VENTING BELT CASTER WHEEL ASSEMBLY OF BATTERY COMPONENT CONTINUOUS CASTING MACHINE

Abstract

A belt caster wheel assembly for a battery component continuous casting machine. The battery component can be a continuous strip of metal grids or a continuous strip of bipolar metal foils. The belt caster wheel assembly, per an implementation, includes a rotatable caster wheel and a moveable belt. One or more gas vents are established in the rotatable caster wheel. The gas vent(s) fluidly communicates with a mold cavity of the rotatable caster wheel. Gas bubbles, voids, and/or other unwanted imperfections in the ultimately-produced battery components can be partly or entirely resolved with the employment of the gas vent(s).

Claims

1. A belt caster wheel assembly for a battery component continuous casting machine, the belt caster wheel assembly comprising: a rotatable caster wheel having a cylindrical wall with a mold cavity residing at an exterior surface of said cylindrical wall, a gas vent established in said cylindrical wall and having fluid communication with said mold cavity; and a moveable belt in confrontation with a circumferential working region of said mold cavity; wherein, amid use of the battery component continuous casting machine and the belt caster wheel assembly, molten lead or lead alloy is delivered to said circumferential working region of said mold cavity and at least some gas present at said mold cavity at the time of molten lead or lead alloy delivery is displaced by the molten lead or lead alloy and escapes said mold cavity via said gas vent.

2. The belt caster wheel assembly as set forth in claim 1, wherein said mold cavity is a grid mold cavity and a vent inlet of said gas vent is located at a lug section of said grid mold cavity.

3. The belt caster wheel assembly as set forth in claim 1, wherein said mold cavity is a grid mold cavity and a vent inlet of said gas vent is located at a grid wire section of said grid mold cavity.

4. The belt caster wheel assembly as set forth in claim 1, wherein said gas vent is a vent clearance established between a separable portion of said cylindrical wall and an adjoining portion of said cylindrical wall.

5. The belt caster wheel assembly as set forth in claim 1, wherein said cylindrical wall comprises at least one separable portion having at least one standoff, and said gas vent is a vent clearance established via press-fit of said at least one separable portion at an adjoining portion of said cylindrical wall and via said at least one standoff.

6. The belt caster wheel assembly as set forth in claim 1, wherein said gas vent comprises a vent passage residing in said cylindrical wall and having fluid communication with an exterior of said rotatable caster wheel.

7. The belt caster wheel assembly as set forth in claim 1, wherein said gas vent comprises a vent passage residing in said cylindrical wall and having fluid communication with an interior of said rotatable caster wheel.

8. The belt caster wheel assembly as set forth in claim 1, wherein a negative pressure is applied at said gas vent via a vacuum pump for facilitation of escape of said at least some gas via said gas vent, said negative pressure being with respect to ambient pressure at said mold cavity.

9. The belt caster wheel assembly as set forth in claim 1, further comprising a vacuum attachment end situated at least adjacent said rotatable caster wheel and in fluid communication with said gas vent and applying a negative pressure to said gas vent.

10. The belt caster wheel assembly as set forth in claim 1, further comprising providing a positive pressure of inert gas to said mold cavity immediately prior to delivery of molten lead or lead alloy to said circumferential working region of said mold cavity.

11. The belt caster wheel assembly as set forth in claim 1, wherein at least one opening resides in said cylindrical wall at said mold cavity, and said rotatable caster wheel comprises at least one plug received in said at least one opening, at least one vent clearance established between said at least one opening and said at least one plug, said at least one vent clearance constituting said gas vent.

12. The belt caster wheel assembly as set forth in claim 1, wherein at least one pocket resides in said cylindrical wall at said mold cavity, and said rotatable caster wheel comprises at least one insert received in said at least one pocket, at least one vent clearance established between said at least one pocket and said at least one insert, said at least one vent clearance constituting said gas vent.

13. The belt caster wheel assembly as set forth in claim 1, wherein said cylindrical wall comprises at least a first ring segment and a second ring segment, said first ring segment and second ring segment layered on each other for formation of said cylindrical wall, at least one vent clearance established between said first ring segment and said second ring segment upon layering, said at least one vent clearance constituting said gas vent.

14. A battery component continuous casting machine comprising said belt caster wheel assembly as set forth in claim 1, the battery component continuous casting machine further comprising at least one temperature-controlled shoe engaging said moveable belt at the confrontation with said circumferential working region of said mold cavity.

15. A method of actively venting gas from a mold cavity of a belt caster wheel assembly amid molten lead or lead alloy delivery, the method comprising: providing an active gas vent at said mold cavity and in fluid communication with said mold cavity; delivering molten lead or lead alloy to said mold cavity; and actively venting at least some of displaced gas present at said mold cavity upon the delivery of molten lead or lead alloy thereto via said active gas vent.

16. The method of actively venting gas from the mold cavity of the belt caster wheel assembly as set forth in claim 15, further comprising actively venting at least some of displaced gas through a vent passage residing in a cylindrical wall of said belt caster wheel assembly and to an exterior of said belt caster wheel assembly.

17. The method of actively venting gas from the mold cavity of the belt caster wheel assembly as set forth in claim 15, further comprising actively venting the at least some of displaced gas through a vent passage residing in a cylindrical wall of the belt caster wheel assembly and to an interior of said belt caster wheel assembly.

18. The method of actively venting gas from the mold cavity of the belt caster wheel assembly as set forth in claim 15, further comprising applying a negative pressure at said active gas vent to facilitate venting of the at least some of displaced gas.

19. The method of actively venting gas from the mold cavity of the belt caster wheel assembly as set forth in claim 15, further comprising providing a positive pressure of inert gas to said mold cavity immediately prior to delivery of molten lead or lead alloy thereto.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will become more fully understood from the detailed description provided below and the accompanying drawings, which are given by way of illustration only, and do not limit the present disclosure, and wherein:

[0010] FIG. 1 is a perspective view of an embodiment of a battery component continuous casting machine equipped with a belt caster wheel assembly having a gas vent;

[0011] FIG. 2 is another perspective view of the battery component continuous casting machine;

[0012] FIG. 3 is a schematic view of the belt caster wheel assembly;

[0013] FIG. 4 is a side view of a first embodiment of the belt caster wheel assembly;

[0014] FIG. 5 shows an embodiment of a continuous strip of a multitude of serially-connected lead-acid battery metal grid;

[0015] FIG. 6 is a sectional view of the first embodiment of the belt caster wheel assembly;

[0016] FIG. 7 is an enlarged view of a gas vent of the first embodiment of the belt caster wheel assembly;

[0017] FIG. 8 is another enlarged view of the gas vent of the first embodiment of the belt caster wheel assembly;

