LR03 alkaline battery.Detailed introduction to lead-acid battery production process

　　Detailed introduction to lead-acid battery production process

　　According to the relevant standards of our country, the main battery series products are:

　　Starting batteries: Mainly used for starting and lighting cars, tractors, diesel ships, etc.

　　Stationary batteries: Mainly used in communications, power plants, and computer systems as backup power sources for protection and automatic control.

　　Traction batteries: Mainly used for various battery vehicles, forklifts, forklifts and other power sources.

　　Railway batteries: Mainly used for starting and lighting power of railway diesel locomotives, electric locomotives, and passenger cars.

　　Motorcycle batteries: mainly used for starting and lighting various specifications of motorcycles.

　　Coal mine batteries: mainly used for traction power supply of electric locomotives.

　　Batteries for energy storage: mainly used for wind power and hydropower energy storage.

　　Classified by battery plate structure: formed, paste-coated and tubular batteries.

　　According to the battery cover and structure classification: there are open type, exhaust type, acid-proof and explosion-proof type and sealed valve-controlled type batteries.

　　According to the battery maintenance method, there are ordinary type, low maintenance type and maintenance-free type batteries.

　　How lead-acid batteries work

　　The positive active material of a lead-acid battery is lead dioxide, the negative active material is sponge lead, and the electrolyte is a dilute sulfuric acid solution. The discharge chemical reaction is that lead dioxide, sponge lead, and electrolyte react to produce lead sulfate and water, pb (negative electrode) +pbO2 (positive electrode) +2H2SO4====2pbSO4+2H2O (discharge reaction) The charging chemical reaction is that lead sulfate and water are converted into lead dioxide, sponge lead and dilute sulfuric acid. 2pbSO4+2H2O====pb (negative electrode)+pbO2 (positive electrode)+2H2SO4 (charging reaction) The rated voltage of a lead-acid battery is 2.0V. It is generally connected in series at 6V and 12V for starting lighting in cars and motorcycles. Single batteries are generally connected in series to 48V, 96V, 110 or 220V for different occasions. Rubber, PVC, PE or AGM separators are used between the positive and negative plates in the battery, which have extremely low resistance, few impurities and stable ions to pass through.

　　Lead-acid battery process flow and main equipment

　　Lead powder manufacturing, grid casting, plate manufacturing, plate formation, battery assembly

　　Lead powder manufacturing equipment: pellet casting machine or cutting machine, lead powder machine and transportation and storage system;

　　Grid casting equipment: lead melting furnace, plate casting machine and various molds;

　　Plate manufacturing equipment: paste mixing machine, smear machine, surface drying, curing and drying system, etc.;

　　Plate forming equipment: charging and discharging machine;

　　Water cooling formation and environmental protection equipment;

　　Assembling battery equipment: automobile batteries, motorcycle batteries, large, medium and small sealed valve-regulated lead-acid battery assembly lines

　　Battery testing equipment: various battery performance testing.

　　Overview of typical lead-acid battery process

　　Lead-acid batteries are mainly composed of battery tanks, battery covers, positive and negative plates, dilute sulfuric acid electrolyte, separators and accessories. The manufacturing process is briefly described as follows:

　　Lead powder manufacturing: 1# electrolytic lead is made into lead powder that meets the requirements through oxidation screening using a special equipment lead powder machine.

　　Grid casting: Lead-antimony alloy, lead-calcium alloy or other lead alloys are usually cast by gravity casting into various types of grids that meet the requirements.

　　Electrode plate manufacturing: Mix lead powder with dilute sulfuric acid and additives, apply it on the surface of the grid, and then dry and solidify it to form a raw electrode plate.

　　Plate formation: The positive and negative plates react with dilute sulfuric acid under the action of direct current to produce lead oxide through an oxidation-reduction reaction, and then through cleaning and drying, the positive and negative plates can be used for battery assembly.

　　Assembling batteries: Assembling different models and numbers of plates into various types of batteries according to different needs.

　　Note: Each unit can choose different processes due to different process conditions.

　　Introduction to grid casting

　　The grid is a carrier of active materials and a conductive current collector. Ordinary open battery grids are generally cast with lead-antimony alloy, maintenance-free battery grids are generally cast with low antimony alloy or lead-calcium alloy, and sealed valve-regulated lead-acid battery grids are generally cast with lead-calcium alloy.

　　The first step: Determine the alloy lead model according to the battery type, put it into a lead furnace, heat and melt it. After meeting the process requirements, the lead liquid is cast into a metal mold. After cooling, the mold is removed and trimmed and stacked.

　　Step 2: The trimmed grid can be transferred to the next process after a certain period of aging.

　　The main control parameters of the grid: grid quality; grid thickness; grid integrity; grid geometric dimensions, etc.;

　　Introduction to lead powder manufacturing

　　Lead powder is produced by the Shimadzu method and the Patton method, both of which process the 1# electrolytic lead into lead powder that meets the requirements of the battery production process. The main components of lead powder are lead oxide and metallic lead. The quality of lead powder is closely related to the quality of its manufacture. In my country, the Shimadzu method is often used to produce lead powder, while in Europe and the United States, the Patton method is often used to produce lead powder.

