How is a car battery made?

A car battery, typically a lead-acid battery, is made through a process involving alternating plates and an electrolyte solution.

Here's a breakdown of the process, focusing on the components and their arrangement:

Key Components:

• Plates: These are the heart of the battery. A typical lead-acid car battery contains plates of lead alternating with plates made up of other materials. These "other materials" are often a lead alloy grid filled with a spongy lead compound (Pb) for the negative plate and lead dioxide (PbO2) for the positive plate.
• Electrolyte: The plates are immersed in an electrolyte solution. This solution is crucial for the chemical reactions that generate electricity. It consists of about one-third sulfuric acid and two-thirds water.
• Separators: These are insulating sheets placed between the positive and negative plates. They prevent short circuits while allowing the electrolyte to flow freely.
• Case: The battery components are housed in a durable plastic case.
• Terminals: Positive and negative terminals allow the battery to connect to the car's electrical system.

Assembly Process:

1. Plate Preparation: Lead and lead alloy grids are cast. The grids are then pasted with a lead compound to form the active material.
2. Plate Formation: The pasted plates undergo a "formation" process. This involves applying an electrical charge to convert the lead compound into spongy lead (negative plate) and lead dioxide (positive plate).
3. Plate Stacking: Positive and negative plates are stacked alternately, with separators placed between them to prevent contact.
4. Cell Assembly: The plate stacks are assembled into individual cells. Each cell produces approximately 2 volts. A typical 12-volt car battery has six cells connected in series.
5. Inter-cell Connections: The cells are connected in series to achieve the desired voltage.
6. Electrolyte Filling: The battery case is filled with the sulfuric acid electrolyte solution.
7. Sealing and Testing: The battery is sealed to prevent leaks, and then tested to ensure it meets performance specifications.