[0018] FIG. 9 is another enlarged view of the gas vent of the first embodiment of the belt caster wheel assembly;

[0019] FIG. 10 is a perspective view of an embodiment of a plug of the gas vent of the first embodiment of the belt caster wheel assembly;

[0020] FIG. 11 is a sectional view of the plug of the gas vent of the first embodiment of the belt caster wheel assembly;

[0021] FIG. 12 is a front view of another embodiment of a plug of the gas vent of the first embodiment of the belt caster wheel assembly;

[0022] FIG. 13 is a side view of the plug of the gas vent of the first embodiment of the belt caster wheel assembly;

[0023] FIG. 14 is an exploded view of a second embodiment of the belt caster wheel assembly;

[0024] FIG. 15 is an enlarged view of a gas vent of the second embodiment of the belt caster wheel assembly;

[0025] FIG. 16 is a perspective view of a ring segment of the second embodiment of the belt caster wheel assembly;

[0026] FIG. 17 is an enlarged view of a portion of the ring segment of the second embodiment of the belt caster wheel assembly;

[0027] FIG. 18 is a sectional view of the second embodiment of the belt caster wheel assembly;

[0028] FIG. 19 is an exploded view of a third embodiment of the belt caster wheel assembly;

[0029] FIG. 20 is a sectional view of the third embodiment of the belt caster wheel assembly;

[0030] FIG. 21 is an enlarged view of a pocket and of an insert of the third embodiment of the belt caster wheel assembly;

[0031] FIG. 22 is a sectional view of an embodiment of a gas vent of the third embodiment of the belt caster wheel assembly;

[0032] FIG. 23 is an enlarged view of another embodiment of a pocket and of an insert of the third embodiment of the belt caster wheel assembly;

[0033] FIG. 24 is a sectional view of a gas vent of the third embodiment of the belt caster wheel assembly;

[0034] FIG. 25 is an enlarged view of the gas vent taken from FIG. 24; and

[0035] FIG. 26 is an enlarged view of a vacuum end taken from FIG. 24.

DETAILED DESCRIPTION

[0036] With reference to the figures, embodiments of a battery component continuous casting machine 10 (hereafter, continuous casting machine) equipped with a belt caster wheel assembly 12 are shown and described herein. Battery components made by the continuous casting machine 10 and belt caster wheel assembly 12 can include lead-based metal grids for lead-acid batteries, as well as lead-based metal foils for bipolar batteries, among other possible components. The battery components, when made, are serially-connected in a continuous strip as they exit the continuous casting machine 10. Compared to previous approaches, the belt caster wheel assembly 12 is designed and constructed with active gas venting measures to more readily facilitate venting of gas present at a mold cavity of the belt caster wheel assembly 12 at the time of delivering molten lead or lead alloy to the mold cavity. Gas bubbles, voids, and/or other unwanted imperfections in the ultimately produced battery components observed in previous approaches and determined to be caused by gas trapped within the mold cavity are at least partly resolved or altogether precluded with the employment of the active gas venting measures of the belt caster wheel assembly 12. One or a multitude of gas vents are established to reside in the belt caster wheel assembly 12 and in fluid communication with one or more mold cavities therein, whereby, at the time of molten lead or lead alloy delivery to the mold cavity(ies), displaced gas can more easily escape the mold cavity(ies) by way of the gas vent(s). Therefore, desired and sought-after properties and metallurgic microstructure control of the produced battery components is more readily attained, such as imparted mechanical strength and structural integrity, corrosion resistance, creep resistance, and paste adhesion. Overall, a more effective and efficient continuous casting machine and process and procedure for battery component production is furnished, enhancing facilitation of commercial and mass production operations.

[0037] The continuous casting machine 10 can be employed in operation to continuously cast a continuous strip of a multitude of serially-connected lead-acid battery metal grids or a continuous strip of a multitude of axial serially-connected bipolar battery metal foils. With reference to FIG. 1, the continuous casting machine 10 can be part of a larger casting system and line that may further include a liquid and molten lead or lead alloy supply and delivery system 14 (hereafter, molten lead delivery system) equipped upstream of the continuous casting machine 10, and a coiling machine 16 equipped downstream of the continuous casting machine 10 (unless otherwise specified in a particular circumstance of usage, the terms upstream and downstream are used in this description with reference to the general direction of forward manufacturing progression of the battery components). With reference now to FIG. 3, the molten lead delivery system 14 serves to deliver molten lead or lead alloy ML to a mold cavity (introduced below) of the belt caster wheel assembly 12 via feed lines 18 and a feed head 20 during operation of the continuous casting machine 10. The coiling machine 16, on the other hand, serves to spool the continuous strip of battery components BC (FIG. 1) produced by the caster wheel assembly 12, whether the battery components BC are lead-based metal grids for lead-acid batteries or lead-based metal foils for bipolar batteries.

[0038] In general, the continuous casting machine 10 has been shown to produce battery components of metal composition exhibiting a desirably relatively small grain size, relatively uniform grain size, and a crystal morphology throughout the metal structure. It has been determined that these enhanced grain properties are due in part or more to the machines gravity-fed liquid lead or lead alloy delivery capabilities. The continuous casting machine 10 can have various designs, constructions, and components in various embodiments. In the embodiment of the figures, the continuous casting machine 10 includes as some of its primary components and assemblies the belt caster wheel assembly 12, a pair of rollers 22, a pair of temperature-controlled shoes 24, and a frame 26. Still, in other embodiments, the continuous casting machine could have more, less, and/or different primary components and assemblies. Examples of such continuous casting machines are set forth in U.S. Patent No. 12,138,681 with an issue date of November 12, 2024, assigned to the present applicant, the contents of which are hereby incorporated by reference herein in their entirety.

[0039] The belt caster wheel assembly 12 serves to continuously cast the continuous strip of the multitude of serially-connected lead-acid battery metal grids or the continuous strip of the multitude of serially-connected bipolar battery metal foils during operation of the continuous casting machine 10. The belt caster wheel assembly 12 is driven to rotate rapidly during operation by a drive motor (unshown) supported beneath a top wall 28 (FIG. 2) of the frame 26. The drive motor can be of the variable speed electric motor type, or another type, and can have its activation and deactivation and other parameters managed by a system controller such as a programmable logic controller (PLC). A gearbox can be equipped with the drive motor. The belt caster wheel assembly 12 is situated and supported atop the top wall 28 of the frame 26 adjacent the rollers 22 and adjacent the shoes 24. The belt caster wheel assembly 12 can have various designs, constructions, and components in various embodiments. In this embodiment, and with general reference to FIGS. 3, 4, and 6, the belt caster wheel assembly 12 includes a rotatable caster wheel 30 and a moveable belt 32; still, in other embodiments the belt caster wheel assembly 12 could include more, less, and/or different components.

