Lead-acid batteries, as one of the most mature electrochemical energy storage technologies, rely heavily on the quality of their battery plates. The manufacturing of battery plates integrates precision processes from metallurgy, chemistry, and materials science. This article delves into the full production process of green plates (unformed plates), from raw materials to final shaping, revealing the modern industrial wisdom behind this traditional technology.

I. Raw Material Preparation: Metallurgical Purification of High-Purity Lead

1. Lead Ingot Melting

We utilize electrolytic lead ingots with a purity of ≥99.99%, which are melted into liquid lead in a lead melting furnace at 450-500°C. To enhance mechanical strength, alloying elements are added in proportion:

Positive Plates: 0.3%-1.2% antimony (Sb) is added to enhance corrosion resistance;

Negative Plates: Lead-calcium alloy (0.08%-0.12% Ca) is used to reduce the risk of hydrogen evolution.

2. Lead Powder Preparation (Lead Oxide Generation)

Molten lead is atomized into micrometer-sized lead particles through a lead powder machine (using the Barton method or ball milling method). These particles react with air in an oxidation chamber to form porous lead oxide (PbO):

2Pb + O₂ → 2PbO

The lead powder has a particle size controlled at 2-5μm and a specific surface area of 0.8-1.5 m²/g, ensuring high reactivity for subsequent reactions.

II. Paste Preparation: The Core Carrier of Electrochemical Active Substances

1. Formula Mixing

Lead oxide powder, deionized water, sulfuric acid (density 1.40g/cm³), and fibrous additives (such as lignin) are mixed in proportion in a paste mixer:

Positive Plate Paste: Lead powder:Sulfuric acid:Water ≈ 100:8:12, forming a porous PbO·PbSO₄ framework;

Negative Plate Paste: Expanding agents (such as carbon black, barium sulfate) are added to inhibit passivation.

2. Paste Maturation

The mixed paste is left to mature in an environment at 35-45°C with humidity >90% for 8-12 hours, completing the following reaction:

4PbO + H₂SO₄ → 3PbO·PbSO₄·H₂O + H₂O

This forms a stable basic lead sulfate network structure, with the paste density reaching 4.0-4.3g/cm³.

III. Grid Manufacturing: The Mechanical Framework of Battery Plates

1. Alloy Casting

Using die-casting or continuous expanded mesh processes, lead-calcium/lead-antimony alloys are formed into grid-like structures:

Thickness: Positive plates 1.8-2.5mm, negative plates 1.2-1.8mm;

Grid Design: Diamond or radial patterns to reduce internal resistance and enhance active material adhesion.

2. Surface Treatment

The grids are cleaned with dilute sulfuric acid (5%) to remove oxide layers, forming a micro-rough surface to enhance paste adhesion.

IV. Coating and Curing: Precision Shaping of Active Materials

1. Automated Coating

Grids are evenly coated with paste using a double-belt coater, with precise paste application within ±0.5g per plate. The thickness is controlled by rolling (positive plates 2.5-3.0mm, negative plates 1.8-2.2mm).

2. Curing and Drying

The coated plates undergo a three-stage curing process in a humidity-controlled tunnel kiln:

Surface Drying (40°C, 2h): Rapid dehydration to prevent cracking;

Crystal Transformation (65°C, 12h): PbO·PbSO₄ → 4PbO·PbSO₄;

Final Drying (50°C, 6h): Residual moisture <0.5%.

This results in porous, high-mechanical-strength green plates (positive plates PbO/PbSO₄, negative plates sponge-like Pb).

V. Quality Control: Precision Manufacturing Empowered by Digitalization

Online Inspection: X-ray thickness gauges monitor paste uniformity in real-time;

Physical Indicators: Plate hardness (Shore A 50-65), bending strength (>15MPa);

Electrochemical Pre-testing: Random sampling for 0.5C discharge testing, with capacity deviation ≤3%.

