Method of welding a arc battery intercell connector

The process of assembling a multicell, lead-acid storage battery comprising the steps of:

• forming a case having a plurality of partitions subdividing the case into a plurality of individual cell compartments, said partitions having apertures therein adapted to receive battery intercell connectors for electrically series interconnecting the several cells of the battery;
• assembling a cell group for each of said compartments, said group comprising a stack of alternating positive and negative plates, a positive plate strap electrically joining the positive plates together, a negative plate strap electrically joining the negative plates together and upstanding lugs on said plate straps, wherein pairs of said lugs are adapted by fusion to electrically join the plate straps of adjacent groups through the apertures in the partitions and wherein one lug member of each lug pair has a substantially flat face on its partition-abutting side and the other lug member of each pair has a cavity formed in its partition-abutting side;
• inserting said groups in said cell compartments such that the lugs of each pair overlie said aperture on opposite sides of said partition and so as to have said cavity in substantial axial alignment with said aperture;
• orienting said case such that said other lug member lies beneath said one lug member and the partition positioned therebetween;
• applying the arc of an inert-gas-shielded, nonconsumable-electrode, arc welding torch to the backside of said one lug member such as to fuse through substantially only the center of said lug member and to cause the melt therefrom to flow by gravity through said aperture into said cavity in sufficient quantity to substantially fill said cavity and said aperture;
• inverting said previously oriented case and applying the arc of an inert-gas-shielded, nonconsumable-electrode, arc welding torch to the backside of said other lug member such as to fuse through substantially only the center thereof and weld it to the one lug material filling the cavity;
• and
• squeezing the lugs together to form a substantially fluid-tight intercell connector through said aperture.