[0040] The rotatable caster wheel 30 is directly driven to rotate during operation by the drive motor. In this embodiment, the rotatable caster wheel 30 is made-up of a cylindrical wall 34, a top wall 36, and a bottom wall 38. The top wall 36 and bottom wall 38 are affixed to the cylindrical wall 34 such as via bolting, and close the top and bottom ends of the cylindrical wall 34. Together, the cylindrical wall 34, top wall 36, and bottom wall 38 make a hollow cylindrically-shaped structure. An interior 40 resides at an inside of the hollow cylindrically-shaped structure and is defined by interior confronting surfaces of the cylindrical, top, and bottom walls 34, 36, 38. At an exterior surface 42 of the cylindrical wall 34, a mold cavity 44 resides wholly around a circumference of the cylindrical wall 34. The mold cavity 44 can itself constitute a region or more of the exterior surface 42 of the cylindrical wall 34. The mold cavity 44 serves to provide a negative space for accepting delivery of the molten lead or lead alloy ML via the molten lead delivery system 14 during operation of the continuous casting machine 10, and for ultimate formation of the continuous strip of battery components BC. The mold cavity 44 can be a single, uninterrupted mold cavity spanning wholly around the circumference of the cylindrical wall 34, and can be made-up of multiple individual grid or foil mold cavities situated one-after-another therearound. Because the mold cavity 44 receives delivery of the molten lead or lead alloy ML, the rotatable caster wheel 30 itself can experience increased heat conduction and increased temperatures. To manage thermal conduction and transfer at the rotatable caster wheel 30, the rotatable caster wheel 30 can be outfitted with a liquid-cooled assembly or an air-cooled assembly. In the liquid-cooled assembly, internal coolant passages can reside within the cylindrical wall 34 for recirculation of coolant fluid-flow such as water fluid-flow. In the air-cooled assembly, on the other hand, air can be circulated within the interior 40 of the rotatable caster wheel 30.

[0041] Depending on its intended production, the mold cavity 44 can be a grid mold cavity 46 or a foil mold cavity (unshown). Once solidified and upon exiting the belt caster wheel assembly 12, the grid mold cavity 46 forms the continuous strip of metal grids, and the foil mold cavity forms the continuous strip of metal foils. Initially, the strip of metal strips and foils are connected together, but are ultimately severed and separated downstream the continuous casting machine 10 into individual battery metal grids and individual battery metal foils. The battery metal grids and foils are typically planar and thin, and designed and constructed according to parameters of the battery in which they will be installed. The grid mold cavity 46 is depicted best in FIG. 4. Sections of the grid mold cavity 46 are engraved within cylindrical wall 34. The grid mold cavity 46, per this example embodiment, has a central grid wire section 48 with many horizontally-extending grid wire grooves and many vertically-extending grid wire grooves configured in a crisscrossing and intersecting arrangement. Bottom and top frame sections 50, 52 bound upper and lower extents of the central grid wire section 48, and side frame sections 54 bound side extents thereof. Further, each individual battery metal grid produced has a connector lug, and hence the grid mold cavity 46 has an associated lug section 56 for formation thereof. The molten lead or lead alloy ML flows to all of the central grid wire section 48, bottom and top sections 50, 52, side frame sections 54, and lug sections 56 for proper formation of the produced battery metal grids during operation of the continuous casting machine 10.

[0042] With reference now to FIG. 5, an example of an as-cast continuous strip of the multitude of serially-connected lead-acid battery metal grids 15 or elongated web is depicted. The battery metal grids 15 can be formed by use of the belt caster wheel assembly 12 and via the grid mold cavity 46. The battery metal grids 15 include multiple individual battery metal grids 17 that are connected together at this stage of processing, but are ultimately severed and separated prior to installation in a lead-acid battery. The grids 17 are typically flat, planar, and thin, and designed and constructed per parameters of the lead-acid battery in which they are installed. The grids 17 can be utilized for a positive plate (i.e., cathode) and a negative plate (i.e., anode) of an assembled lead-acid battery. In the example of FIG. 5, the battery metal grids 15 include connector lugs 19 provided for each grid 17. The battery metal grids 15 and each individual grid 17, per this example, have a multitude of horizontally-extending grid wires 21 and a multitude of vertically-extending grid wires 23 in a crisscrossing and orthogonal arrangement. The grid wires 21, 23 intersect one another at nodes, and open and empty spaces 25 reside among the grid wires 21, 23. A top frame wire 27 and a bottom frame wire 29 bound the associated extents of the battery metal grids 15 and each individual grid 17, and side frame wires 31 bound sides of each grid 17.

[0043] Still, the produced battery metal grids could have other designs, constructions, and arrangements in other examples; for instance, two sets of continuous strips connected in parallel could be cast concurrently, and/or the grid wires could have other arrangements such as an angular zig-zag pattern. Such alternatives will be appreciated by skilled artisans. Furthermore, a gate or runner system located adjacent a top end of the cylindrical wall 34 can be provided. When provided, the runner system fluidly communicates with the mold cavity 44 and serves to facilitate and ease the supply and delivery of the molten lead or lead alloy ML to the mold cavity 44. The runner system can include a series of elongated and axially-directed ribs with channels residing between neighboring ribs (unless otherwise specified in a particular circumstance of usage, the terms axial, radial, and circumferential as well as their grammatical variations are used in this description with reference to the generally cylindrical shape of the rotatable caster wheel). The channels can serve as flues for the flow of the molten lead or lead alloy ML.

[0044] With reference now to FIGS. 2 and 3, the moveable belt 32 moves in coordination with the rotatable caster wheel 30 and comes into confrontation with a moving circumferential working region CWR of the rotatable caster wheel 30 in order to continuously cast the continuous strip of the multitude of serially-connected lead-acid battery metal grids or the continuous strip of the multitude of serially-connected bipolar battery metal foils during operation of the continuous casting machine 10. The moveable belt 32 overlies the mold cavity 44 and can overlie the runner system (when provided), and is urged against the rotatable caster wheel 30 via the temperature-controlled shoes 24 in sealing engagement at the circumferential working region CWR where the molten lead or lead alloy ML is delivered to the mold cavity 44 and sufficiently downstream thereof for the molten lead or lead alloy ML to substantially solidify before the continuous strip of battery components BC exit the mold cavity 44. Movement of the rotatable caster wheel 30 drives movement of the moveable belt 32. In construction, the moveable belt 32 can possess a vertical and transverse width that is greater than the vertical and axial extent of the mold cavity 44 and the runner system. Further, the moveable belt 32 can be composed of a stainless-steel material, can be endless, and can be relatively thin and flexible in nature. In embodiments in which the moveable belt 32 moves at the same tangential speed as the rotatable caster wheel 30, there may be no relative movement between the moveable belt 32 and rotatable caster wheel 30; here, it has been found that friction is minimized or substantially lacking therebetween, and hence a lead antimony alloy with an antimony content of approximately three percent (3%) by weight, for example previously unavailable can be utilized as the material of the continuous strip of battery components BC. Still, in other embodiments, slight relative movement may exist between the moveable belt 32 and rotatable caster wheel 30 amid operation of the continuous casting machine 10.

