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 (拉網工藝) | Stamped Grid (沖網工藝) |
|---|---|---|
| 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.
Over 95% Happy Customers!
Warmly welcome all the new and old customers to visit our company. Professional sales team to offer fast responce and good service. We are always at your service if you have any needs. Looking forward to our future profound cooperation and mutual success!
LEARN MORE