Temporary plug for use in making a battery and method of manufacturing the temporary plug

Abstract

A plug for temporarily covering an opening in a lid of a battery. The plug includes a hat, a substructure extending from the hat, and a stem extending from the substructure, away from the hat. The hat includes a crown, a brim extending from the crown, and a collar extending from the brim. The substructure includes a trunk having radially extending branches that each include a radially extending plateau adjacent a raised foot. The raised foot is disposed radially inward of the collar and extends away from the hat and away from the plateau. The stem extends from the trunk of the substructure and has a noncircular cross-sectional shape defined by grooves spaced apart from one another by lobes. The grooves and the lobes in the stem each extend in a longitudinal direction along a periphery of the stem. The plug may be made using a plastic injection molding process.

Description

Attorney Docket No. 0275-001795-WO-POATEMPORARY PLUG FOR USE IN MAKING A BATTERY AND METHOD OF MANUFACTURING THE TEMPORARY PLUGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No.63 / 749,773, filed on January 27, 2025, which is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to temporary plugs for use in making batteries, and methods of making such temporary plugs.BACKGROUND

[0003] The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

[0004] Secondary or rechargeable batteries include an electrode assembly comprising a positive electrode, a negative electrode, and a separator disposed between the positive and negative electrodes. The electrode assembly is typically sealed within a case and infiltrated with an ionically conductive electrolyte that provides a medium for the conduction of ions between the positive and negative electrodes during charge and discharge of the batteries. During assembly of the batteries, the electrode assembly may be positioned within the case and then a lid may be welded to the case to seal the battery in an interior chamber thereof. An opening may be provided in the lid through which the electrolyte is introduced into the interior chamber and into the electrode assembly after the lid is welded to the case. To prevent weld splatter from being deposited near the opening in the lid and / or entering the interior chamber during the welding process, a temporary plug may be received in the opening in the lid prior to welding the lid to the case. Thereafter, the temporary plug may be removed and replaced with a permanent plug to seal the battery and prevent the electrolyte from leaking.Attorney Docket No. 0275-001795-WO-POASUMMARY

[0005] A plug for covering an opening in a lid of a battery, in accordance with one or more aspects of the present disclosure, comprises a hat, a substructure extending from an underside of the hat, and a stem extending in a longitudinal direction from the substructure, away from the hat. The hat defines a cavity in an underside thereof and includes a crown, a brim extending in a radial direction from the crown, and a collar extending in a longitudinal direction from an outer circumference of the brim. The substructure includes a trunk having a number of radially extending branches. Each of the branches includes a radially extending plateau adjacent a raised foot. The raised foot of each branch is disposed radially inward of the collar and extends in a longitudinal direction away from the hat and away from the plateau. The stem extends in a longitudinal direction from the trunk of the substructure and has a noncircular cross-sectional shape defined by a number of grooves spaced apart from one another by lobes. The grooves and the lobes in the stem each extend in a longitudinal direction along a periphery of the stem.

[0006] The hat, the substructure, and the stem may be of unitary one-piece construction.

[0007] The plug may be made of polypropylene and / or rigid plastic.

[0008] The stem may have a triad cross-sectional shape. In such case, the number of grooves may be three and / or the number of radially extending branches may be three.

[0009] When the stem of the plug is received in the opening of the lid, the raised foot of each branch may be configured to rest against a surface of the lid such that the hat completely covers the opening in the lid and covers an annular region on the surface of the lid surrounding the opening. Additionally or alternatively, the plateau of each branch may be spaced-apart from and may not contact the surface of the lid. The plug may not form a fluid-tight seal with the opening.

[0010] The branches of the substructure may be separated from one another by valleys. In such case, the grooves in the stem may be radially aligned with the valleys in the substructure and the lobes of the stem may be radially aligned with the branches of the substructure.

[0011] The crown may include a sidewall extending from an inner circumference of the brim in a longitudinal direction away from the collar to a land. In such case, the crown may further include a circular recess extending in a longitudinal direction from the land toward the substructure.Attorney Docket No. 0275-001795-WO-POA

[0012] The collar may have a tapered peripheral surface that narrows as the collar extends in a longitudinal direction from the brim, away from the crown.

[0013] Each of the branches of the substructure may have a proximal end adjacent the trunk and a distal end adjacent the collar. In such case, the plateau of each branch may be disposed radially inward of the raised foot.