[0045] With reference to FIG. 2, the rollers 22 serve to support continuous movement of the moveable belt 32 amid operation of the continuous casting machine 10, and are mounted on the top wall 28 of the frame 26. In this embodiment there are a total of two rollers a first roller 58 and a second roller 60; still, in other embodiments there could be other quantities of rollers such as four rollers or more or less. The first roller 58 is situated at an upstream side of the temperature-controlled shoes 24 with respect to a rotational direction RD of the rotatable caster wheel 30 during use of the continuous casting machine 10. The second roller 60, on the other hand, is situated at a downstream side of the temperature-controlled shoes 24 with respect to the rotational direction RD. The first and second rollers 58, 60 are journaled for rotation at their respective locations via associated shafts. Rotational movement of the first and second rollers 58, 60 is driven by the moveable belt 32.

[0046] With reference to FIGS. 2 and 3, the temperature-controlled shoes 24 serve to urge the moveable belt 32 into firm sealing engagement with the rotatable caster wheel 30 and, depending on their arrangement and type, can serve to promote full filling with the molten lead or lead alloy ML of the complete vertical extent of the circumferential working region CWR of the mold cavity 44 and/or can serve to promote rapid solidification of the molten lead or lead alloy ML in the mold cavity 44. There can be various quantities and arrangements of the shoes in various embodiments, and the shoes themselves can have various designs, constructions, and components in various embodiments. In the embodiment of FIGS. 2 and 3, a total of two shoes are provided a heating shoe 62 and a cooling shoe 64; still, in other embodiments there could be other quantities of shoes such as four shoes or more or less.

[0047] The heating shoe 62 can exhibit an arcuate front face for complementary confrontation with the rotatable caster wheel 30, and the cooling shoe 64 can likewise exhibit an arcuate front face for the same purpose. The heating and cooling shoes 62, 64 are situated immediately next to each other, with the heating shoe 62 positioned upstream relative to the cooling shoe 64 with respect to the rotational direction RD of the rotatable caster wheel 30, and hence the cooling shoe 64 positioned downstream relative to the heating shoe 62. The heating shoe 62 is situated at the site of molten lead or lead alloy supply and delivery between the rotatable caster wheel 30 and moveable belt 32 in order to aid complete filling with the molten lead or lead alloy ML of the circumferential working region CWR of the mold cavity 44 prior to solidification occurring. The molten lead or lead alloy ML can more readily make its way to a lower and bottom region of the mold cavity 44 with use of the heating shoe 62. The heating shoe 62 can be equipped with internal electric heating elements to generate increased heat within the heating shoe 62. The generated heat is, in turn, furnished from the heating shoe 62 and to the moveable belt 32 and to the circumferential working region CWR of the mold cavity 44 via the engagements thereamong. Conversely, to actively decrease the temperature of, and hence cool, the cooling shoe 64, liquid coolant supply and return lines can communicate with interior passages of the cooling shoe 64 for circulation therethrough.

[0048] The frame 26 serves to carry and support other primary components and assemblies of the continuous casting machine 10. The frame 26 can have various designs, constructions, and components in various embodiments, some of which may be dictated in part or more by the design and construction and components of the caster wheel assembly 12. With reference to FIG. 2, in this embodiment the frame 26 includes the top wall 28 and four structural legs 66. The rotatable caster wheel 30, moveable belt 32, first and second rollers 58, 60, and heating and cooling shoes 62, 64 are all supported and carried at the top wall 28, among other components and assemblies possibly situated thereon.

[0049] In some past approaches, it has been observed that gas bubbles, total voids, and/or other unwanted imperfections could arise in the structure of the produced battery components after casting. In the example of the continuous strip of battery metal grids, for instance, certain areas of its grid wires (e.g., horizontally-extending grid wires 21 and vertically-extending grid wires 23 in the example of FIG. 5) could possess gas bubbles and/or, in worse cases, could have a complete absence of grid wires in areas of intended wire production. Such unwanted imperfections have especially been observed at increased rotational speeds and runs of the associated caster wheel, and can be a cause of subsequent degradation in battery performance. The gas bubbles, voids, and/or other unwanted imperfections have been determined to be a consequence of gas trapped within an accompanying grid mold cavity by molten lead or lead alloy flow and fill therein that occurs at the time of delivery. Rather than being displaced by molten lead or lead alloy flow and escaping, gas remains and becomes trapped and can manifest as gas bubbles in the produced battery grids and/or, in worse cases, as voids at the grid wires. It has been found that most gas is displaced and escapes the grid mold cavity at a rearside RS (FIG. 2) thereof, as intended, upon delivery of molten lead or lead alloy. But in some circumstances, and especially at increased rotational speeds and runs, it has been determined that molten lead or lead alloy flows around the top and bottom and side frame sections of the grid mold cavity faster than it flows in the more centrally-located grid wire section, trapping gas at the grid wire section before the gas is able to escape via the rearside RS. The trapped gas can hence preclude and block thorough molten lead or lead alloy flow at certain areas of the gird wire section. Consequently, inadequate gas venting at the mold cavity has been found to be detrimental to the production of quality battery components.

[0050] To resolve these drawbacks, gas venting is introduced at the mold cavity 44 in the embodiments of the belt caster wheel assembly 12 described herein. Gas present at the mold cavity 44 at the time of molten lead or lead alloy delivery is displaced and able to escape the mold cavity 44 not only at the rearside RS but also at the introduced gas vent. Indeed, gas can escape via the rearside RS, via the gas vent, or via both the rearside RS and gas vent. The gas venting measures set forth herein are termed active (as well as grammatical variations thereof) in the sense that they are introduced with the intended purpose to vent gas that is displaced at the time of molten lead or lead alloy delivery to the mold cavity 44, or gas is otherwise incited to exit the gas vents, as described below; this contrasts with gas that exits at the rearside RS that is more passive in nature. Accordingly, it has been found that gas more readily escapes the mold cavity 44 and is inhibited or altogether precluded from becoming trapped with the employment of the gas vents herein. Molten lead or lead alloy more thoroughly flows within the mold cavity 44, even at increased rotational speeds and runs of the belt caster wheel assembly 12. The gas bubbles, voids, and/or other unwanted imperfections are prevented, and quality battery component production is more readily ensured.

