METHOD OF CONSTRUCTING A BATTERY CONNECTOR

A method is disclosed for producing through-the-partition battery intercell electrical connections. Flat surfaced connector lugs are placed on each side of a battery partition wall, adjacent an aperture. The connector lugs are each cold formed by a pair of opposed electrodes under the application of high shear force sufficient to extrude the lugs into the aperture until they meet. The high initial shear force on the electrodes then is reduced to a lower secondary shear force, and an electrical welding current is then applied. The welding current is increased as the metal-to-metal contact of the opposed connector lugs increases until the welded connector lugs fills the aperture with metal. The welding current then ceases and the welded connector lugs are allowed to cool while still under the lower secondary shear force. The electrodes are removed from connection and the battery casing, containing liquid-tight intercell battery connections, is ready for further manufacturing or assembling steps.