　　The process of producing lead powder by Shimadzu method is briefly described as follows:

　　The first step: process the electrolytic lead that has passed the laboratory test into lead balls or lead segments of a certain size through casting or other methods;

　　Step 2: Put the lead ball or lead segment into the lead powder machine, and the lead ball or lead segment will be oxidized to produce lead oxide;

　　Step 3: Put the lead powder into the designated container or powder storage bin. After 2-3 days of aging, it can be used after passing the test.

　　The main control parameters of lead powder: oxidation degree; apparent density; water absorption; particle size, etc.;

　　Introduction to plate manufacturing

　　The plate is the core part of the battery, and its quality directly affects various performance indicators of the battery. The production process of paste-type electrode plates is briefly described as follows:

　　The first step: use special equipment to make lead paste from qualified lead powder, dilute sulfuric acid and additives;

　　Step 2: Apply the lead paste to the grid using a smear machine or manually;

　　Step 3: Solidify and dry the coated electrode plate to obtain a green electrode plate.

　　The main control parameters of the green electrode plate: lead paste formula; apparent density; acid content; paste amount; thickness; free lead content; moisture content, etc.

　　Introduction to assembly process

　　Battery assembly has a big difference between car batteries and sealed valve-regulated lead-acid batteries. Sealed valve-regulated lead-acid batteries require tight assembly and generally use AGM separators, while car batteries generally use pE, pVC or rubber separators. The assembly process is briefly described as follows:

　　The first step: install the qualified plates into the welding tool according to the process requirements;

　　Step 2: Put the cast-welded or hand-welded electrode group into a clean battery tank;

　　Step 3: The car battery needs to be through-wall welded and heat-sealed. If the sealed valve-regulated lead-acid battery uses an ABS battery tank, it needs to be bonded with a special adhesive.

　　The main control parameters of battery assembly: bus welding quality and materials; sealing performance, positive and negative polarity, etc.

　　Introduction to chemical formation process

　　Plate formation and battery formation are two different methods of battery manufacturing, which can be chosen according to specific circumstances. Plate formation is generally relatively easy to control, the cost is high, and environmental pollution requires special control. It is difficult to control the quality of battery formation. Generally, the quality requirements of the green plates produced are relatively high, but the cost is relatively low. The formation of sealed valve regulated lead-acid batteries is briefly described as follows:

　　Step 1: Put the qualified green plates into the battery tank and seal them according to the process requirements;

　　Step 2: Pour dilute sulfuric acid of a certain concentration into the battery in the specified amount;

　　Step 3: After being placed, apply direct current according to the specified size. After generalization, it needs to be discharged and inspected and assembled before being put into storage and ready to be shipped out of the factory.

　　The main control parameters of battery formation: tank acid volume; tank acid density; tank acid temperature; charging capacity and time, etc.

　　Use and maintenance

　　Lead-acid batteries play an irreplaceable role in secondary chemical power sources due to their simple manufacturing process, abundant sources of raw materials, and moderate prices. In particular, the emergence of valve-regulated batteries has given traditional batteries a new lease of life. The service life of the battery is closely related to its manufacturing, and also has a great influence on the method of use. The correct use method is of great benefit to extending the life of the battery. For traditional open-type batteries, the following aspects must be paid attention to daily:

　　① Pay attention to the quantity, density and charging degree of the electrolyte, especially the charging system closely related to it. If the charging capacity is large, the battery will lose a lot of water, which will easily cause the active material of the plate to fall off, causing a short circuit at the bottom. High internal temperature of the battery shortens its life. If the charge capacity is small, it will easily cause the battery to lose power. When the battery loses power for a long time, it can lead to irreversible sulfation of the plates, which is manifested in a rapid rise in voltage during the charging process. , completed in a short time, and the voltage drops rapidly during discharge.

　　② For the purity of the electrolyte, the battery-specific electrolyte or replenishing solution is generally used for filling. It is strictly forbidden to use ordinary sulfuric acid and tap water instead.

　　③Keep the surface used in daily use clean and the exhaust vent unobstructed.

　　④ Fully charge the battery when not in use, and recharge it once every three months.

　　For sealed valve-regulated lead-acid batteries, the following aspects must be paid attention to daily:

　　① Pay attention to the range of charging voltage. The voltage is generally controlled at 2.15±0.1V/single cell during float charging and 2.35±0.1V/single cell during cycle use. If the instructions require it, the operation should be carried out according to the instructions.

　　② Pay attention to the ambient temperature of use, which is generally not more than 30 degrees. When the temperature changes greatly, the voltage adjustment should be strengthened.

　　③ Products from different manufacturers cannot be mixed, and new and old products from the same manufacturer cannot be mixed.

　　④For sealed valve-regulated lead-acid batteries, it is best not to open the cover to replenish the electrolyte and replace the safety valve yourself.

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