Abstract: A positive electrode for a lead-acid battery having a heat-treated metal grid with an interconnected grain structure, wherein the grid is heat-treated after being at least partially coated with a paste containing lead. Also disclosed is a method of making a positive electrode for a lead-acid battery including applying a lead containing paste to a metal grid to produce a pasted grid, heating the pasted grid at a temperature and relative humidity sufficient to produce a cured grid, heat treating the cured grid at a temperature of at least about 125° C., for a period of time sufficient to produce an interconnected grain structure within the grid to produce a heat treated grid, and forming the electrode by assembling the heat treated grid into an electrochemical cell including a negative electrode and a sulfuric acid electrolyte, wherein an electric current is passed through the cell to convert at least a portion of the cured paste into lead dioxide.

Abstract: A method of making a lead alloy grid for use in a plate for a lead acid battery that enables thin battery plates with a high surface area. The method of the present invention includes forming the lead alloy, such as by direct casting, to a very small thickness, then work hardening the cast strip to create a grid by forming indentations and protrusions in the thinly cast alloy strip, which in addition to strengthening the strip, provides a desirable surface topography for paste adhesion and interface characteristics. The work hardening, for example embossing, may further include splitting the strip at a high point of the protrusions and indentations to create perforated protrusions and indentations. The grid may then be used to make a plate by pasting an active mass onto the grid, steaming the pasted grid, and curing the pasted grid to provide a plate having a thickness of about 0.05 inch or less.