The lead grid in a lead acid battery serves two main purposes. It provides mechanical support for the active material. It also helps in the flow of electrons produced during the electrochemical reaction in the…
How it is Made: The Lead Acid Battery Part VI
Lead grid for lead-acid battery
The lead grid in a lead-acid battery serves two main purposes. First and foremost, it provides essential mechanical support for the active material, ensuring stability and durability. In addition to this, it plays a crucial role in facilitating the flow of electrons generated during the electrochemical reaction. As a result, the lead grid contributes significantly to the overall efficiency and functionality of the lead-acid battery, making it an essential part of the Lead Grid system.
The final use of the battery determines the different types of grids.
1. casting grid with shell mould;
2. continuous casting grid;
3. grid obtained with expansion systems (rolling strip);
4. grid obtained with punching systems (rolling strip);
5. grid obtained with die-casting systems.
CASTING LEAD GRID WITH SHELL MOULD
To obtain the desired product, workers carefully pour liquid lead into a shell mould. Since they thermally control the mould and equip it with extractors, this method efficiently shapes the lead, which is essential for producing a high-quality Lead Grid. Additionally, it allows for the production of different grid shapes at a relatively low cost, making it a practical choice for lead-acid batteries.
Notably, this process can produce a wide variety of grids, which are essential components in applications such as automobiles, electric traction systems, and uninterruptible power supplies. However, because the process is manual, it results in lower machine performance compared to fully automated methods. While the overall product quality is satisfactory, there is still room for improvement to enhance consistency and durability.
By optimizing the manufacturing process, it would be possible to achieve higher efficiency, better product quality, and greater scalability. Consequently, this could lead to improved performance in various applications that rely on these Lead Grids.
CONTINUOUS CASTING LEAD GRID
A drum surface is first carved to create a precise grid shape. Once the structured surface is ready, workers carefully apply liquid lead, ensuring it flows into the carved cavities. Afterward, they scrape off the excess material, leaving only the thread cavities filled with lead. Following this, they allow the material to cool and solidify. Once the lead has duly cooled down, it forms a strong and well-defined Lead Grid, completing the process effectively.
This system provides a cheap, but poor quality product. The so-called rotary cast system can be mainly used for the production of negative plates in a lead-acid battery.
GRID OBTAINED WITH EXPANSION SYSTEMS
This grid is created by stretching a strip that originates from a rolling mill. Notably, it has the capability to produce both positive and negative grids. Since the grid undergoes a stretching process, it lacks side frames, which in turn makes it somewhat weak. However, despite this limitation, it remains suitable for manufacturing medium-quality batteries in the Lead Grid industry. Specifically, it is often used in lead-acid battery configurations, where its structural properties are still sufficient to ensure reliable performance.
GRID OBTAINED WITH PUNCHING SYSTEMS
The process begins with punching a strip that matches the width of the grid. While the system is highly valuable, it is also quite costly. There are two primary reasons behind its high cost. First, the strip production system itself is quite large, requiring significant resources and infrastructure. Second, the process generates a substantial amount of material waste, and the team must recycle it, further adding to the overall expenses.
However, despite these costs, the final product is of exceptional quality. The strip’s high crystalline density and the grid’s perfect shape, achieved through precise moulding, primarily contribute to this premium quality. As a result, manufacturers widely use these high-quality Lead Grids to produce positive plates for high-end lead-acid batteries, where superior performance and durability are essential.
GRID OBTAINED WITH DIE-CASTING SYSTEMS
A die-casting system makes this grid by pumping molten lead into a closed mould at high speed and pressure. A press keeps the mould closed. The lead fills the structure under high-pressure conditions, thereby achieving greater compactness in its crystalline form. As a result, the grid’s resistance to the corrosion process is significantly higher. Subsequently, the active material envelops it, and a special container securely holds it in place. Ultimately, the final product may not perform as efficiently as the standard version of a lead-acid battery. Nevertheless, when considering charging cycles in a Lead Grid application, it will exhibit a much longer lifespan.
ERNEST VOLCKMAR AND THE SPEEDBOAT ON THE THAMES
In 1882, Ernest Volckmar, a scientist, made headlines. He was on a mission related to
lead-acid batteries. Volckmar was the first person to suggest using a Lead Grid in these
batteries. This idea received a lot of media attention. He worked with engineers Messers and Sellon. Together, they developed a new version of Planté’s accumulator. They used the new Siemens Dynamos for help. With this technology, they built the first electric boat. This boat could handle the stress of navigation.
Additionally, to stay updated with the latest developments in STEM research, visit ENTECH Online. Basically, this is our digital magazine for science, technology, engineering, and mathematics. Furthermore, at ENTECH Online, you’ll find a wealth of information.
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Until 2023, Dr. Charudatta S Pathak held multiple academic positions, including lecturer, assistant professor, professor, dean, principal, director, and vice chancellor at public and private universities across India. From 2008 to 2010, he held the position of project lead in the CAE department at a European multinational corporation. Throughout his 28-year professional experience, he observed a requirement for reliable publications aimed at youngsters in grades 8 to 12, specifically for early-stage career planning. He initiated the establishment of ENTECH Digital Magazine, a complimentary periodical released on a monthly basis, accessible via stemconference.in and magzter.com. Teenagers with a keen interest in Science, Technology, Engineering, and Mathematics (STEM) and aspiring to pursue professional paths in these domains can consider reading ENTECH Digital Magazine.