Design concepts for lead-acid batteries in distributed and bulk power applications

Valve-regulated Pb-acid batteries in distributed and bulk power applications such as cabinets are often subjected to higher temperature environments. Unless the float voltage is compensated for temperature or the trickle charge current is limited, the battery internal temperature may increase due to heat generated by oxygen recombination. In designing batteries for these extreme environments, case and cover materials must be chosen to minimize water loss, promote heat dissipation and withstand high temperatures. Post and case-to-cover seals must be robust enough to cycle between high and low temperatures under pressurized conditions in which hot acid vapors inside the battery can chemically attack the materials. Standard valve designs are not always reliable at temperatures where frequent pressure release and closure are required. If the valve does not close after the pressure is released, atmospheric oxygen can rapidly discharge the negative plate. Leading to permanent loss of cell voltage and capacity. Other design factors such as the grid material and configuration and plate processing methods reduce internal heating by improving heat transfer and minimizing cell imbalances. In this paper, the authors discuss some of the key design and manufacturing approaches used in secondary batteries to improve their performance in high temperature environments