Reformed battery grids

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

• piercing and pulling a cast or cast and rolled lead alloy solid strip to form a grid strip of the lead alloy having a plurality of connected grids with each grid having a generally planar surface, a plurality of spaced-apart wire segments interconnected at nodes, and a plurality of open spaces between the wire segments;
• stamping the plurality of the wire segments of each grid with a reforming die without removing lead alloy from them, to change the transverse cross-sectional shape of said wire segments of each grid and thereby forming on said wire segments respective land surfaces inclined at an angle which is neither perpendicular nor parallel to the generally planar surface of the grid;
• and
• forming a controlled surface roughness having a substantially uniform distribution and a size of about 100 micro inches Ra to 900 micro inches Ra on the plurality of the inclined land surfaces of the wire segments of each grid with stamping or rolling dies without removing lead alloy from said wire segments to promote adhesion to said plurality of wire segments of each grid of subsequently applied and cured battery paste.

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

• continuous casting a molten lead alloy to form a grid strip of the lead alloy having a plurality of connected grids with each grid having a generally planar surface, a plurality of spaced-apart wire segments interconnected at nodes, and a plurality of open spaces between the wire segments;
• stamping the plurality of the wire segments of each grid with a reforming die without removing lead alloy from them, to change the transverse cross-sectional shape of said wire segments of each grid and thereby forming on said wire segments respective land surfaces inclined at an angle which is neither perpendicular nor parallel to the generally planar surface of the grid;
• and
• forming a controlled surface roughness having a substantially uniform distribution and a size of about 100 micro-inches Ra to 900 micro-inches Ra on the plurality of the inclined land surfaces of the wire segments of each grid with stamping or rolling dies without removing lead alloy from said wire segments to promote adhesion to said plurality of wire segments of each grid of subsequently applied and cured battery paste.