[0051] The gas venting measures introduced can have various designs, constructions, and components in various embodiments depending on, among other possible factors, the design and construction and components of the accompanying belt caster wheel assembly and rotatable caster wheel and mold cavity. With initial reference to FIGS. 4 and 69, in a first embodiment a gas vent 68 more actively furnishes gas venting at the grid mold cavity 46, compared to that provided at the rearside RS. Gas present at the grid mold cavity 46 at the time of delivery of the molten lead or lead alloy ML to the circumferential working region CWR is displaced and able to escape via the gas vent 68 and via the rearside RS. In this embodiment, the gas vent 68 is situated adjacent the lug section 56 of the grid mold cavity 46. A vent inlet 70 (FIGS. 8 and 9) in which escaping gas is initially received at the gas vent 68 is located at the lug section 56. Here, all lug sections 56 of the grid mold cavity 46 are provided with a gas vent 68 and an accompanying vent inlet 70, as depicted best by FIG. 4. At this location, the gas vents 68 and vent inlets 70 have fluid and gas communication with the grid mold cavity 46 for accepting ready escape of displaced gas. The gas vents 68 are established within the structure of the cylindrical wall 34.

[0052] Referring now to FIGS. 811, in the first embodiment the gas vent 68 includes a plug 72 that is inserted and received in an opening 74 that itself resides in the cylindrical wall 34 of the rotatable caster wheel 30 at the lug section 56. The plug 72 constitutes a separable portion of the cylindrical wall 34, with an adjoining portion constituted adjacent the opening 74. The plug 72 and opening 74 can have various designs and constructions in various embodiments. Here, one or a multitude of vent clearances 76 are established between the plug 72 and the opening 74. The vent clearance(s) 76 forms and constitutes a part or more of the gas vent 68. The vent clearance(s) 76 can be established in different ways. In this embodiment, the vent clearance(s) 76 are formed by an intentionally non-flush fit between the plug 72 and opening 74 upon their engagement. An interface between the components lacks precise surface-to-surface contact, providing slight gaps at a boundary therebetween and via confrontation between an outside circumferential surface 78 of the plug 72 and an inside surface 80 of the opening 74. The plug 72 has a multitude of planar surface 82 around its outside circumferential surface 78, while the inside surface 80 of the opening 74 lacks corresponding planar surfaces and rather is more consistently cylindrical. This slight mismatch in shape between the components works to establish the vent clearance(s) 76 according to this embodiment.

[0053] There are a total of four planar surfaces 82 in the plug 72 of FIGS. 10 and 11, establishing four attendant vent clearances 76; still, other quantities are possible in other embodiments. For example, another embodiment of a plug 172 is presented in FIGS. 12 and 13; here, a total of twelve planar surfaces 182 are provided, establishing twelve attendant vent clearances. Referring back to the embodiment of FIGS. 10 and 11, the planar surfaces 82 span from a frontside 84 of the plug 72 to a rearside 86. The vent clearances 76 also span from the frontside 84 to the rearside 86. Between the frontside 84 and rearside 86, the plug 72 exhibits a tapered extent. In various examples, the vent clearances 76 can have a widthwise dimension taken between the inside surface 80 and planar surface 82 that ranges between approximately one-half thousandth of an inch (0.0005 inches) to three thousandths of an inch (0.003 inches), or could be approximately 0.0005 inches, 0.001 inches, 0.002 inches, or 0.003 inches. These dimensional values have been found to permit gas venting and yet prevent entry of the gravity-fed molten lead or lead alloy ML. It is currently thought that surface tension prevents entry of the gravity-fed molten lead or lead alloy ML. Still, other dimensional values are possible in other embodiments. Furthermore, in alternative embodiments the vent clearances could be established in other ways including via planar surfaces at the opening rather than at the plug or other non-flush fit or mismatched shape. Yet further, in an alternative embodiment, the plugs could be composed of a porous metal material such as a pressed powder or sintered metal.

[0054] Gas displaced and escaping the grid mold cavity 46 via the gas vent 68 can be led to the interior 40 of the rotatable caster wheel 30 and/or to an exterior 88 of the rotatable caster wheel 30. In the first embodiment, and referring to FIGS. 7 and 9, the gas escapes to the exterior 88. Here, the gas vent 68 includes a vent passage 90. The vent passage 90 has fluid and gas communication with the vent inlet 70 and vent clearance(s) 76, and has downstream fluid and gas communication with the exterior 88 (downstream is used in this context with reference to the direction of gas traveling through the vent from the vent inlet and to the exterior). The vent passage 90 can reside within, and be defined by, the cylindrical wall 34. The vent passage 90 spans axially and vertically downward through the cylindrical wall 34 toward the bottom wall 38, where it ultimately communicates with the exterior 88. The vent passage 90 can terminate at an open end or outlet 92 at the bottom end of the cylindrical wall 34. In this embodiment, the escaping gas is expelled to the exterior 88. In an alternative embodiment in which gas escapes to the interior 40 of the rotatable caster wheel 30, the vent passage 90 could span toward the interior 40 and communicate therewith.

[0055] Furthermore, in other embodiments, the escape of gas from the grid mold cavity 46 can be prompted and incited via application of a negative pressure at the gas vent 68. The negative pressure is with respect to ambient pressure at the grid mold cavity 46. Its application serves to facilitate the escape of gas by way of the gas vent 68, and can be carried out in various ways. Resistance to the flow of the molten lead or lead alloy previously observed in some circumstances with the gas present at the grid mold cavity 46 is minimized or altogether removed with the application of the negative pressure. With reference to FIG. 7, in an embodiment with negative pressure application, a vacuum is communicated with the vent passage 90. The vacuum subjects the vent passage 90 and the gas vent 68 to a partial vacuum and suction condition that draws gas from the grid mold cavity 46 and through the gas vent 68 and through the vent passage 90. In various examples, the negative pressure and partial vacuum condition can have a measurement that ranges between approximately 2 inches of mercury (inHg) and 10 inHg; still, other values are possible in other embodiments. In FIG. 7, a vacuum attachment end 94 is situated adjacent the rotatable caster wheel 30 and at the bottom end of the cylindrical wall 34, and provides communication with the vent passage 90. The vacuum attachment end 94 directly communicates with the open end 92 of the vent passage 90. A vacuum tube 96 (FIGS. 4 and 6) communicates with the vacuum attachment end 94 and leads from it. A vacuum pump 98 is equipped with the vacuum tube 96 and generates the partial vacuum condition in operation.