VI. Environmental Protection and Innovation: The Industrial Revolution of Green Manufacturing

Lead Dust Control: Fully enclosed production lines with bag filters, lead emissions <0.1mg/m³;

Paste Recycling: Centrifugal separation technology achieves a paste reuse rate >95%;

Smart Factory: MES systems optimize process parameters at the millisecond level, reducing energy consumption by 18%.

The manufacturing process from lead ingots to green plates represents the perfect integration of materials science and engineering technology. Kaiying Power ensures that each battery plate combines high energy density with ultra-long cycle life through full-process digital control and green process innovation, providing a reliable power core for global energy storage systems.

(Data support provided by Kaiying Power's R&D Institute)

In today's competitive market, brand value is increasingly important. The emergence of counterfeit and substandard products is a serious threat to brand reputation and market order. As a large lead-acid battery factory, Kaiying Power has recently discovered counterfeit batteries bearing our brand in the market. Although this is distressing, it also presents an opportunity for us to reaffirm our commitment to quality and strengthen our brand image to the market and consumers. Here are some strategies and actions we are taking in response to this incident.

1. Identifying Counterfeit Products

During market research, we identified counterfeit products through various issues on the battery casing, including:

Poor Casing Quality: Counterfeit batteries have thin casings with numerous scratches.

Inferior Silk-Screen Printing: The silk-screen printing on counterfeit batteries contains errors in text, data, and certification codes, and is often blurry. These issues not only affect the product's appearance but also indicate unstable internal quality.

Irregular Date Coding: The date coding on counterfeit batteries is irregular and does not accurately reflect the production date.

Irregular Terminals and Acid Leakage: The terminals on counterfeit batteries are poorly made and prone to acid leakage and corrosion, which can lead to unstable connections, affecting the battery's performance and safety.

These subtle differences, though easily overlooked, are crucial in quality control. Our batteries feature clear and accurate silk-screen printing, consistent laser date coding, and well-made terminals with strict prevention of acid leakage. This discovery further strengthens our commitment to quality and reminds us to focus more on detail presentation and education in market promotion. Below are some examples:

2. Comprehensive Harms of Substandard Lead-Acid Batteries to Equipment

The impact of substandard lead-acid batteries on equipment is multifaceted, mainly reflected in the following aspects:

Performance and Lifespan

Difficulty in Starting and Unstable Operation: Due to poor quality electrode materials and electrolyte, substandard batteries have increased internal resistance and rapidly decreasing discharge voltage. This not only makes it difficult to start equipment, such as motorcycles failing to start, but also causes voltage fluctuations during operation, leading to unstable equipment performance, like frequent restarts of data center servers.

Shortened Lifespan: Poor material quality can lead to incomplete chemical reactions and electrode material shedding, causing the battery capacity to drop quickly and shortening its lifespan. This increases the maintenance cost and downtime of equipment, such as the need for frequent battery replacements in UPS systems.

Safety and Environment

Equipment Damage and Safety Risks: Leakage and expansion issues can cause electrolyte to corrode the metal parts and electronic components of equipment, causing damage. Moreover, the poor quality casing of substandard batteries can easily break, potentially causing short circuits, overheating, and even fires, endangering personnel and property safety.

Environmental Pollution: Substandard batteries are prone to leaking harmful substances, such as lead and acid, during use and disposal, posing a threat to the ecological environment and human health. Discarded substandard batteries can contaminate soil and water sources if not disposed of properly.

Economy

Increased Maintenance Costs: Due to unstable performance, frequent inspections and maintenance are required, and the replacement frequency is high, which significantly increases the maintenance cost of equipment, affecting its economic efficiency and usability.

Faced with counterfeit and substandard lead-acid batteries in the market, we understand the importance of protecting consumer rights and maintaining market order. Through strict quality control, we ensure that every battery meets high-quality standards. We not only strictly monitor the production process but also focus on detail presentation and education in market promotion to help consumers identify genuine products. Our efforts can effectively combat counterfeit and substandard products, enhance consumers' trust in the Kaiying brand, and ensure the stable operation and safe use of equipment. We will continue to uphold our commitment to quality and provide consumers with higher quality products and services.

