Patent ID: 7635537

Claim:
A lead acid storage battery, comprising: (a) a plurality of cells, each cell including alternating positive and negative plates at least partially submerged in acid electrolyte, each plate including an upstanding lug; (b) partitions for separating adjacent cells; (c) at least one lightweight connector, comprising: (i) at least one cell plate connector for electrically connecting the plates of a cell including a prefabricated tray formed by a bottom wall and a plurality of opposed side and end walls, the bottom wall having a plurality of spaced slots therein for receiving therethrough the lugs from either the positive or negative plates of the cell, the lugs projecting upwardly above the bottom wall a prescribed distance; (ii) a strap extending from an upper edge of one of the side and end walls of the cell plate connector; (iii) the cell plate connector and the strap being formed of a metal substrate that has a lower specific gravity and higher conductivity than lead, the bottom walls, sidewalls, and end walls of the tray and the straps being covered by a lead-based outer coating that resists the corrosive effects of the battery acid; and (iv) a lead-based material deposited in the tray around the lugs to a depth of between 0.05 inches and 0.50 inches to bond the lugs therein.