[0014] The plateau of each branch may have an axially facing substantially flat surface and may be configured to serve as a contact point for an ejection pin during manufacture of the plug.

[0015] The stem may have a tapered profile that narrows as the stem extends in a longitudinal direction away from the substructure.

[0016] The stem may include a base extending from the trunk of the substructure and a tip extending from the base to an apex. In such case, the base and the tip each may have a tapered profile that narrows as the stem extends in a longitudinal direction away from the substructure. In such case, the tapered profile of the base may be relatively shallow as compared to that of the tip.

[0017] The apex may have an axially facing substantially flat surface and may be configured to serve as a contact point for an ejection pin during manufacture of the plug.

[0018] A method of making a plug, in accordance with one or more aspects of the present disclosure, comprises injecting molten plastic into a mold defining a void, allowing the molten plastic to cool in the void to form the plug, and then ejecting the plug from the mold. The mold includes a cavity and a core extending into the cavity. The cavity and the core together define the void. The plug includes a hat, a substructure, and a stem. The hat includes a crown and a brim extending in a radial direction from the crown. The brim has a longitudinally extending peripheral surface and at least partially defines an underside of the hat. The substructure extends in a longitudinal direction from the underside of the hat to at least one foot. The at least one foot is disposed radially inward of the peripheral surface of the brim. The stem extends in a longitudinal direction from the substructure, away from the hat, and has a base extending to a tip.

[0019] The crown of the hat may extend in a longitudinal direction from the brim away from the substructure to a land and may include a circular recess extending in a longitudinal direction from the land toward the substructure. In such case, the method may further comprise injecting the molten plastic into the cavity in the mold via a gate,Attorney Docket No. 0275-001795-WO-POAand the gate may be aligned with a location in the void corresponding to the circular recess in the crown.

[0020] The at least one foot may include a plurality of feet. In such case, the method may further comprise ejecting the plug from the mold via a plurality of ejection pins that each exert a force against one of the feet of the substructure.

[0021] The tip of the stem may include an apex having an axially facing substantially flat surface. In such case, the method may further comprise ejecting the plug from the mold via an ejection pin that exerts a force against the apex of the stem.

[0022] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0024] FIG. 1 is a perspective view of a plug for a battery according to one or more embodiments of the present disclosure, the plug comprising a hat, a substructure extending from the hat, and a stem extending from the substructure.

[0025] FIG. 2 is a perspective view of the plug of FIG. 1 depicting an underside of the hat, the substructure extending from the hat, and the stem extending from the substructure.

[0026] FIG. 3 is a side view of the plug of FIG. 1.

[0027] FIG.4 is a cross sectional view of the substructure of FIG. 1 , taken along line 4-4 of FIG. 3.

[0028] FIG. 5 is a cross sectional view of the stem of FIG. 1, taken along line 5-5 of FIG. 3.

[0029] FIG. 6 is a diagram of steps in a method of manufacturing a battery in which the plug of FIG. 1 is received in an opening in a lid of the battery.

[0030] FIG. 7 is a cross sectional view of a step in a method of manufacturing a battery in which a lid of the battery is welded to a case thereof.Attorney Docket No. 0275-001795-WO-POA

[0031] FIG. 8 is a side cross sectional view of a mold for use in manufacturing the plug of FIG. 1 via an injection molding process.

[0032] FIG. 9 is a side cross sectional view of a multi-cavity mold for use in simultaneously manufacturing multiple identical plugs during a single cycle of an injection molding process.

[0033] FIG. 10 is a top view of a core plate of the multi-cavity mold of FIG. 9.

[0034] In the drawings, reference numbers may be reused to identify similar and / or identical elements.DETAILED DESCRIPTION

[0035] The presently disclosed temporary plug is configured to allow the plug to be efficiently and precisely manufactured as a single piece from plastic using an injection molding process, which may allow the plug to be manufactured in high volumes at relatively low cost and in a relatively short amount of time, as compared to if the plug were manufactured using a machining process. Although machining processes may have shorter lead times than injection molding processes because they do not require the time and upfront expense of making a mold, injection molding processes tend to produce less waste and require fewer steps than machining processes, which may be beneficial, for example, where large production volumes are desired.

