Guide to VRLA Batteries

3
Exclusive Gel Formula & Computerized Mixing
Proper gel mixing is critical to life and performance. Our
state-of-the-art gel battery manufacturing facility is one of
t
he finest in the world with a proprietary computerized gel
mixing operation. Our exclusive formula is mixed using
computer control in every stage of the process. Computer
control delivers superior consistency for gel battery
performance that is unequaled. Our temperature-
c
ontrolled process and specially designed equip ment
a
ssures a homogenous gel. Our equipment was designed
by our engineers specifically for gel mixing – even down to
the contour of the tank bottoms and feed pipe loca tions.
Exclusive AGM Electrolyte and Filling Process
Our AGM electrolyte contains high purity sulfuric acid and
pure, demineralized and deionized water. Avoiding impurities
enables the battery to function at the critical performance
levels necessary of the recombinant principle utilized in a
valve-regulated design. This assures minimized gassing as
well as water and capacity loss providing longer service life
and sustained performance.
The AGM filling process assures that each cell is saturated
with the maximum amount of electrolyte that can be held by
the separators, without leaving excess electrolyte that could
spill or leak.
Multi-Staged Filling and Vacuuming Operation
Our gel process fills and vacuums each cell several times. This
multi-step process assures complete evacuation of air and
complete gel-to-plate contact. Our computerized process also
weighs every SLI and Stationary battery before and after filling
as a check for proper gel levels. The result is a battery with
more consistent and reliable performance.
Our AGM topping process assures that the maximum retain-
able elec trolyte quantity is held within the battery separators,
to produce a complete electrolyte-to-plate contact optimizing
battery performance and power.
Gel Ultra-Premium, Glass Mat, Double
Insulating Separators
Another critical component is the separator, which isolates
the positive from the negative plate. The separator must
allow maximum charge flow between the plates for maxi-
mum performance.
East Penn’s Gel battery utilizes a separator with two layers:
n
The first fiberglass sheet layer maintains compression
force over the entire surface of the positive plate pro-
hibiting active material shedding. The fiberglass strands
from this layer also prevent shedding by embedding
themselves into the surface of the plates. This acts like
reinforcing rods in concrete. These extra reinforcements
lock the active material to prevent capacity degradation
for longer life performance.
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The second layer is a porous organic polymer. The quan-
tity and size of the pores is optimized to balance the
performance characteristics of the battery with its life
characteristics. This layer has ribs on both sides to allow
gel to reach the entire surface of both plates and to
maintain the correct plate spacing.
Gel Polyester Element Wrap
To prevent life-shortening mossing in our gel batteries, we use
a special polyester fiber sheet that is wrapped around the edge
of each element, similar to the wrap in an industrial battery.
The result is longer service life.
AGM Ultra-Premium Glass Mat Separators
Variations in separator properties can be detrimental to the
AGM battery’s functional performance. East Penn uses
glass mats that are engineered to have consistency and an
ideal balance of critical properties. This attention to detail
r
esults in high performance and long life.
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High absorption and retention rate holds acid securely in
glass fibers to prevent uneven saturation and acid strati-
fication (see explanation of acid stratification under Acid
Stratification Prevention section).
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Thick, highly compressible mats provide padded protec-
tion around plates and absorb shock and vibration. This
maintains compression force over the entire surface of
the positive plate prohibiting shedding, which results in
capacity degradation. An AGM separator contains no
materials subject to failure from oxidation.
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Low electrical resistance from electrolyte holding fibers
and micro-porous composition optimizes current flow
between plates for a more efficient transfer of power.
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Durable mats are wrapped around the bottom of the
plate and are wider than the plates. This inhibits failures
from direct contact electrical plate shorts or shorts from
the build-up of material on the battery elements.
Exclusive Alloy Compositions
Our exclusive alloy compositions provide the optimal combi-
nation of longer shelf life, more power conductance, enhanced
durability, and superior corrosion resistance. By using special
grain refiners, we can dramatically improve performance and
life. Calcium strengthens the grid for processing in the plant
so that its integrity is upheld in the battery to withstand the
forces of vibration and shock in service.
Heavy-Duty Grid Style Design
for Heavy-Duty Service
East Penn uses a high-performance deep cycle grid designed
for durability. The thick grid wires not only lock the active
material onto the grid, but also act as “bus bars” to collect and
direct the energy to the terminals.
Acid Stratification Prevention
Acid stratification can occur in conventional flooded cells.
During charge, acid is released at the plate surfaces. During
discharge, acid is consumed at the plate surfaces. Since the
concentration is not uniform, diffusion (spontaneous mixing
by random molecular motions) begins. If this mixing
occurred rapidly, stratification would not occur, but it is
relatively slow, allowing lighter parts of elec trolyte to “float”
toward the surface and heavier parts to “sink” toward the
bottom. The top portion of the plates do not perform as well
in contact with lower concentration electrolyte. The bottom
portion of the plates do not perform as well with the higher
concentration and will corrode prematurely. High voltage
“equalization” charging is sometimes used in flooded
batteries to make gas bubbles that remix the elec trolyte.
Immobilized gel or separator-absorbed electrolyte will not “float”
or “sink” within itself when a non-uniform concentration exists
so it cannot stratify. Therefore, no high-voltage equalizing charge
is necessary. Simply recharge at the recommended recharge
settings. This means longer life and consistent performance.