Why Batteries fail.

75% causes of Battery Failure - Sulfation.

WHAT IS BATTERY SULFATION?

Battery sulfation is a normal by-product of charging and discharging lead-acid batteries. As the battery discharges the sulfate radical (SO4) is attracted from the electrolyte to the plate and combines with the lead to form lead sulfate (PbSO4).

Under perfect circumstances the lead sulfate would be completely recombined into the electrolyte during the charging process. However, in the real world, a portion of the lead sulfate remains stuck to the plate and begins hardening, causing sulfation. As this accumulates, the resistance of the battery increases and the electro-chemical reaction necessary for the good functioning of the battery is impaired. The battery performance is gradually reduced to the point where it becomes practically unusable, even though there may be substantial amounts of active material remaining in the plates.

New Battery with spongy lead                                

As sulfation remains unchecked on the plates, it crystallizes into a harder form of sulfation. Sulfation in general is further aggravated by less-than-perfect charging practices or by the batteries being left idle for a period of time, especially in a discharged state.

Learn how to deal with sulfations using PowerPlus Battery Maintenance units.


                                                                                                        Sulfation crystalized, hardened.

Compromising on quality?

In this day and age where price of lead continues to soar, many battery manufacturer in Asia are constantly looking for ways to reduce cost to the extend of reducing the number of lead plates in their battery.

In a recent test conducted on 2 batteries, an unbranded battery for a truck was taken to compare against a German made car battery. As we have seen on the video, the main components of a battery comprise of Lead, Plastic casing and Battery water. Remove the shell, drain off the batter water and left on it's own, the German battery contained about 3kgs of lead more than the truck battery. The larger lead plates in a battery, the more power it generates.

Placement of the battery in an engine compartment.

This is probably the least noted, yet another big cause for battery failure. On a hot day where cars are stuck in traffic, the inside of an engine compartment can get really hot, and over time,  causing the battery water to evaporate and battery plates to go bad. On an ordinary day, the manifold tempreature can go up to 204°C. The radiant heat inside the engine compartment can easily soar up to 85°C.

204.8 °C ?

Of late, it has been noted that some car manufacturers have gone to the extend of making simple battery shields. Shileds like this don't look like much, but in hot climates like Malaysia, every bit counts. The shields block hot air from being blown at the batteries directly.

Find out how you can DIY your own Battery Shields using corgurated plastic boards.

Some pictures of hot engines without battery shields. Note the red arrows that show how heat from the engine affect the battery.