[0036] FIGS. 1-5 depict a temporary plug 10 for use during manufacture of a battery 100, for example, a prismatic battery or a cylindrical battery. As shown in FIGS. 6-7, the battery 100 comprises a housing 101 including a lid 104 and a case 106 that together define an interior compartment 102 of the battery 100. Although not shown in the drawings, the battery 100 may further comprise an electrode assembly comprising a positive electrode, a negative electrode, and a separator disposed between the positive and negative electrodes. The electrode assembly may be disposed in the housing 101 and infiltrated with a liquid electrolyte (not shown). The lid 104 of the battery 100 has an upper surface 112, an opposite lower surface 114 facing the interior compartment 102, and an opening 108 extending from the upper surface 112 to the lower surface 114 of the lid 104. During assembly of the battery 100, the lid 104 is positioned on the case 106 and the plug 10 is received in the opening 108 in the lid 104.

[0037] After the plug 10 is positioned in the opening 108 of the lid 104, the lid 104 may be welded to the case 106. The plug 10 is configured such that, when the plug 10 isAttorney Docket No. 0275-001795-WO-POApositioned in the opening 108 of the lid 104, the plug 10 completely covers the opening 108 in the lid 104 and also covers an annular region 110 surrounding the opening 108. In such an arrangement, the plug 10 can effectively prevent weld splatter from entering the interior compartment 102 of the battery 100 when the lid 104 is welded to the case 106 during manufacture of the battery 100. After the lid 104 is welded to the case 106, the plug 10 is typically removed from the opening 108 and thus may be referred to as a “temporary” plug. For example, the plug 10 may be removed from the opening 108 in the lid 104 after the lid 104 is welded to the case 106 to allow the interior compartment 102 and the electrode assembly disposed therein to be filled with the liquid electrolyte via the opening 108. After the interior compartment 102 is filled with the liquid electrolyte, a “permanent” plug (e.g., a ball plug) may be installed in the opening 108 to seal the liquid electrolyte and the electrode assembly in the housing 101 of the battery 100.

[0038] As best shown in FIGS. 1-5, the plug 10 has a central longitudinal axis A and comprises a hat 12, a substructure 14 extending from the hat 12, and a stem 16 extending from the substructure 14. The hat 12, the substructure 14, and the stem 16 are configured to allow the plug 10 to be efficiently and precisely manufactured as a single piece from plastic using an injection molding process. For example, the rounded corners, thin walls, and tapered profile of certain features of the plug 10 may help facilitate the precise and repeatable manufacture of the plug 10 via an injection molding process, for example, by ensuring good filling of the mold, uniform cooling, and easy removal of the plug 10 from the mold. The plug 10 may be relatively light weight, as compared to similar plugs manufactured by machining processes. The plug 10 may be made of an inelastic rigid material that does not conform, compress, or bend in response to pressure. As such, the plug 10 may not deform or conform to the shape of the opening 108 when the plug 10 is received in the opening 108 in the lid 104. In addition, the hat 12, the substructure 14, or the stem 16 may be configured to not move relative to one another and may not move relative to one another when the plug 10 is received in the opening 108 in the lid 104. In aspects, the plug 10 may be made of rigid plastic (e.g., polypropylene). In the example shown in FIGS. 1-5 and 8, the plug is solid (not hollow) and does not include an opening or passageway extending therethrough, for example, the plug 10 does not include an opening extending through the hat 12, the substructure 14, and / or the stem 16, e.g., along the central longitudinal axis A.

[0039] The hat 12 is configured to facilitate transport and placement of the plug 10 relative to the lid 104 and has a topside 13 defining at least one planar surface that facesAttorney Docket No. 0275-001795-WO-POAaway from the substructure 14, an opposite underside 25 that faces toward the substructure 14, and a longitudinally extending outer peripheral surface 23. In embodiments, the underside 25 of the hat 12 may define at least one planar surface that faces toward the substructure 14. In aspects, the at least one planar surface defined by the topside 13 of the hat 12 and / or the at least one planar surface defined by the underside 25 of the hat 12 may be annular in shape. In embodiments, the hat 12 may comprise a cylindrical crown 18, an annular brim 20, and a collar 22. In such case, the brim 20 may extend in a radial direction between the crown 18 and the collar 22 and may have a radially inner circumference 50 adjacent the crown 18 and a radially outer circumference 52 adjacent the collar 22. Together, the crown 18, the brim 20, and the collar 22 may define a cavity 24 in the underside 25 of the hat 12 (FIG. 2). The crown 18 and the brim 20 together may define the topside 13 of the hat 12. The cavity 24 in the hat 12 may help minimize the thickness of the crown 18, the brim 20, and the collar 22 of the hat 12, which may help reduce the weight of the plug 10 and may help promote uniform cooling of the material of the plug 10 during the injection molding process.

