Engineers faced an important question, as lead-acid batteries became popular. Searchers for longer-lasting solutions wondered how batteries could last longer without losing performance…
The Answer Came Through Decades Of Improvements
The answer to the search for longer-lasting lead batteries came through decades of improvements in materials, plate design and manufacturing techniques.
One common cause of battery failure was shedding. During repeated charging and discharging, some of the active material gradually loosened from the plates. The particles collected at the bottom of the battery, reducing the amount of material available to store energy.
As Corrosion Spread The Grid Weakened And Failed
Grid corrosion was another challenge. The positive grid operated in a highly acidic environment and slowly corroded over time. As corrosion spread, the grid weakened and could eventually fail, even if active material remained.
Engineers Improved Battery Life With Stronger Lead Alloys
Engineers improved battery life by developing stronger lead alloys. Adding small amounts of antimony, calcium, selenium and other elements made grids more resistant to corrosion while maintaining their strength. Different alloys evolved for different battery applications.
Plate design also improved. Better grid patterns supported active material more effectively and reduced the chance of shedding. Tubular plates, introduced for deep-cycle batteries, held active material inside porous tubes, making them especially durable.
Separators Prevented Positive And Negative Contact
Manufacturers improved separators as well. Stronger separators prevented the positive and negative plates from touching while allowing acid to move freely between them.
Better charging methods also extended battery life. Overcharging and deep discharging were found to damage batteries, so charging systems became more carefully controlled, particularly in motor vehicles.
The Result Was a Series Of Gradual Improvements
The result was a series of gradual improvements rather than one dramatic invention. Each advance reduced one cause of battery failure and made batteries more dependable.
More Information
