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TECHNICAL DETAILS

Battery Hardware - battery fasteners and inter cell connectors:
To be precise the term battery hardware is restricted to battery fasteners and inter cell connectors.

Battery fasteners are generally made of mild steel or brass with lead coating and inter cell connectors are made of copper or aluminium with lead coating.

Lead Coating:
Lead coating is essentially the process of composite electroplating , which is highly specialized job.

Secure battery connections enhance the performance ( charging as well as output ) of lead acid batteries . Secure battery connections can be provided by lead coated battery fasteners.

In lead acid batteries , there is gassing during the charging process, which gives rise to problems like sulphation.

Why to use lead coated battery hardware :
The acid fumes react with mild steel and form iron sulphate , which is twice in volume in comparison to iron. This situation leads to bloating of fasteners and very often fasteners get jammed. If extra force is applied to work upon fasteners ,the battery poles can get damaged.
If the fasteners used are lead coated, the iron sulphate formed shall be significantly low and there shall not be any problem of bloating of bolts and servicing of terminal connections , can be undertaken very smoothly.

Is sulphation related to lead coated battery hardware :
No not at all. Since the cause of sulphation in lead acid batteries is gassing, the use of lead coated battery hardware shall have hardly any affect on the rate of sulphation , but on contrary , the effect of sulphation on lead coated battery hardware shall be minimal.

The sulphation can considerably be controlled by placing lead acid batteries in properly ventilated places and in exclusive battery rooms , where large battery banks are commissioned , minimum six air changes per hour are required.

How to remove sulphation from lead coated battery hardware :
Lead being soft metal , hard scrubbing should be avoided , only soft cloth with hot washing soda solution must be used to remove sulphation without damaging the lead coating under-neath.

Are Zinc coated fasteners with petroleum jelly and sticky paraffin wax , right substitutes of lead coated battery hardware :
No , not at all, since battery electrolyte ( dilute sulphuric acid) has got the tendency to absorb the petroleum jelly , oils and wax, the exposed zinc surface can quickly be eroded by electrolyte and later , raw mild steel fasteners will bloat and get jammed.

Can we use stainless steel battery fasteners :
Yes, certain grades of stainless steel are acid resistant , but one will have to consider the financial aspects as stainless steel fasteners are 3.5 times costlier than ms lead coated fasteners.

Dear customer, we are in this industrial trade of lead electroplating for last fifteen years.We take privilege to have reached out to common battery man with our quality battery hardware products at most economical rates. We have installed capacity of four tons per month .while processing the battery hardware we ensure to use the best raw materials available in the market to get the finest out come. For your battery hardware requirements , you can contact or email us your specifications alongwith quantity required.We will definately work out best deals for you.

Please Remember

• Secure battery connections optimize the performance of lead acid batteries.
• Long lasting secure battery connections can only be provided by lead coated battery hardware.

GRAPHITE TWIN TUBULAR LEAD ACID BATTERY In this newly developed lead acid battery the conventional lead grids are replaced with the flexible graphite. The Flexible Graphite has the following properties:- No effect of battery electrolyte on flexible graphite . The Flexible Graphite has conductivity much higher than the lead . With the same cross sectional area, the graphite carries current almost 1.5 times that of lead. The Flexible Graphite has low density , the batteries designed with graphite grids shall have considerably low weight, making such batteries the right choice where the weight of batteries plays negative role.The batteries made with the flexible graphite grids shall have higher output over weight ratio. The flexible graphite being docile in nature,the flexible graphite has to be embedded in pigments in tubular bags. Since the flexible graphite can not be welded , the connections of battery plates have to be secured through the lead current collectors and the batteries can be assembled in the way, very similar to the conventional lead acid batteries. In graphite twin tubular lead acid batteries we have designed both negative and positive plates as tubular plates, making this battery as twin tubular graphite lead acid battery. To adapt twin tubular design ,was compulsion, since flexible graphite can not be made into ordinary mesh grids, to be pasted in the conventional way. Though Fire Fly has obtained desired results by using complicated process of strengthening flexible graphite but process is too complicated and costly ,defeating the idea of using graphite foam. Here we have used basic lead current collectors with graphite tubular plates to completely simplify the process and making it most suitable process for our indian working conditions.The sealing of both negative and positive tubular plates is done with high quality acid proof resins,thus virtually reducing the possibility of shedding of active materials of plates to nil . Graphite twin tubular lead acid batteries shall have longer life as these batteries are free from the ills of short circuits and shedding. These Batteries shall cost twenty percent less than the ordinary lead acid batteries due to saving in the lead used for making the batteries.In graphite twin tubular lead acid batteries , lead is used only for making connections. It shall be our pleasure to provide free technical support to the battery manufacturers across the length and breadth of India. For further technical support and procurement of components for manufacturing graphite twin tubular lead acid batteries, please get in touch and enjoy the benefits of simple and durable graphite twin tubular battery concept which shall be most suitable for batteries required for inverters and battery operated scooters and other vehicles.

For further information and technical support , please contact us.

Pritpal Singh
BSc Engineering (Electrical)
University of Delhi
Sumit Enterprises
15 B, Gokhle Market
Delhi 110054

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