[0040] The crown 18 includes a sidewall 27 and a land 26 having a circular recess 28 defined therein. The sidewall 27 extends from the inner circumference 50 of the brim 20 in a longitudinal direction (i.e., along the central longitudinal axis A) away from the collar 22 to the land 26. The circular recess 28 extends in a longitudinal direction from the land 26 toward the substructure 14. The circular recess 28 in the crown 18 may be configured to mask any imperfections in the visual appearance of the plug 10 which may occur, for example, during the injection molding process. In aspects, the circular recess 28 in the crown 18 may serve as an injection site during filling of the mold and, in such case, the surface of the circular recess 28 may have imperfections. For example, when the circular recess 28 is used as an injection site during filling of the mold, a sunken region may be formed in the circular recess 28 during cooling. However, since the circular recess 28 is recessed relative to the land 26, such imperfections may not be visible or may be less noticeable to the naked eye. In addition, because the circular recess 28 is recessed relative to the land 26, any imperfections in the circular recess 28 will not interfere with the ability of the land 26 to provide a flat, consistent surface that is free of imperfections. Such a flat surface may help establish adequate suction in embodiments where a vacuum is applied to the crown 18 during transfer of the plug 10 and / or placement of the plug 10 on the lid 104. In various implementations, the crown 18 may be omitted, in which case the brim 20 alone may define the topside 13 of the hat 12, theAttorney Docket No. 0275-001795-WO-POAbrim 20 may define the circular recess 28, and the brim 20 and the collar 22 may define the cavity 24 in the underside 25 of the hat 12.

[0041] The collar 22 extends in a longitudinal direction from the outer circumference 52 of the brim 20, away from the crown 18 to a lower edge 35. The collar 22 may be configured to shield the opening 108 in the lid 104 of the battery 100 and the annular region 110 surrounding the opening 108 in the lid 104 from weld splatter generated during welding of the lid 104 to the case 106 of the battery 100. As best shown in FIG. 3, to facilitate easy removal of the plug 10 from the mold after completion of the injection molding process, the collar 22 has a tapered peripheral surface 29 that narrows as the collar 22 extends from the outer circumference 52 of the brim 20, away from the crown 18. For example, the tapered peripheral surface 29 of the collar 22 may extend at an angle a of about 1 degree with respect to the central longitudinal axis A of the plug 10.

[0042] The substructure 14 is disposed radially inward of the outer peripheral surface 23 of the hat 12 and includes one or more feet 40 configured to engage the upper surface 112 of the lid 104 defined by the annular region 110 to accurately orient the plug 10 with respect to the lid 104 during the welding process. The substructure 14 extends between the underside 25 of the hat 12 and the stem 16 and extends in a longitudinal direction from the underside 25 of the hat 12 beyond the lower edge 35 of the collar 22, as best shown in FIG. 2.

[0043] In embodiments, the substructure 14 may include a trunk 31 , a plurality of radially extending equally spaced-apart branches 32, and a plurality of feet 40 respectively extending from the branches 32, as shown in cross-section in FIG. 4. The trunk 31 extends in a longitudinal direction along the longitudinal axis A of the plug 10. The branches 32 are at least partially disposed in the cavity 24 defined in the underside 25 of the hat 12 and are separated from one another by valleys 33 in the underside 25 of the hat 12. Each of the branches 32 extends from a proximal end 34 adjacent the trunk 31 to a distal end 36 adjacent the collar 22 and has a plateau 38 extending between the proximal end 34 and the distal end 36 thereof, as best shown in FIG. 2. The plateau 38 of each branch 32 extends in a radial direction between the proximal end 34 and the distal end 36 of the branch 32 and faces in an axial direction away from the underside 25 of the hat 12. Each foot of the plurality of feet 40 extends from the distal end 36 of one of the branches 32 and is disposed radially inward of the collar 22 and radially outward of the plateau 38. Each foot of the plurality of feet 40 is raised with respect to a remainingAttorney Docket No. 0275-001795-WO-POAportion of the substructure 14 and extends in a longitudinal direction from the distal end 36 of one of the branches 32, away from the hat 12, and away from of the plateau 38. Together, the plurality of feet 40 are configured to rest against the upper surface 112 of the lid 104 in the annular region 110 during the welding process to ensure the stable positioning of the plug 10 with respect to the lid 104.