[0056] The vacuum attachment end 94, vacuum tube 96, and vacuum pump 98 remain static relative to the rotatable caster wheel 30 during operation of the continuous casting machine 10. In particular, the vacuum attachment end 94 is equipped at the rotatable caster wheel 30 and located adjacent the circumferential working region CWR where the molten lead or lead alloy ML is delivered to the mold cavity 44. At such location, the vacuum attachment end 94, vacuum tube 96, and vacuum pump 98 can communicate with the vent passage 90 and gas vent 68 associated with the grid mold cavity 46 subject to delivery of the molten lead or lead alloy ML. Communication via the vacuum attachment end 94 occurs vent-passage-to-vent-passage as the rotatable caster wheel 30 rotates. The negative pressure and partial vacuum condition is applied only to the grid mold cavity 46 accepting delivery of the molten lead or lead alloy ML and at the time of delivery, per this embodiment. Here, the vacuum attachment end 94 lacks a permanent mounting directly to the walls of the rotatable caster wheel 30 so that the rotatable caster wheel 30 can rotate free of the vacuum attachment end 94. Rather, the vacuum attachment end 94 is maintained in abutment with the bottom end of the cylindrical wall 34 without constraint thereto. Further, to minimize the generation of friction at an abutment interface between the bottom end of the cylindrical wall 34 and the vacuum attachment end 94 that could arise upon rotation of the rotatable caster wheel 30, a friction-reducing component and/or material can be furnished at the abutment interface. In various examples, a graphite component or material is provided at the vacuum attachment end 94 and/or at the bottom end of the cylindrical wall 34.

[0057] Furthermore, in embodiments in which the displaced and escaping gas is directed to the interior 40 of the rotatable caster wheel 30 via the gas vent 68, the negative pressure and partial vacuum condition could be applied through the interior 40. For instance, the vacuum pump and accompanying components could communicate with the interior 40, generating the partial vacuum condition at the interior 40 and hence drawing gas through the gas vent 68 and associated vent passage.

[0058] Turning now to FIGS. 1418, a second embodiment of the rotatable caster wheel is presented. In the second embodiment, certain corresponding components and elements are numbered similarly but with numerals 1xx when referring to this second embodiment. For example, the rotatable caster wheel is referenced by numeral 30 in the first embodiment, and is correspondingly referenced by numeral 130 in the second embodiment. Moreover, many similarities exist between the first embodiment and the second embodiment, some of which may not be repeated here in the description of the second embodiment. At least certain appreciable differences between the embodiments are described.

[0059] In the second embodiment, numerous gas vents 168 are established in a different manner than in the first embodiment. Here, the rotatable caster wheel 130 is divided and made-up of a multitude of ring segments a first ring segment 111, a second ring segment 113, a third ring segment 115, a fourth ring segment 117, and a fifth ring segment 119; still, other quantities of ring segments are possible in other embodiments. The ring segments are stacked and layered on top of one another in assembly and formation of a cylindrical wall 134, and ultimately forming the gas vents 168 too, as set forth below in more detail. Grid mold cavities 146 are segmented via the ring segments and fully formed when the ring segments are stacked together in assembly. The ring segments can be secured to one another when they come together and circumferentially aligned as intended for proper establishment of the grid mold cavities 146 by way of pegs 121 projecting axially from the ring segments that are inserted and received in associated holes (not shown) residing in opposed ring segments. The interengaged pegs 121 and holes serve to constrain relative circumferential and radial movement among the ring segments, keeping them in place once stacked. Further, the ring segments constitute separable portions of the cylindrical wall 134, with adjoining portions constituted by adjacent segments or portions of the cylindrical wall 134.

[0060] With continued reference to FIGS. 1418, in the second embodiment the gas vents 168 are established among the first, second, third, fourth, and fifth ring segments 111, 113, 115, 117, and 119, and more specifically between an immediately stacked pair of ring segments. A multitude of standoffs 123 can be situated at top and/or bottom surfaces 125, 127 of one or more or all of the ring segments 111, 113, 115, 117, and 119. The standoffs 123 are minimally raised structures with respect to the immediately contiguous surface at the top and/or bottom surfaces 125, 127. In various examples, the standoffs 123 can have a raised height and extent that ranges between approximately 0.0005 inches and 0.003 inches; still, other dimensional values are possible in other examples. Instead of flush surface-to-surface contact and seating between the ring segments and their top and bottom surfaces 125, 127 when brought together and stacked, slight gaps are provided via the standoffs 123, effectively establishing numerous vent clearances 176 among the ring segments. The standoffs 123 set the ring segments slightly apart from each other at the vent clearances 176. With particular reference to FIGS. 16 and 17, in this embodiment the standoffs 123 are arranged and located circumferentially around the ring segments and around the top surface 125 thereof. The standoffs 123 can be spaced equally apart from one another therearound, as shown. Further, the standoffs 123 extend between an exterior surface 142 of the cylindrical wall 134 and an interior surface 143 of the cylindrical wall 134.

[0061] With reference now to FIGS. 1518, the vent clearances 176 are established between neighboring standoffs 123 and span radially between the exterior surface 142 and interior surface 143 of the cylindrical wall 134. The vent clearances 176 have fluid and gas communication with the grid mold cavities 146 at the exterior surface 142, and have fluid and gas communication with an interior 140 of the rotatable caster wheel 130. Accordingly, gas displaced and escaping the grid mold cavity 146 via the vent clearances 176 and gas vents 168 is directed to the interior 140 of the rotatable caster wheel 130. When the rotatable caster wheel 130 is fully assembled, as depicted in FIG. 18, the multitude of vent clearances 176 are situated circumferentially all around the rotatable caster wheel 130 and the cylindrical wall 134, and are situated axially upward and downward within the extent of the grid mold cavities 146. In this embodiment, all of the grid mold cavities 146 exhibit fluid and gas communication with multiple vent clearances 176, although in an alternative embodiment each grid mold cavity could have fluid and gas communication with a single vent clearance. Furthermore, as before, the vent clearances 176 form and constitute a part or more of the gas vents 168.

[0062] The gas vents 168 and vent clearances 176 are situated at central grid wire sections 148 of the grid mold cavities 146 and, specifically per this embodiment, at horizontally-extending grid wires thereof. The gas vents 168 and vent clearances 176 within a single grid mold cavity 146 are set apart at different axial locations relative to one another. Vent inlets 170 of the gas vents 168 are located at the central grid wire sections 148. Moreover, as depicted best by FIG. 16, at least some side frame sections 154 of the grid mold cavities 146 can be intersected by the gas vents 168 and vent clearances 176, and hence can exhibit fluid and gas communication therewith. In this embodiment, every circumferential stratum of gas vents 168 and vent clearances 176 are arranged with their individual vents and clearances in axial and radial alignment with one another among the ring segments 111, 113, 115, 117, and 119 (see FIG. 18), but could be axially and radially offset with respect to one another in an alternative embodiment. Further, as before, the vent clearances 176 can have a widthwise dimension taken between the top and bottom surfaces 125, 127 that ranges between approximately one-half thousandth of an inch (0.0005 inches) to three thousandths of an inch (0.003 inches), or could be approximately 0.0005 inches, 0.001 inches, 0.002 inches, or 0.003 inches. These dimensional values have been found to permit gas venting and yet prevent entry of the gravity-fed molten lead or lead alloy ML. It is currently thought that surface tension prevents entry of the gravity-fed molten lead or lead alloy ML. Still, other dimensional values are possible in other embodiments.

