Electrodeposited, dispersion-hardened, lightweight grids for lead–acid batteries

We report a novel processing route to produce battery grids by electrocodeposition of lead with dispersed particles. The grid thickness and design can be chosen within a wide range. This permits us to minimise grid weight and to optimise grid design for current density distribution. The process development has reached a state of maturity permitting us to produce test quantities for battery tests. The grid properties have been investigated thoroughly. Hardness can be adjusted in the range of 4–25 HV units by choice of particle size and volume fraction of dispersoid (oxides or Cu). Creep resistance is excellent. Corrosion tests indicate that grid corrosion is similar to that of Pb–Ca–Sn grids. Such grids were used to make several hundred positive and negative battery plates and eventually test cells and batteries. First test results have been very promising and have shown clearly that the new grid type allows us to make batteries of high specific energy. The process is, also, suitable for the production of lead alloy foil for alternative battery designs. The new manufacturing process can be combined with a hydrometallurgical process for the recycling of battery grids and paste such that a fully integrated processing route from the treatment of battery scrap to the production of new battery grids for batteries featuring significantly higher specific energy is now available.