[0044] In aspects, the substructure 14 may have a triad-shaped body 30 and may include three feet 40 respectively extending from three radially extending equally spacedapart branches 32, as shown in cross-section in FIG. 4. In such case, the branches 32 may divide the cavity 24 defined in the underside 25 of the hat 12 into three distinct sections. In such case, during the welding process, the three feet 40 of the substructure 14 may rest against the upper surface 112 of the lid 104 in the annular region 110 to help ensure the stable positioning of the plug 10 with respect to the lid 104. In various implementations, one or more features of the substructure 14, such as the trunk 31 and / or the branches 32, may be omitted. For example, the substructure 14 may include only one or more (e.g., three) of the feet 40, which may project directly from the underside 25 of the hat 12.

[0045] The plateaus 38 shown in FIGS. 2, 3, and 5 have substantially flat, smooth surfaces; however, in practice, this may not be the case. For example, in aspects, an ejection pin may be constructed and arranged to exert a force against the plateau 38 of one of the branches 32 to eject the plug 10 from the mold after completion of the injection molding process. In such case, the ejection pin may leave an imperfection in the surface of the plateau 38. The plateau 38 and the plurality of feet 40 are configured to prevent any imperfections in the shape of the plateau 38 from interfering with the stable positioning of the plug 10 with respect to the lid 104. Because each foot of the plurality of feet 40 extends in a longitudinal direction away from the hat 12 and away from the axial facing surface of the adjacent plateau 38, the plateaus 38 do not contact the upper surface 112 of the lid 104 when the plug 10 is received in the opening 108 of the lid 104, and therefore any imperfections in the plateaus 38 do not interfere with the stable positioning of the plug 10.

[0046] The stem 16 extends from the substructure 14 in a longitudinal direction away from the hat 12 and is configured to mate with and form a sliding fit with the opening 108 in the lid 104 of the battery 100. The stem 16 includes a base 42 and a tip 44 having an apex 48, with the base 42 extending from the substructure 14 to the tip 44. The stem 16Attorney Docket No. 0275-001795-WO-POAfurther includes a plurality of grooves 46 that are radially spaced-apart from one another by a plurality of radially extending lobes 49. The grooves 46 and the lobes 49 each extend in a longitudinal direction along a periphery of the stem 16, from the base 42 to the tip 44, causing the stem 16 to have a noncircular cross-sectional shape. The grooves 46 may be aligned with the valleys 33 defined between the branches 32 of the substructure 14 and the lobes 49 may be radially aligned with the radially extending branches 32, as best shown in FIG. 5. When the plug 10 is received in the opening 108 in the lid 104, the lobes 49 of the stem 16 provide multiple contact points between the stem 16 and the opening 108, which makes the plug 10 more adaptable to variations in the mating surface of the battery 100 relative to plugs with a stem having a circular perimeter. In aspects, the stem 16 may include three grooves 46 equally spaced-apart from one another by three radially extending lobes 49, causing the stem 16 to have a triad cross-sectional shape, as best shown in FIG. 5. In such case, when the plug 10 is received in the opening 108 in the lid 104, the lobes 49 of the stem 16 provide three contact points between the stem 16 and the opening 108.

[0047] The base 42 and the tip 44 of the stem 16 may each have a uniformly tapered profile that narrows as the stem 16 extends away from the substructure 14, as best shown in FIG. 3. In aspects, the tapered profile of the base 42 may be relatively shallow as compared to that of the tip 44. For example, a periphery of the base 42 of the stem 16 may extend in a longitudinal direction at an angle [3 of greater than or equal to about 2 degrees and less than about 4 degrees with respect to the central longitudinal axis A of the plug 10, and a periphery of the tip 44 of the stem 16 may extend in a longitudinal direction at an angle y of greater than or equal to about 4 degrees and less than or equal to about 5 degrees with respect to the central longitudinal axis A of the plug 10. The tapered profile of the base 42 and the tip 44 may allow for easy removal of the plug 10 from the mold after completion of the injection molding process. The apex 48 of the stem 16 may define a relatively flat plane extending substantially perpendicular to the central longitudinal axis A, which may help facilitate ejection of the plug 10 from the mold, for example, by providing a flat surface for good contact with an ejection pin of the mold.