[0063] Furthermore, per an embodiment, the escape of gas from the grid mold cavity 146 can be prompted and incited via application of a negative pressure and partial vacuum at the gas vents 168. As previously described with reference to the first embodiment, here, the negative pressure and partial vacuum condition could be applied through the interior 140. For instance, a vacuum pump and accompanying components could communicate with the interior 140, generating the partial vacuum condition at the interior 140 and hence drawing gas through the gas vents 168.

[0064] Furthermore, per an embodiment, to facilitate displacement of gas and its escape from the grid mold cavity 146, a slightly positive pressure of inert gas can be applied and provided to the grid mold cavity 146 immediately prior to the delivery of the molten lead or lead alloy ML to the grid mold cavity 146. The positive pressure is with respect to ambient pressure at the grid mold cavity 146, and the inert gas can be helium (He), as an example; still, other inert gases are possible in other examples. Resistance to the flow of the molten lead or lead alloy previously observed in some circumstances with the gas present at the grid mold cavity 146 is minimized or altogether removed with the provision of the positive pressure. The positive pressure of inert gas serves to displace gas otherwise present at the grid mold cavity 146 at the time of the molten lead or lead alloy ML delivery. Since certain inert gases, such as helium (He), are lighter in atomic weight and exhibit smaller molecule sizes than gas typically present at the grid mold cavity 146, it has been determined that the inert gas is more readily displaced and escapes the grid mold cavity 146 and hence its trapping by the molten lead or lead alloy ML is minimized or altogether precluded. The inert gas can escape via the rearside RS, via the gas vents 168, or via both the rearside RS and gas vents 168. Its implementation can be carried out in various ways.

[0065] With reference to FIG. 18, in an embodiment with positive pressure provision, a positive pressure generator 129 is communicated with the gas vents 168. The positive pressure generator 129 subjects the gas vents 168 to a positive pressure condition that expels gas from the grid mold cavity 146 previously present. In various examples, the positive pressure condition can have a measurement that ranges between approximately 2 inHg and 20 inHg; still, other values are possible in other embodiments. In FIG. 18, as an example, the positive pressure generator 129 is equipped at the rotatable caster wheel 130 and is provided in fluid and gas communication with the interior 140 thereof. The positive pressure generator 129 is furnished with a source and supply of the inert gas. Upon activation, a sudden blow or puff of inert gas is propelled from the positive pressure generator 129, through the interior 140, through the gas vents 168, and ultimately to the grid mold cavity 146. The inert gas travels in the opposite direction of escaping gas that can otherwise occur via the gas vents 168. Once at the grid mold cavity 146 which is merely momentary and upon the delivery of the molten lead or lead alloy ML and upon its displacement, the inert gas can reverse course and escape via the gas vents 168, via the rearside RS, or via both the gas vents 168 and rearside RS. Moreover, an ancillary benefit of the positive pressure provision is the reduction or full removal of dross that can otherwise form due to oxidation. Furthermore, this application and provision of positive pressure of inert gas can be implemented in embodiments described elsewhere in this patent, including in the first embodiment and alternatives thereof.

[0066] Turning now to FIGS. 19-26, a third embodiment of the rotatable caster wheel is presented. In the third embodiment, certain corresponding components and elements are numbered similarly but with numerals 2xx when referring to this third embodiment. For example, the rotatable caster wheel is referenced by numeral 30 in the first embodiment, and is correspondingly referenced by numeral 230 in the third embodiment. Moreover, many similarities exist between the first and second embodiments and the third embodiment, some of which may not be repeated here in the description of the third embodiment. At least certain appreciable differences between the embodiments are described.

[0067] In the third embodiment, numerous gas vents 268 are established in a different manner than in the first and second embodiments. Here, the rotatable caster wheel 230 includes a multitude of inserts 231 that are received in a multitude of complementary pockets 233 residing in a cylindrical wall 234 of the rotatable caster wheel 230. The inserts 231 and pockets 233 exhibit elongated oval shapes that are arranged with their long extents and major axes in an axial direction; still, other shapes and arrangements are possible in other embodiments. The inserts 231 and pockets 233 are situated at central grid wire sections 248 of grid mold cavities 246 and inboard of respective top, bottom, and side frame sections thereof. Indeed, at their exterior surfaces, individual inserts 231 have portions of the central grid wire sections 248 with the accompanying horizontally- and vertically-extending grid wires. The inserts 231 are inserted and received in the pockets 233 in assembly and formation of the cylindrical wall 234, and ultimately forming the gas vents 268 too. The reception and insertion can be by press-fitting the components firmly together. The grid mold cavities 246 and the central grid wire sections 248 are fully formed when the inserts 231 are set in place within the pockets 233. Further, the inserts 231 constitute separable portions of the cylindrical wall 234, with adjoining portions constituted by surrounding portions of the pockets 233 and of the cylindrical wall 234.

[0068] With specific reference to FIGS. 19 and 21, in the third embodiment the gas vents 268 are partly established among the inserts 231 and pockets 233 when inserted and received together. A multitude of standoffs 223 can be situated at side surfaces 235 of each of the inserts 231, while the confronting side surfaces of the pockets 233 lack corresponding structures and rather are more consistently smooth in nature; still, in other embodiments the standoffs could be situated at the pocket side surfaces instead of the insert side surfaces. In this embodiment, a pair of standoffs 223 are located at each side surface 235 of each insert 231. As before, the standoffs 223 are minimally raised structures with respect to the immediately contiguous surface of the side surfaces 235. In various examples, the standoffs 223 can have a raised height and extent that ranges between approximately 0.0005 inches and 0.003 inches; still, other dimensional values are possible in other examples. Thereby, instead of flush surface-to-surface contact and seating between the inserts 231 and respective pockets 233 when brought together, slight gaps are provided via the standoffs 223, effectively establishing numerous vent clearances 276 among the inserts 231 and pockets 233. Further, the standoffs 223 extend wholly radially along the side surfaces 235. With reference now to FIGS. 21 and 22, like the standoffs 223, the vent clearances 276 span wholly radially over the side surfaces 235 from the exterior surfaces of the inserts 231 to backsides 237 thereof. The vent clearances 276 have fluid and gas communication with the grid mold cavities 246 at an exterior surface 242 thereof, and have downstream fluid and gas communication with a vent spacing 239 (FIG. 22) established at a confrontation between the backside 237 and a frontside 241 of the pockets 233. The vent spacing 239 is a slight radial gap that resides and is defined between the backsides 237 of the inserts 231 and the frontsides 241 of the pockets 233.

