially solidify, the method further comprises:
 removing the at least partially solidified battery grid material from the battery grid cavity; and 
 removing at least one of the first and second insert plates from the corresponding first and second die blocks. 
 
     
     
         21 . The method of  claim 18 , further comprising allowing the battery grid cavity to vent while introducing the casting material into the battery grid cavity. 
     
     
         22 . The method of  claim 18  wherein after allowing the battery grid material to at least partially solidify, the method further comprises ejecting the at least partially solidified battery material from at least one of the first and second recesses by contacting the at least partially solidified battery material with an ejector that moves through the corresponding first or second insert plates.