[0048] Referring now to FIGS. 6-7, the plug 10 is configured for use during manufacture of the battery 100 to prevent weld splatter from entering the interior compartment 102 of the battery 100 during a welding step in which the lid 104 is welded to the case 106 of the battery 100 (FIG. 7). As illustrated in FIG. 6, during assembly of the battery 100, the lid 104 is positioned on the case 106, and then the stem 16 of the plug 10 is received inAttorney Docket No. 0275-001795-WO-POAthe opening 108 of the lid 104. As shown in FIG. 7, during assembly of the battery 100, the plug 10 is received in the opening 108 and positioned on the lid 104 such that the stem 16 extends through the lid 104 into the interior compartment 102 of the battery 100 and the raised feet 40 of the substructure 14 rest against the annular region 110 on the upper surface 112 of the lid 104. In such an arrangement, when the lid 104 is welded to the case 106, the collar 22 effectively shields the annular region 110 and the opening 108 in the lid 104 from weld splatter and effectively prevents weld splatter from entering the interior compartment 102 of the battery 100. As shown in FIG. 7, the lid 104 may be welded to the case 106, for example, by laser welding, at contact points 116 along an interface between the lid 104 and the case 106.

[0049] Referring now to FIG. 8, the hat 12, the substructure 14, and the stem 16 of the plug 10 are designed so that the plug 10 can be entirely formed in a mold 200 using an injection molding process. As such, the physical configuration of the plug 10 effectively eliminates the need for the plug 10 to undergo various machining processes after the plug 10 is removed from the mold 200. For example, after the plug 10 is removed from the mold 200, the plug 10 does not need to be further machined, such as, e.g., by being turned on a lathe. The mold 200 comprises a cavity 220 and a core 222 extending into the cavity 220. The cavity 220 defines a gate 224 through which molten plastic 230 is injected into the cavity 220 and solidified to form the plug 10. Four (4) ejection pins 226 may be used to eject the plug 10 from the mold 200. The cavity 220 and the core 222 interface with each other along a parting line 228 and together define a void 232 in the shape of the plug 10. As shown in FIG. 8, the gate 224 may be formed in the cavity 220 and aligned with the location in the void 232 corresponding to the circular recess 28 in the crown 18 of the plug 10. The molten plastic 230 fills the void 232 defined between the cavity 220 and the core 222 and then cools and solidifies forming the plug 10, which is ejected from the mold 200 by the ejection pins 226. As shown in FIG. 8, the ejection pins 226 may be configured to eject the plug 10 from the mold 200 by applying forces to the plateau 38 of each of the branches 32 of the substructure 14 and to the apex 48 of the tip 44 of the stem 16.

[0050] Referring now to FIGS. 9-10, in aspects, the mold 200 may be a multi-cavity mold and may include a cavity plate 234 defining multiple cavities 220 and a complementary core plate 236 defining multiple cores 222 corresponding to the cavities 220. A multi-cavity mold allows for the manufacture of multiple plugs 10 during a singleAttorney Docket No. 0275-001795-WO-POAcycle of the injection molding process and may be beneficial, for example, in commercial production operations where high volumes are required.

[0051] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

[0052] When an element or layer is referred to as being "on," “engaged to,” "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," “directly engaged to,” "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).

[0053] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.Attorney Docket No. 0275-001795-WO-POA

[0054] Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0055] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Claim language or other language reciting “at least one of” a set and / or “one or more” of a set indicates that one member of the set or multiple members of the set (in any combination) satisfy the claim. For example, claim language reciting “at least one of A and B” means A, B, or A and B. In another example, claim language reciting “at least one of A, B, and C” means A, B, C, or A and B, or A and C, or B and C, or A and B and C. The language “at least one of” a set and / or “one or more” of a set does not limit the set to the items listed in the set. For example, claim language reciting “at least one of A and B” can mean A, B, or A and B, and can additionally include items not listed in the set of A and B.

Claims

Attorney Docket No. 0275-001795-WO-POACLAIMSWhat is claimed is:

1. A plug for covering an opening in a lid of a battery, the plug comprising:a hat defining a cavity in an underside thereof and including a crown, a brim extending in a radial direction from the crown, and a collar extending in a longitudinal direction from an outer circumference of the brim;a substructure extending from the underside of the hat and including a trunk having a number of radially extending branches, each of the branches including a radially extending plateau adjacent a raised foot, the raised foot being disposed radially inward of the collar and extending in the longitudinal direction away from the hat and away from the plateau; anda stem extending in the longitudinal direction from the trunk of the substructure away from the hat, the stem having a noncircular cross-sectional shape defined by a number of grooves spaced apart from one another by lobes, the grooves and the lobes each extending in the longitudinal direction along a periphery of the stem.