Since its establishment in 2000, Kaiying Power has been dedicated to the research and manufacturing of lead-acid batteries. With 25 years of technical expertise and large-scale production capabilities, we have become a reliable power solutions provider for global clients. Our products have obtained CE (EU), UL (USA), RoHS, and other international certifications, and are widely used in UPS systems, motorcycle starting, energy storage, and more. With an annual production capacity of 15 million units and an annual output value exceeding 1 billion RMB, we have been ranked among Quanzhou’s Top 100 Taxpayers for five consecutive years. Our modern production base was featured in CCTV’s Craftsmanship and Innovation documentary, showcasing our manufacturing strength.

Core Strengths

25 Years of Technical Expertise, Ensuring Stable Quality

Kaiying Power’s Quanzhou Industrial Park spans 200,000 square meters, featuring two fully automated production facilities and over 1,000 professional technicians. We utilize German hydraulic welding equipment and Japanese CCD visual inspection systems to ensure voltage deviation within ±0.03V for each batch, with end-customer complaint rates consistently 60% below the industry average.

Customized Solutions for Diverse Needs

We deeply understand customer application scenarios and provide tailored solutions.

Motorcycle Batteries for Russia: Customized high CCA (Cold Cranking Amps) batteries for extreme cold climates, achieving a 98% success rate in starting at -30°C, earning high praise from local distributors.

Electronic Scale Batteries for Mexico: Developed low self-discharge batteries to meet the special requirements of electronic scales, extending service life by 30% in high-temperature environments, driving continuous repeat orders.

UPS Batteries: Customized high-rate discharge batteries for a Southeast Asian data center, operating flawlessly for 3 years in 40°C environments, achieving 100% customer satisfaction.

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Customer Service

We focus on rapid response and customized support, offering end-to-end services.

Technical Consultation: Professional team provides product adaptation advice and technical support within 24 hours.

Production Optimization: Adjust production processes based on customer needs to ensure both delivery timelines and quality standards are met.

After-Sales Support: A global service network ensures solutions for quality issues within 48 hours.

Contact Us

Visit http://www.kaiyingpower.com to view product and test report originals, and request a customized quotation.

Electronic scales are essential tools in commercial, industrial, and home settings, where precision and stability are highly dependent on the performance of the power source. Among various battery options, 4V4AH and 6V4AH lead-acid batteries have become the mainstream choice in the industry due to their unique advantages. As a leading manufacturer of lead-acid batteries, Kaiying Power explains the reasons behind this:

High Voltage Compatibility for Accurate Measurement

The circuit design of electronic scales typically requires stable low-voltage input (such as 4V or 6V) to ensure the precise operation of sensors and chips. The voltage output of 4V4AH and 6V4AH batteries perfectly matches the power requirements of electronic scales, preventing measurement errors caused by voltage fluctuations. This is especially critical in high-precision weighing scenarios, such as laboratories and pharmaceutical fields.

Balanced Capacity and Longevity

4AH Capacity: Provides long-lasting power, meeting the needs of electronic scales for extended standby or frequent use (e.g., retail checkout counters, logistics weighing stations).

Lead-Acid Battery Characteristics: Long cycle life and low self-discharge rate ensure stable power even when stored for long periods, reducing replacement frequency and maintenance costs.

Compact Design and Strong Adaptability

Electronic scales often have limited internal space. The compact size and lightweight design of 4V4AH and 6V4AH batteries allow them to be easily integrated into various electronic scale structures, catering to both portable and fixed devices.

