LEAD CRYSTAL® BATTERY TECHNOLOGY
HOW WE MAKE OUR UNIQUE BATTERIES
Just like most high performance cars, Lead Crystal Batteries are hand finished to ensure a consistent high standard of quality
- The process starts with lead ingots coming into the factory, and after melting them down, the plates are pressed in a grid form. Then comes the first part of the quality process – the plates are all shaved and sanded down to the exact same weight and thickness. For this reason all our batteries in a pallet or container will always be exactly the same charge when you receive them.
- The negative plates are then stored for 7 days to cure and allow the lead oxidation process to coat onto the plates leaving them a white greyish colour
- The positive plates go to the coating line to be cleaned in an acid dip, then dipped into our lead dioxide paste which also contains one of the essential ingredients for our special lead crystal process. This is the first reason why our batteries are more expensive than standard old technology batteries.
- The positive plates now go into a drying and curing process where they sit for 21 days to ensure they are fully dry and that the initial reactions bind properly.
- The negative and positive plates now go to our own hand-finishing process compared to the standard batteries for other manufacturers that are made here and machine finished on our own production line controlled by our own engineers, our batteries are hand wrapped with our special SAM (Super Absorbent Mat) to ensure the quality and consistency of the plates. Our special mat contains the second ingredient that creates the lead crystals that form the basis of our unique technology. Here the cells undergo a visual inspection during this process to ensure all the plates are consistent quality. The second reason our batteries are more expensive than the older technologies. Each batch of plates have a test set pulled that goes to the facility labs for our engineers to check the quality of the lead lattice and plates using the available electron microscope. All test reports are kept for review.
- The cells are now inserted into the battery case with a special process to ensure the outer SAM and plates do not bend or crunch up during the insertion process due to friction against the plastic of the casing.
- The busbar that is now melted over our plates is thicker and contains more lead than most other products to ensure that the electron transfer process is super-fast and efficient with minimum resistance.
- Our batteries now undergo an additional process - The cases now go into a special heat drying chamber to ensure they contents are completely dry before being packed and shipped to our own facility for filling.
- When the unfinished batteries arrive at our facility, they need to undergo the filling process.
- The lids are first resin sealed and then cured before moving to the filling station. This is more expensive than the simple heat sealing of standard batteries but is essential to deliver the design life of 18 years.
- The batteries then go into our filling station. The remote station in Australia will monitor the mixing plant and the entire process is computer controlled from there. The system will mix the electrolyte required to fill the batteries in the facility. Once mixed, the non-toxic now milky white liquid will be pumped through a pipe to the filling machines. This is the next reason why our technology is more expensive than traditional lead based technologies – this is not a cheap and cheerful lead acid mix with perhaps some simple additives to extend the life. This is a complex precise scientific mixture that underlies our quality and performance warranty.
- The batteries are first pressurised with air, then the air is sucked out which helps remove any loose impurities that may exist, and the vacuum created then sucks the electrolyte into the battery and fills the battery.
- The filled battery now goes to the charging station where it first undergoes a high voltage charge to crystalise the electrolyte. Now the electrolyte, the additive to the paste on the positive plates and the additive to the SAM bonds to create lead crystal that then absorbs the balance of the electrolyte to create our unique white crystal structure between the plates. The liquid electrolyte is now fully crystalised.
- Subsequent to the first charge our batteries now undergo 6 additional discharge/charge cycles before they go to the final testing line for inspection and cleaning. Now we are satisfied that each product that is shipped is up to our unique quality and performance standards.