Reformed battery grids

A battery plate comprising a grid including a substantially planar web including a plurality of spaced apart and interconnected wire segments that at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments, wherein the web is reformed to simultaneously reduce the thickness of at least a portion of the web and change the cross-sectional shape of at least some of the wire segments.

A method of making a grid for a battery plate of a lead-acid battery, comprising:

• manufacturing a substantially planar web including a plurality of spaced apart and interconnected wire segments, which at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments;
• and
• providing controlled surface roughness of about 100 microinches to about 900 microinches Ra on at least one of the surfaces to increase the surface area of the grid and thereby promote adhesion of an electrochemically active material to the grid.

A method of making a grid for a battery plate of a lead-acid battery, comprising continuously casting molten lead to create a substantially planar web including a plurality of spaced apart and interconnected wire segments at least partially defining substantially planar surfaces of the web and having a plurality of transverse lands and being interconnected at a plurality of nodes to define a plurality of open spaces between the wire segments, by using continuous casting molds having surface texturing to produce surface roughness on at least some of the surfaces of at least some of the wire segments of the web of about 100 microinches to about 900 microinches Ra.

A method of making a grid for a battery plate of a lead-acid battery, comprising:

• manufacturing a substantially planar web including a plurality of spaced apart and interconnected wire segments, which at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments;
• and
• spraying the web to produce controlled surface roughness on at least some of the surfaces of at least some of the wire segments of the web.

A method of making grids for battery plates of lead-acid batteries, comprising:

• continuously casting a strip of grids at least partially defined by substantially planar webs, each including a plurality of spaced apart and interconnected wire segments, which at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments;
• and
• continuously casting at least one sacrificial strip, which includes locating holes and extends along and integral with the continuously cast strip of grids.