High Safety and Environmental Adaptability

Lead-acid batteries remain stable in complex environments, such as overcharging, high temperatures, or vibrations, with no risk of explosion. This meets the safety requirements for electronic scales used in industrial workshops and outdoor settings. Kaiying Power's batteries are even more reliable, with IP67 protection ratings and RoHS certification, ensuring environmental friendliness and durability.

Cost-Effective Solution

Compared to lithium batteries, lead-acid batteries are more cost-effective while offering recyclable environmental advantages. This makes them particularly suitable for enterprises that need to deploy electronic scales on a large scale, such as supermarket chains and warehouse management.

Kaiying Batteries' Commitment

As a professional lead-acid battery manufacturer, we provide customized power solutions for global electronic scale brands:

Strict Quality Control: Fully automated production lines ensure consistency in every battery.

Quick Response: Support for model customization and bulk delivery.

Global Certification: Adherence to international standards such as CE, UL, and ISO9001 ensures quality and reliability.

In today's world, access to reliable lighting is more than just a convenience—it plays a crucial role in improving safety, education, and economic development. Solar lights have emerged as an affordable and sustainable solution, especially in regions with limited access to electricity. By harnessing solar energy, these lighting systems provide a renewable power source that reduces dependence on fossil fuels and minimizes environmental impact.

Solar Lighting is beneficial for enhance social safety. For instance, solar flood lights for outdoor are being placed in public areas, streets, and parks, which helps to lower crime rates and foster safer surroundings. These systems are not only budget-friendly but also easy to install, making them suitable for communities with unstable infrastructure. The availability of light at night acts as a deterrent to crime, providing residents with a greater sense of safety.

Moreover, solar lighting is crucial for enhancing educational opportunities. In regions lacking reliable electricity, solar powered LED lights enable children to study after dark, leading to improved academic outcomes. Additionally, solar garden light enhances the quality of life by making outdoor spaces more accessible in the evenings, encouraging community interaction and social events.

The environmental advantages of solar lighting are significant. By transitioning from traditional, energy-intensive streetlights to integrated solar street light, communities can greatly decrease their carbon emissions. The installation of solar bollard lights in public areas also supports energy conservation and mitigates the environmental harm caused by conventional lighting.

As part of the expanding sustainability movement, SLD provides high-quality solar lighting products that promote social benefits. We focus on energy-efficient solar lighting solutions, tailored to meet the needs of communities around the globe. For more information about our products, please visit us at www.solarlightsdo.com.

Installations of public art have the ability to inspire communities, change environments, and tell tales. It can be difficult to make sure these works remain noticeable and have an impact after nightfall, though. This is where solar lights come in, providing an effective and environmentally friendly way to light up public art while also boosting its aesthetic appeal and usability.

Because they are easy to install and environmentally sustainable, solar lights are a great option for public art installations. Solar lights don’t need complicated wiring or access to electricity networks like conventional lighting systems do. They are an affordable and low-maintenance choice because they use solar energy during the day and turn on automatically at night. This is particularly beneficial for outdoor art projects in parks, plazas, or remote locations where electrical infrastructure may be limited.

Solar lights come in a variety of designs, from sleek, modern fixtures like the solar eagle eye wall lamp to more decorative options such as the solar hexagonal pavilion lights, allowing artists and designers to seamlessly integrate them into their installations. Whether it’s highlighting a sculpture, accentuating a mural, or creating a pathway around an art piece, solar lights can be strategically placed to enhance the visual impact of the artwork. For instance, the solar color changing landscape lamp offers adjustable brightness and a spectrum of colors, providing endless creative possibilities to match the mood and theme of any public art installation.

Another important advantage of solar lights is their durability, particularly for outdoor public art projects. Reputable solar lights are made to resist inclement weather, such as rain, snow, and extremely high or low temperatures. This maintains the integrity of the art installation by guaranteeing that the lighting is dependable and operational throughout the year. Additionally, solar lights use less energy, which lowers carbon emissions and satisfies the growing need for environmentally friendly lighting in public areas.