2. The plug of claim 1 , wherein the hat, the substructure, and the stem are of unitary one-piece construction.

3. The plug of claim 1 or 2, wherein the plug is made of polypropylene.

4. The plug of any one of claims 1 to 3, wherein the stem has a triad cross-sectional shape and the number of grooves is three.

5. The plug of any one of claims 1 to 4, wherein the substructure has a triad cross-sectional shape and the number of radially extending branches is three.

6. The plug of any one of claims 1 to 5, wherein, when the stem of the plug is received in the opening of the lid, the raised foot of each branch is configured to rest against a surface of the lid such that the hat completely covers the opening in the lid and covers an annular region on the surface of the lid surrounding the opening.Attorney Docket No. 0275-001795-WO-POA7. The plug of claim 6, wherein, when the stem of the plug is received in the opening of the lid, the plateau of each branch is spaced-apart from and does not contact the surface of the lid.

8. The plug of claim 6 or 7, wherein, when the stem of the plug is received in the opening of the lid, the plug does not form a fluid-tight seal with the opening.

9. The plug of any one of claims 1 to 8, wherein the branches of the substructure are separated from one another by valleys, and wherein the grooves in the stem are radially aligned with the valleys in the substructure and the lobes of the stem are radially aligned with the branches of the substructure.

10. The plug of any one of claims 1 to 9, wherein the crown includes a sidewall extending from an inner circumference of the brim in the longitudinal direction away from the collar to a land, and wherein the crown further includes a circular recess extending in the longitudinal direction from the land toward the substructure.

11. The plug of any one of claims 1 to 10, wherein the collar has a tapered peripheral surface that narrows as the collar extends in the longitudinal direction from the brim, away from the crown.

12. The plug of any one of claims 1 to 11 , wherein each of the branches of the substructure has a proximal end adjacent the trunk and a distal end adjacent the collar, and wherein the plateau of each branch is disposed radially inward of the raised foot.

13. The plug of any one of claims 1 to 12, wherein the plateau of each branch has an axially facing substantially flat surface and is configured to serve as a contact point for an ejection pin during manufacture of the plug.

14. The plug of any one of claims 1 to 13, wherein the stem has a tapered profile that narrows as the stem extends in the longitudinal direction away from the substructure.Attorney Docket No. 0275-001795-WO-POA15. The plug of any one of claims 1 to 14, wherein the stem includes a base extending from the trunk of the substructure and a tip extending from the base to an apex, and wherein the base and the tip each have a tapered profile that narrows as the stem extends in the longitudinal direction away from the substructure, and wherein the tapered profile of the base is relatively shallow as compared to that of the tip.

16. The plug of claim 15, wherein the apex has an axially facing substantially flat surface and is configured to serve as a contact point for an ejection pin during manufacture of the plug.

17. A method of making a plug, the method comprising:injecting molten plastic into a mold including a cavity and a core extending into the cavity, the cavity and the core together defining a void;allowing the molten plastic to cool in the void to form the plug, the plug including:a hat including a crown and a brim extending in a radial direction from the crown, the brim having a longitudinally extending peripheral surface and at least partially defining an underside of the hat,a substructure extending in a longitudinal direction from the underside of the hat and including at least one foot, the at least one foot being disposed radially inward of the peripheral surface of the brim, anda stem extending in the longitudinal direction from the substructure away from the hat, the stem having a base extending to a tip; andejecting the plug from the mold.

18. The method of claim 17, wherein the crown of the hat extends in the longitudinal direction from the brim away from the substructure to a land and includes a circular recess extending in the longitudinal direction from the land toward the substructure, and wherein the method further comprises injecting the molten plastic into the cavity in the mold via a gate, and wherein the gate is aligned with a location in the void corresponding to the circular recess in the crown.

19. The method of claim 17 or 18, wherein the at least one foot includes a plurality of feet, the method further comprising ejecting the plug from the mold via a plurality of ejection pins that each exert a force against one of the feet of the substructure.Attorney Docket No. 0275-001795-WO-POA20. The method of any one of claims 17 to 19, wherein the tip of the stem includes an apex having an axially facing substantially flat surface, and wherein the method further comprises ejecting the plug from the mold via an ejection pin that exerts a force against the apex of the stem.

Images