The new “S-T-A-R” battery design takes advantage of the properties of thermoplastics in manufacturing a superior battery having the shortest practical electrical path. The injection-molded three-piece construction provides a lighter, stronger battery case and the new design concept adapted to automated assembly provides increased resistance to vibration and improved starting power. The new design concept coupled with automatic assembly also makes possible improved quality assurance, a most important factor in meeting the cost effectiveness and uniformity objectives originally conceived.
This paper describes such key elements of the design as the fastening of molded-in intercell connectors, molded-in high-profile bushings and terminal posts, and the three-piece construction. The automated assembly operation is described in detail, with individual treatment of sleeve-group assembly, group positioner, heat-sealing reservoirs, first leakage tester, plate lug fusion to sleeve inserts, electric shorts testing, heat-sealing covers, post fusion, and final leakage tester.