SLD, Solar Lights Do, is a reliable partner for anyone wishing to include solar lighting in their upcoming public art project. With a focus on producing and marketing premium solar lights, SLD provides a large selection of long-lasting and effective outdoor solar lighting options. If you are interested, visit www.solarlightsdo.com and discover how SLD can help bring your artistic vision to life.

Businesses rely on clear, visible signage to attract customers, especially after dark. Installing and maintaining traditional lighting systems can be difficult due to their complicated wiring and high energy expenses. Outdoor LED solar light that runs on solar power provide a useful and affordable substitute for grid electricity, guaranteeing steady and bright illumination.

In order to power LED lights at night, solar powered lighting converts daylight into electrical energy. By doing away with the necessity for subterranean wiring, this self-sustaining system lowers installation and ongoing electrical expenditures. Modern solar sign lights, made possible by developments in solar technology, offer strong brightness and a long runtime, ensuring that signage is visible all night long.

Businesses signs are always illuminated thanks to long-lasting solar lighting systems that are made to endure a variety of weather situations, such as intense rain, snowfall, and extremely high or low temperatures. Among these solutions, the solar waterproof spotlight stands out as a reliable choice for ensuring consistent brightness and durability for businesses signs. In order to provide smooth operation with little effort, several versions also have automatic sensors that switch the lights on at dusk and off at dawn, making them an energy-efficient and hassle-free option for businesses.

In addition to being a wise financial move, switching to solar illumination is also an environmentally conscious one. Businesses may support sustainability initiatives while preserving a polished and well-lit image by reducing their dependency on conventional energy sources, which also helps to reduce carbon emissions.

SLD, Solar Lights Do, provides high-quality solar lighting solutions designed for commercial signage. Our products combine efficiency, durability, and ease of installation, making them an ideal choice for businesses looking to enhance visibility while reducing energy costs. Please explore our range at www.solarlightsdo.com.

How do half-cut solar cells work?

Half-cut solar cell technology increases the energy output of solar panels by reducing the size of the cells, so more can fit on the panel. The panel is then split in half so the top operates independently of the bottom, which means more energy is created – even if one half is shaded.

That’s the general overview – below, we break the process down.

Traditional monocrystalline solar panels usually have 60 to 72 solar cells, so when those cells are cut in half, the number of cells increases. Half-cut panels have 120 to 144 cells and are usually made with PERC technology, which offers higher module efficiency.

The cells are cut in half, very delicately, with a laser. By cutting these cells in half, the current within the cells is also halved, which essentially means that resistive losses from traveling energy via current are reduced, which, in turn, equals better performance.

Since the solar cells are cut in half, and are thereby reduced in size, they have more cells on the panel than traditional panels do. The panel itself is then split in half so that the top and bottom portions operate as two separate panels – generating energy even if one half is shaded.

The key to half-cut cell design is a different method of “series wiring” for the panel, or the way the solar cells are wired together and pass electricity through a bypass diode within a panel. The bypass diode, indicated by the red line in the images below, carries the electricity that the cells generate to the junction box.

In a traditional panel, when one cell is shaded or faulty and does not process energy, the entire row that is within the series wiring will stop producing power.

For example, let’s take a look at the traditional 3-string series wiring method:

With the traditional full cell string series wiring, shown above, if a solar cell in Row 1 does not have ample sunlight, every cell within that series will not produce energy. This knocks out a third of the panel.

A half-cut, 6-string solar panel works a bit differently:

If a solar cell in Row 1 is shaded, the cells within that row (and that row only) will stop producing power. Row 4 will continue to produce power, generating more energy than a traditional series wiring because only one-sixth of the panel has stopped producing power, instead of one-third.

You can also see that the panel itself is split in half, so there are 6 total cell groups instead of 3. The bypass diode connects in the middle of the panel, instead of on one side like the traditional wiring above.

What are the advantages of half-cut cells?

The advantages of half-cut cell panels are numerous.

