Abstract: A method is provided for manufacturing a battery 18 having battery electrodes 20 and 22 with a desired porosity, using an electrochemical model 42 and a thermal model 44, that includes determining energy and current requirements for a particular application. Characteristics of the battery 18 in response to said energy and current requirements are determined. The battery characteristics and energy and current requirements are prepared for use in the electrochemical model 42 and the thermal model 44. The porosity of the battery electrodes is determined by solving equations within the electrochemical model 42 and the thermal model 44. Porosity of the battery electrodes is varied until voltage potential across the battery varies by less then a predetermined tolerance factor for an operating range state of charge. A paste mixture is created in response to the desired battery electrode porosity. The paste mixture is applied to a grid followed by curing of the grid and paste.

Abstract: A method is provided for manufacturing a battery 18 having battery electrodes 20 and 22 with a desired porosity, using an electrochemical model 42 and a thermal model 44, that includes determining energy and current requirements for a particular application. Characteristics of the battery 18 in response to said energy and current requirements are determined. The battery characteristics and energy and current requirements are prepared for use in the electrochemical model 42 and the thermal model 44. The porosity of the battery electrodes is determined by solving equations within the electrochemical model 42 and the thermal model 44. Porosity of the battery electrodes is varied until voltage potential across the battery varies by less then a predetermined tolerance factor for an operating range state of charge. A paste mixture is created in response to the desired battery electrode porosity. The paste mixture is applied to a grid followed by curing of the grid and paste.