Seven details of lead-acid batteries determine the quality of products

Time：2025-03-26 10:01:07

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Lead-acid batteries seem simple, but their quality is determined by plate material, electrolyte, partition, shell, welding, assembly and detection.

In the field of energy storage, lead-acid batteries, with their low cost, mature technology, stable high and low temperature performance and other characteristics, are widely used in car start-up, communication base station backup power, electric bicycle power and many other scenarios. However, seemingly similar specifications of lead-acid batteries, the actual quality is uneven. Dig deeper and you will find that the quality of a product is often determined by seven key details.

## Plate purity and structural design

Plate is the core component of lead-acid battery, and its material purity directly affects the battery performance. The high purity lead alloy plate can effectively reduce the side reaction caused by impurities, reduce the self-discharge rate, and improve the storage performance of the battery. For example, the use of more than 99.99% pure lead made of the plate, compared with slightly lower purity products, after one month of idle, the power loss can be reduced by 20%-30%. Plate structure design is also key, a reasonable grid, grid structure, can increase the contact area between the active substance and the electrolyte, improve the efficiency of electrochemical reaction. Some advanced design of the plate, by optimizing the grid bar layout and thickness, so that the battery's large current discharge capacity increased by 15%-20%, to meet the car instant start, high power operation of power tools and other needs.

## Electrolyte concentration and mass stability

Electrolyte is responsible for conducting ions in lead-acid batteries, and its concentration has a significant effect on battery performance. The appropriate concentration of sulfuric acid can ensure that the electrochemical reaction is fully carried out to achieve the best charging and discharging effect. In general, under the fully charged state, the standard proportion of lead-acid battery electrolyte for electric vehicles is about 1.280 (20 ° C), and too much deviation will lead to a decrease in battery capacity. In addition to the concentration, the quality stability of the electrolyte can not be ignored. The high-quality electrolyte should have good anti-volatilization and anti-pollution ability, reduce water evaporation and impurity mixing, and maintain long-term stable ion conductivity. Some high-quality electrolyte by adding special additives, water evaporation rate can be reduced by 30%-40%, to ensure the reliable operation of the battery in high temperature, high humidity and other harsh environments.

## Partition performance is good or bad

The separator is located between the positive and negative plates, and although it seems insignificant, it has a profound impact on the quality of the battery. High-quality partitions need to have good ion permeability to ensure that ions in the electrolyte can pass smoothly, while having excellent insulation to prevent short circuit of positive and negative plates. The microporous separator made of advanced materials has uniform pore size distribution, high porosity and low ion transmission resistance, which can effectively improve the charge and discharge efficiency of the battery. Moreover, the chemical stability of the separator is crucial, and it will not be corroded and dissolved in a long-term acidic electrolyte environment to ensure the battery life. For example, high-performance fiberglass partitions can withstand tens of thousands of charge and discharge cycles, significantly extending battery life.

## Shell material and tightness

The battery shell not only plays a role in protecting the internal structure, but its material and tightness also have an important impact on battery performance. Strong, impact-resistant housing materials, such as high-strength engineering plastics, can effectively resist external impact and avoid damage to the internal plate. At the same time, good sealing prevents electrolyte leakage and outside air entry. For batteries with poor sealing performance, the electrolyte is easy to dry up, resulting in increased internal resistance and decreased capacity; The entry of outside air will also accelerate plate oxidation and shorten battery life. Through the use of advanced sealing technology and high-quality sealing rubber rings, high-quality lead-acid batteries can ensure that under extreme vibration, tilt and other conditions, there is still no electrolyte leakage, maintain stable performance.

## Precision of welding process

The welding quality between plates is directly related to the conductivity and reliability of the battery. Fine welding works ensure low resistance and high mechanical strength at the connection site. The use of advanced laser welding, ultrasonic welding technology, can make the solder joint uniform, firm, reduce the risk of virtual welding, welding. Poor welding quality will lead to increased internal resistance of the battery, and serious local heating during charging and discharging, which not only reduces the performance of the battery, but also has safety risks. Research shows that the proportion of early battery failure caused by welding problems is as high as 10%-15%, and fine welding technology can reduce this proportion to less than 5%, greatly improving product reliability.

## Precision of assembly process

The assembly process of lead-acid batteries is like the assembly of precision instruments, and accuracy is crucial. The installation position deviation of each component and the uneven tightening strength will affect the electric field and ion current distribution inside the battery, and then reduce the battery performance. The precise assembly process ensures that the plate, separator, electrolyte and other components are closely matched, reducing internal gaps and optimizing the electrochemical reaction path. For example, strict control of plate spacing through automated assembly equipment can increase the consistency of battery capacity by 15%-20% to ensure the stable performance of the same batch of products.

## Quality testing system perfection

Perfect quality inspection system is the final guarantee of product quality. From the incoming inspection of raw materials, to the sampling of semi-finished products in the production process, and then to the complete inspection of finished products, every inspection process is indispensable. In addition to the conventional capacity, charge and discharge performance detection, advanced detection means such as X-ray flaw detection to check the welding quality, electrochemical impedance spectroscopy analysis of the internal state of the battery, can be more comprehensive and accurate control of product quality. Strict implementation of testing standards can screen out unqualified products and ensure that every lead-acid battery entering the market meets high quality requirements. For example, a well-known brand through the establishment of a perfect testing system, the product factory pass rate increased from 90% to more than 98%, establishing a good brand reputation.

Lead-acid batteries seem simple, but their quality is determined by plate material, electrolyte, partition, shell, welding, assembly and detection. Only in every link of the production enterprises to achieve excellence, in order to create high-quality products to meet the market's stringent requirements for lead-acid battery performance, life, reliability, and stand out in the fierce market competition.

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