Abstract: A method for making a plurality of lead-acid cells requiring a constant width, a height varying from a maximum to a minimum to accommodate plates of varying height and a cell depth to accommodate a minimum to a maximum number of plates is disclosed which utilizes blow molding to form a jar precursor which is cut to the height desired, and, in its preferred aspects, including use of a mold and insert sets which simplify tooling and change-over time, as well as a cover and jar design which simplifies the heat sealing of these components.

Abstract: A method for making a family of lead-acid cells requiring a constant width, a height varying from a maximum to a minimum to accommodate plates of varying height and a cell depth to accommodate a minimum to a maximum number of plates is disclosed which utilizes blow molding to form a jar precursor which is cut to the height desired, and, in its preferred aspects, including use of a mold and insert sets which simplify tooling and change-over time, as well as a cover and jar design which simplifies the heat sealing of these components.

Abstract: A method for making a molded plastic component for a bipolar battery, such as a lead-acid battery, comprises molding a plastic frame about a thin electrically conductive substrate, embedding the periphery of the substrate in the plastic frame and then removing the warpage resulting from the molding by a suitable surface reformation step, as by die stamping, to restore a surface that will allow desirable electrical performance to be achieved when the bipolar battery is used in service.

Abstract: A method of fabricating a modular, recombinant lead-acid battery is provided for. The method includes providing a plurality of thermoplastic frames, including at least two frames which support electrochemically active plates. The frames are adapted to be stacked and welded together such that the plates are spaced apart from each other a predetermined distance. One or more separators also are provided. The separators have an uncompressed state in which their thickness is equal to or greater than the predetermined distance between plates and a compressed state. The frames and separators are stacked such that a separator is disposed between adjacent plates in its compressed state. The frames then are successively vibration welded together, again while the separator is in its compressed state. The separator has a predetermined thickness in its compressed state effective to reduce damage to the separator caused by abrasion of the separators by the plates during vibration welding.