0102030405
Stamped Grid vs Expanded Grid: Optimizing Lead-Acid Battery Manufacturing for Cost and Performance | MINHUA Group
2025-02-21
Technical Comparison Module (Infographic-Friendly)
1. Core Process Principles
| Parameter | Expanded Grid (拉网工艺) | Stamped Grid (冲网工艺) |
|---|---|---|
| Material Prep | Molten lead → Continuous casting (0.8-2.0mm strip) | Molten lead → Continuous rolling (1.2-3.0mm strip) |
| Forming Method | Punching + Mechanical stretching (18-25m/min) | Precision stamping (300-500 strokes/min) |
| Dimensional Tolerance | ±0.2mm | ±0.05mm (mold-dependent) |
| Key Equipment | Expanding machine | Progressive die stamping press |
Key Differences:
- Stamped grids rely on high-precision molds (±0.05mm) for complex geometries; expanded grids prioritize flexibility with lower precision.
2. Performance Metrics
2.1 Mechanical Strength (ASTM E8 Standard)
| Test Parameter | Expanded Grid | Stamped Grid |
|---|---|---|
| Tensile Strength | 38-42 MPa | 55-62 MPa |
| Elongation at Break | 15-18% | 8-12% |
| Fatigue Life (Cycles) | 5,000 | 8,000+ |
ASTM E8 Compliance:
- Gauge length: 4D (E8) or 5D (E8M) for consistent specimen preparation.
- Strain rate: 0.015±0.006 mm/mm/min (closed-loop control).
2.2 Production Economics (USD/10k Units)
| Cost Category | Expanded Grid | Stamped Grid |
|---|---|---|
| Tooling Cost | 0 | 700-1,200 |
| Energy Cost | 120 | 180 |
| Scrap Recycling | 25 | 85 |
| Total Cost | 145 | 965+ |
Key Insight:
- Stamped grids incur 75% tooling costs, viable only for mass production; expanded grids reduce scrap rates by 70%, ideal for cost-sensitive projects.
Industry Application Guide
3. Recommended Scenarios
| Technology | Applications |
|---|---|
| Expanded Grid | ✅ Automotive SLI batteries (>100k units/month) |
| ✅ Cost-sensitive ESS projects (40% lower CAPEX) | |
| ✅ Standardized grid designs (diamond/rectangular patterns) | |
| Stamped Grid | ✅ Start-stop/deep-cycle batteries (>1,200 cycles, per IEC 61427) |
| ✅ Custom geometries (honeycomb/radial grids) | |
| ✅ High-precision tolerance (thickness variation < ±0.1mm) |
Scenario Analysis:
- Start-Stop Systems: Stamped grids’ tensile strength (55-62 MPa) and fatigue life (8,000+ cycles) meet frequent charge-discharge demands.
- ESS Projects: Expanded grids’ total cost (145 USD/10k units) suits CAPEX-sensitive deployments, with standardized designs enabling scalability.
Innovation Trends & References
- Advanced Grid Geometries: Stamped grids enable 18% higher active material loading via honeycomb structures, validated in grid-forming ESS projects (e.g., Xinjiang Bazhou Shared ESS).
- Mold Technology: GREE’s ±0.001mm precision molds and 380-strokes/min stamping speed are accelerating adoption in premium EV batteries.
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