Battery manufacturing process

Manufacturing steps of lead acid batteries:

 Batteries are manufactured using carful maintenance of equipments in automated
controlled environment. Manufacturing processes can be divided into several
stages.
 OXIDE AND GRID PRODUCTION PROCESS
 PASTING AND CURING
 ASSEMBLING THE ELEMENTS
 FILLING AND FORMATION
 CHARGING AND DISCHARGING
1. Oxide and Grid Production Process:
Lead Oxide Production

Lead oxide is obtained by masses of lead from melting furnaces either by Milling or Barton
Pot process methods. In the milling process, the tumbling action generated by the rotating
mill on solid lead generates heat and then the surface of the lead gets oxidized. The surface
layers of the oxide are removed while the lead particles roll in the drum. In Barton Pot
process a fine stream of lead droplets is produced by blowing air on molten lead. These
droplets are reacted with oxygen and produce lead oxide.

Casting and stamping methods are generally used for making battery grids. In casting
method, the lead alloy slabs are melted in melting pot and this molted lead is poured into the
patterns of battery grids whereas stamping operation produces on battery grids based on
stamping on lead sheets. When these grids are cooled after casting operation, these are passed
to trimming machine where rough edges and casting gates are trimmed.
Grid Casting Process

2. Pasting and Curing:

Battery Plates after Pasting and Curing

Manufacturers consider the pasting material as a trade secret, and therefore not reveal this to
public. However, this paste material in general is made with oxide of lead, red lead, litharge,
water and dilutes sulphuric acid. These pastes are used to fill the grids, i.e., positive and
negative grids; but, for both, the pastes are not exactly filled with the same material, some
expander materials are added for making negative paste.

The paste is then forced or pressed on the interstices of the grids by a machine or by hand,
and then these are turned as plates. These pasted plates are cured in ovens under certain
conditions of temperature near 32 degree centigrade for about 48 hours, with humidity
nearing about 90 percent and are finally allowed to dry condition at ambient temperatures.

3. Assembling the Elements:

Battery Plates Stacking
In this process, all the parts are assembled into a battery case and covered with the plastic
moulds plastic molding plant. This step involves the formation of positive and negative plate
stacks, insertion of separators, inter-cell connector and plate burning. In this step positive and
negative plates are formed like groups which are strapped to a suitable rack, slipped together
and a separator is inserted in-between them. This separator is made up of non-conductive
material such as paper, plastic or a glass fiber.

During the burning operation each positive and negative plate tab is welded to lead to
produce an element and these are then welded to respective positive and negative posts on the
battery’s case top. After keeping this element in the jar or case, sealing compound is applied
to make the space leak proof between the battery jar and cover.

4. Filling and Formation:

Filling Battery with Electrolyte

After the assembling, battery jar is filled with required amount of electrolyte through a filling
or vent tube. Then, it is ready for initial charging, which may require several hours of
charging depending on the battery size. Low charging rate is generally employed that may be
nearly one day to several days. This charge formation may either be dry or wet. In a dry-
formation method, batteries are shipped as dry after the positive and negative elements are
fully charged or formed and dried in tanks or as an individual plates and are connected to
positive and negative terminals of the battery. In a wet-formation method, a battery undergoes
initial charging for several hours after plates are immersed in an electrolyte battery case.
And, in some cases, this acid is dumped and fresh acid is added after forming it.

Formation Process

5. Charging and Discharging:

Charging and Discharging Process

After the formation, batteries are subjected to high-rate discharge test for short duration to
rule out any defects before sending them out to the final charge. After discharging and
recharging batteries for several times to attain best working condition, these are inspected and
tested with some measuring instruments.

Then finally these are recharged for certain backup hours and sent to the next level where
additional connections, labeling and caps are inserted to battery with sealed-cotton packing.
At last, these are dispatched to ordered places.