Carbon honeycomb grids for advanced lead-acid batteries. Part I: Proof of concept

► Carbon honeycomb current collectors are developed for lead-acid battery grids. ► The grids are compatible with most of the VRLAB manufacturing processes. ► AGM–VRLA cell with positive honeycomb grid demonstrates over 180 deep cycles. The carbon honeycomb grid is proposed as innovative solution for high energy density lead acid battery. The proof of concept is demonstrated, developing grids suitable for the small capacity, scale of valve-regulated lead acid batteries with 2.5–3Ah plates. The manufacturing of the grids, includes fast, known and simple processes which can be rescaled for mass production with a minimum, investment costs. The most critical process of green composite carbonisation by heating in inert, atmosphere from 200 to 1000°C takes about 5h, guaranteeing the low cost of the grids. An AGM–VRLA, cell with prototype positive plate based on the lead–2% tin electroplated carbon honeycomb grid and, conventional negative plates is cycled demonstrating 191 deep cycles. The impedance spectroscopy, measurements indicate the grid performance remains acceptable despite the evolution of the corrosion, processes during the cycling.