They improve the power output and performance of solar modules because they offer a higher shade tolerance due to their unique wiring system. This means that if your home has some trees that cast shade onto your roof at certain times during the day, your entire solar panel will not be unusable, like it would with a traditional solar panel.

Another benefit is the fact that they usually offer a higher wattage than traditional panels, meaning they produce more power per square foot.

Additionally, the effects of hot spots are less severe on your solar panels with half-cut cells. Hot spots are the shifting of excess heat on a panel, say from a very hot part to the shaded, cooler section. With a half-cut cell, hot spots will not be as damaging because there are more cells to spread the excess heat to.

Half-cut cells also reduce power loss suffered by traditional panels by reducing internal resistance. Internal series resistance occurs just by the nature of energy traveling through the panel via electric current. But because solar cells are cut in half, there is less current generated from each cell, meaning less resistive losses.

Amid constant iteration in high-efficiency solar cell technology, domestic businesses have exceeded 23% in the efficiency of mass production at new PERC production lines in 2021, and managed to develop ceilings at an efficiency of almost 24%, which further solidifies the determination of domestic businesses in establishing additional production lines for the N-type solar cell.

In the race to develop the most efficient type of solar panels, manufacturers have developed bifacial solar panels. This type of panel has solar cells on both sides which allows the technology to capture more sunlight leading to greater solar cell efficiency compared to traditional solar arrays.

How Do Bifacial Solar Panels Work?
Lets first dig deep into how bifacial solar panels function. The top and bottom solar cells on a bifacial solar array function differently. The top solar cells function like a conventional solar panel array. They face the sun, so they capture incident sun rays directly, absorbing only certain wavelengths.

On the other hand, the bottom solar cells absorb light that is reflected off the ground. Since white or light colors reflect better than dark colors, painting a white or silver surface on the roof or driveway under the panels is encouraged. According to a study by Burns & McDonnell, white surfaces reflect more than 80% of this light while grass only reflects 23%.

How Is Bifacial Solar Panels Installed to Increase Efficiency?
To understand the difference, let’s first uncover how a monofacial solar array is set up. A monofacial solar panel system, or a group of one-sided solar panels, are placed in racks parallel to a surface such as a rooftop. Unlike single-sided panels, bifacial solar panels are installed on a tilt because they produce more energy when they are angled off of the roof or ground at varying degrees.

Below are three benefits of the titled installment of the bifacial solar array.

1. More sunlight to absorb
In these types of titled installations, there is a great amount of reflection. Because sunlight bounces off of all objects reflectively at many different angles, bifacial solar panels are able to capture more of it.

2. Productive on cloudy days
Because of the point above, bifacials can be productive on cloudy days while monofacial solar cells are at a greater disadvantage when there isn’t direct sunlight. Also, bifacials are less susceptible to weather damage because they are more durable. According to the Solar Magazine, because they are more durable than conventional solar panel systems, warranties for bifacial solar panels are typically 5+ years longer (that is, 30+ years versus 20–25 years).

3. Two energy peaks a day
A titled installation can also produce two energy peaks throughout the day based on their placement. For example, half of the bifacials in an array can be tilted toward the east to capture sunrise and morning rays. The second half can then be tilted to the west to soak up afternoon intensity and sunset rays.

Another installation that can achieve this is a vertical installation. During each peak, the reflection of sunlight on the other side of the solar panels will also contribute to energy production.

How Much More Efficient is a Bifacial Solar Array?
When we say efficiency, we are referring to how a solar cell takes the amount of solar energy it received and converts it into electrical energy. Although bifacials produce more electricity than monofacial panels, it definitely isn’t double the efficiency although solar panel manufacturers are working to make that happen in the future. Bifacials can increase energy efficiency by 11% compared to a conventional solar panel system, according to our study. And with a solar tracking system that tilts solar cells continuously toward the sun, the bifacial solar cell efficiency can be as high as 27%.