[0069] In this embodiment, all of the grid mold cavities 246 exhibit fluid and gas communication with multiple vent clearances 276. Further, as before, the vent clearances 276 form and constitute a part or more of the gas vents 268. Vent inlets 270 of the gas vents 268 are located at the central grid wire sections 248. Lastly, the vent clearances 276 can have a widthwise dimension taken between respective side surfaces of the inserts 231 and pockets 233 that ranges between approximately one-half thousandth of an inch (0.0005 inches) to three thousandths of an inch (0.003 inches), or could be approximately 0.0005 inches, 0.001 inches, 0.002 inches, or 0.003 inches. These dimensional values have been found to permit gas venting and yet prevent entry of the gravity-fed molten lead or lead alloy ML. It is currently thought that surface tension prevents entry of the gravity-fed molten lead or lead alloy ML. Still, other dimensional values are possible in other embodiments.

[0070] Gas displaced and escaping the grid mold cavity 246 via the gas vents 268 can be led to an interior 240 of the rotatable caster wheel 230 and/or to an exterior 288 of the rotatable caster wheel 230. In the embodiment of FIGS. 19-22, the gas escapes to the interior 240. Here, the gas vents 268 include vent passages 290. The vent passages 290 have fluid and gas communication with the vent inlets 270, vent clearances 276, and vent spacings 239, and has downstream fluid and gas communication with the interior 240. Each of the pockets 233 has a pair of vent passages 290 leading from it. As depicted perhaps best by FIG. 21, the pockets 233 each have a vent passage 290 at an upper region thereof and at a lower region thereof. The vent passages 290 can reside within, and be defined by, the cylindrical wall 234. Furthermore, and with specific reference now to FIG. 22, the vent passages 290 span radially wholly through the cylindrical wall 234 from the pockets 233 and to the interior 240. Inlets of the vent passages 290 reside at the vent spacings 239 and outlets of the vent passages 290 reside at the interior 240. In this embodiment, the escaping gas is expelled to the interior 240.

[0071] Furthermore, per an embodiment, to facilitate displacement of gas and its escape from the grid mold cavity 246, a slightly positive pressure of inert gas can be applied and provided to the grid mold cavity 246 immediately prior to the delivery of the molten lead or lead alloy ML to the grid mold cavity 246. As previously described with reference to the second embodiment, here, the positive pressure condition can be applied through the interior 240. For instance, as depicted in FIG. 20, a positive pressure generator 229 can propel a puff of inert gas through the interior 240, through the vent passages 290, through the vent spacings 239, through the vent clearances 276, and ultimately to the grid mold cavity 246.

[0072] In an alternative of the third embodiment, gas displaced and escaping the grid mold cavity 246 is led to the exterior 288 of the rotatable caster wheel 230. This alternative is presented in FIGS. 23-26. Here, the vent passages 290 have downstream fluid and gas communication with the exterior 288, rather than with the interior 240 as described in connection with FIGS. 19-22. Each pocket 233 has fluid and gas communication with a single vent passage 290. Inlets of the vent passages 290 are situated and located at side surfaces 245 of the pockets 233 and, more specifically, at a lowermost region of the side surfaces 245 as perhaps depicted best by FIG. 23. With reference now to FIGS. 24 and 25, at and near the vent passage inlets, the inserts 231 have narrowed ends that provide expanded vent spacings 247. The expanded vent spacings 247 are open to, and have direct fluid and gas communication with, the vent passages 290. Providing the expanded vent spacings 247 can facilitate flow of gas through the vent passages 290. The vent passages 290 can reside within, and be defined by, the cylindrical wall 234. The vent passages 290 span axially and vertically downward through the cylindrical wall 234 toward a bottom wall 238. The vent passages 290 can terminate at an open end or outlet 292 at the bottom end of the cylindrical wall 234.

[0073] Furthermore, per an embodiment and with reference to FIGS. 24 and 26, the escape of gas from the grid mold cavity 246 can be prompted and incited via application of a negative pressure and partial vacuum at the gas vents 268. As previously described with reference to the first embodiment, here, the negative pressure and partial vacuum condition could be applied through the interior 240. For instance, a vacuum attachment end 294 can be situated at the bottom end of the cylindrical wall 134 in selectively fluid and gas communication with the vent passages 290. A vacuum tube 296 can communicate with the vacuum attachment end 294. And a vacuum pump 298 can be equipped with the vacuum tube 296. The partial vacuum condition generated by the vacuum pump 298 draws gas from the grid mold cavity 246, through the gas vents 268, through the vent clearances 276, through the vent spacings 239, through the expanded vent spacings 247, and through the vent passages 290. Further, as described previously, a friction-reducing component and/or material can be furnished at an abutment interface between the cylindrical walls bottom end and the vacuum attachment end 294.

[0074] In general, while a multitude of embodiments have been depicted and described with a multitude of components and steps in each embodiment, in alternative embodiments of the belt caster wheel assembly and accompanying method the components and steps of various embodiments could be intermixed, combined, and/or exchanged for one another. For example, the negative pressure described in connection with FIG. 7 can be employed in other embodiments described. In other words, components and/or steps described in connection with a particular embodiment are not necessarily exclusive to that particular embodiment.

[0075] As used herein, the terms general, generally, approximately, and substantially are intended to account for the inherent degree of variance and imprecision that is often attributed to, and often accompanies, any design and manufacturing process and measurement, including engineering tolerances, and without deviation from the relevant functionality and intended outcome, such that mathematical precision and exactitude is not implied and, in some instances, is not strictly possible. In other instances, the terms general, generally, approximately, and substantially are intended to represent the inherent degree of uncertainty that is often attributed to any quantitative comparison, value, and measurement calculation, or other representation, such that mathematical precision and exactitude is not implied and, in some instances, is not strictly possible.

[0076] It is to be understood that the foregoing description is not a definition of the invention, but is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

[0077] As used in this specification and claims, the terms for example, for instance, and such as, and the verbs comprising, having, including, and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

[0078] Those of skill in the art will understand that modifications (additions and/or removals) of various components of the substances, formulations, apparatuses, methods, systems, and embodiments described herein may be made without departing from the full scope and spirit of the present disclosure, which encompass such modifications and any and all equivalents thereof.