Modification of the shape/surface finish of battery grid wires to improve paste adhesion

A method of making a plurality of battery grids, the method comprising:

• forming a strip of interconnected battery grids from a grid material, each interconnected battery grid including a grid network bordered by at least one frame element, one of the frame elements having a current lug, the grid network comprising a plurality of spaced apart grid wire elements, each grid wire element having opposed ends, each opposed end being joined to one of a plurality of nodes to define a plurality of open spaces in the grid network;
• deforming at least a portion of the grid wire elements at a position intermediate the opposed ends of the grid wire element such that a first transverse cross-section taken at the position intermediate the opposed ends of the grid wire element differs from a second transverse cross-section taken at one of the opposed ends of the grid wire element;
• and
• cutting the strip to form a plurality of battery grids,
• wherein the grid network and each of the frames define opposed planar surfaces, and each first transverse cross-section does not extend above or below the planar surfaces.

A method of making a plurality of battery plates, the method comprising:

• melting a grid material;
• continuously casting the grid material to form a continuous strip;
• rolling the strip;
• punching grid material out of the strip to form interconnected battery grids, each interconnected battery grid including a grid network bordered by a frame, the frame having a current collector lug, the grid network comprising a plurality of spaced apart grid wire elements, each grid wire element having opposed ends, each opposed end being joined to one of a plurality of nodes to define a plurality of open spaces in the grid network;
• stamping at least a portion of the grid wire elements at a position intermediate the opposed ends of the grid wire element such that a first transverse cross-section taken at the position intermediate the opposed ends of the grid wire element differs from a second transverse cross-section taken at one of the opposed ends of the grid wire element;
• applying battery paste to the strip;
• and
• cutting the strip to form a plurality of battery plates,
• wherein the grid network and each of the frames define opposed planar surfaces, and each first transverse cross-section does not extend above or below the planar surfaces.

A method of extending the cycle life of a lead-acid storage battery having a positive plate, the method comprising:

• melting a lead alloy grid material;
• continuously casting the grid material to form a continuous strip;
• rolling the strip;
• punching grid material out of the strip to form interconnected battery grids, each interconnected battery grid including a grid network bordered by a frame, the frame having a current collector lug, the grid network comprising a plurality of spaced apart grid wire elements, each grid wire element having opposed ends, each opposed end being joined to one of a plurality of nodes to define a plurality of open spaces in the grid network;
• stamping at least a portion of the grid wire elements at a position intermediate the opposed ends of the grid wire element such that a first transverse cross-section taken at the position intermediate the opposed ends of the grid wire element differs from a second transverse cross-section taken at one of the opposed ends of the grid wire element;
• applying battery paste to the strip;
• and
• cutting the strip to form a plurality of positive plates,
• wherein the grid network and each of the frames define opposed planar surfaces, and each first transverse cross-section does not extend above or below planar surfaces.

A method of making a battery grid, the method comprising:

• forming a preform battery grid, the preform battery grid including a grid network bordered by at least one frame element, one of the frame elements having a current collector lug, the grid network comprising a plurality of spaced apart grid wire elements, each grid wire element having opposed ends, each opposed end being joined to one of a plurality of nodes to define a plurality of open spaces in the grid network;
• and
• deforming at least a portion of the grid wire elements of the preform battery grid at a position intermediate the opposed ends of the grid wire element such that a first transverse cross-section taken at the position intermediate the opposed ends of the grid wire element differs from a second transverse cross-section taken at one of the opposed ends of the grid wire element,
• wherein the grid network and each of the frames define opposed planar surfaces, and each first transverse cross-section does not extend above or below the planar surfaces.

A grid for a battery comprising:

• a grid network bordered by at least one frame element, one of the frame elements having a current collector lug,
• the grid network comprising a plurality of spaced apart grid wire elements, each grid wire element having opposed ends, each opposed end being joined to one of a plurality of nodes to define a plurality of open spaces,
• at least a portion of the grid wire elements having a first transverse cross-section taken at a position intermediate the opposed ends of the grid wire element that differs from a second transverse cross-section taken at one of the opposed ends of the grid wire element,
• wherein the grid network and each of the frames define opposed planar surfaces, and each first transverse cross-section does not extend above or below the planar surfaces.