Conventional lead-acid batteries are relatively heavy and thus have a low specific energy. Therefore, to improve the energy density, a lighter grid has been proposed. In this work, a novel lead-acid battery with high specific surface area negative foam current collectors was designed and constructed. The collectors were studied by cyclic voltametery (CV) and electrochemical impedance spectroscopy (EIS). The foam collectors were designed and suitable paste composition and formation algorithm was obtained. The basic cells were manufactured and its performance was evaluated. The results showed that the foam grids resistance was lower than that for lead grids and the specific surface area of the foam grids was very greater than lead grids. The foam battery has good discharge characteristics compared with common lead-acid batteries. The discharge curve was flat and negative mass utilization efficiency was higher than 50% when the cell was discharged with C5/5 A (137 Ah kg(-1) negative active materials). The foam grids were used as negative electrode for various types of lead-acid batteries such as 60 Ah starter battery, 2, 3 and 10 Ah VRLA batteries. The batteries with foam grids were shown longer cycle life than conventional lead-acid batteries. (c) 2005 Elsevier B.V. All rights reserved.