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Is Lifeline At the Heart of Your System?

If you are a fine coffee barista and you purchased a top of the line european espresso machine, would you put generic store can coffee grounds in it? If you built a first class outdoor BBQ station would you flip frozen beef patties on it? If you had a Porsche, BMW or Ferrari would you put low grade fuel in your tank? So, if you spent the money to purchase an RV, trailer, boat or yacht what kind of battery would you choose to put at the heart of your system? Shouldn’t you think about getting the best battery for your best stuff? On that note, who makes the best battery and how do they do it?

When it comes to manufacturing AGM deep cycle batteries, what does it take to be the best, to be set apart from the rest of the Industry? There are many significant factors involved in contributing to Lifeline battery’s unparalleled performance.  The best possible material selection, unmatched innovation and an unprecedented, zero flaw manufacturing process is what is required. This article is going to highlight the top four factors!

Number 1

Let’s say it first and then explain it – proprietary lead oxide paste. This particular material may be considered the single most important ingredient in a battery. It is after all called the active ingredient. Lifeline has unmatched proprietary lead-oxide paste. The 100% virgin lead is subjected to extremely stringent testing prior to using!  This is a significant fact,  that the this proprietary lead oxide paste (the active ingredient) that is used in the lifeline RV/Marine/Deep cycle batteries is the same one they use in the aerospace industries and applications within the branches of the US military and others around the world. It is used on both the positive and negative battery grids.  Inside the battery these grids, rectangular shaped lead alloy framework, are compressed or packed with a lead metallic (lead oxide) paste. When these grids receive electrical current through electrical charging down from and through the terminals into the grids, then the paste material reacts with the electrolyte (sulfuric liquid acid) and that creates an electrochemical reaction-that’s the power! The paste & grid are together as one structure called the plate. This is the key ingredient and this paste is where so much difference can be made. If you can make your active ingredient material and it’s holding structure it adheres to better and able to last longer than it stands to reason you can dramatically increase your battery power potential and the longevity of that potential in your battery. This is a primary focus at Lifeline and this is largely responsible for expanding the lifespan past other battery manufacturers.  However, aside from highest possible quality material, you have to look further to the process as well! When you talk with Lifeline representatives and ask what is it really that’s different you get an earful. However, regarding the proprietary “secret sauce” you won’t get that specific private info, but you will get answers that address in great detail about the elaborate process of how it is chemically structured and how the higher quality materials are put together. There is an enormous difference in the development process too. It gets very scientific and the explanations become lengthy and require time to grasp the difference and their implications. It’s not so easy to casually summarize in layman’s terms for those who don’t have chemical engineering degrees.  The standards there are uber stringent!  The Lifeline process for curing or forming the proprietary lead oxide paste onto the grids is laborious, prolonged and painstakingly overseen for minute imperfections and flaws. There are a multitude of redundancy checks along the way. This plate forming process with other battery manufacturers can take several hours and batteries get finished up and put out to market rather quickly. That is fine for the conventional batteries but the lifeline process takes several days just for this plate forming stage! There are extraordinary details that simply cannot be rushed or mass produced. This plate forming process for Lifeline is just not seen elsewhere in the industry. It requires a specific multi-set of levels of humidity and temperatures that are controlled and yet are varied thru the stages of the curing process over a much longer period of time. It has to be this way to perfectly form the most important component in the battery. The grids and plates that allow any imperfectly attached active material on it will shed and 10 or 15% or any measure imperfectly cured material is not acceptable and will impact the battery and its performance and lifespan. That’s why Lifeline has a 10-12 year design life. And through this whole process the structures have to be inspected by human eyes the whole way through. These structures are cured slowly and scientifically formed for flawless adhesion. Less than perfect results are identified at each stage check and are abandoned and thrown out and recycled. If the paste is not 100 % adhered to the grid for plate perfection all that production run gets dumped and is viewed as unreliable. If the grids have 10 or 15 percent lack of cohesion of the formed plate then your battery active material and structure may be 10 or 15 percent defective already before it gets put into the battery boxes! Chemical ratios and a much longer curing processes are strictly followed and inspected and overseen to perfection. These are the standards and specs for aerospace and military industries and their demands and standards make no exceptions. This is what you are paying for when you buy a Lifeline battery!

Number 2

Another manufacturing focus is the “double separator” which resides between the positive and negative plates. The highest standard of glass matting in the world has been identified and is employed. No other glass matt options are allowed. Unlike other battery manufacturers, lifeline envelopes their AGM separators with a thin layer of microporous polyethylene. The polyethylene is then sealed along the side eliminating the possibility of a short at the edges of the plate. A short in the battery is caused by released or shed material falling off the plate inside the battery and is the most common cause of battery failure. Greater lifespan of the formed materials leads to greater life span of the battery. Again this same process is used in the military spec and commercial aviation batteries from condord/lifeline and the requirements in those industries are the most stringent. Again entire lots of batteries have to pass mil spec with virtually identical results or entire groups of batteries are rejected and scrapped. To pass such tests the materials and the process have to be flawless and perfect.

Number 3

A third consideration to look at is the “over the partition” cell connections. The plates formed from the grids with other combined items become the cells within each of the cell sections inside the battery box where they reside but they have to be connected together and connected back up to the terminal post at the top of the battery to complete the electrical series. The battery industry has one way of doing this but Lifeline has a better way. The battery industry using spot welds connects the cells by going through the partitions (plastic cell chamber walls) in the battery box. It is certainly faster that way in mass production to complete the manufacturing process and get the batteries to market and yes faster involves less labor, time and is cheaper over all. But defects can not be inspected that way as the process is not in full view to the human eye and therefore defects are simply not visible. When the cells are conencted over the partition the process is reviewable and inspection can catch any manufacturing defects. Additionally, larger and stronger inter cell connections can be made over the partition.

Number #4

Not that all of the contributing factors are revealed here and certianly no privately guarded industry secrets are available to the public eye, but the fourth and final contributor on this list is extra thick positive grids. Once again the industry has a standard by which they follow, but Lifeline chooses to set new standards that are significantly higher. The industry norm for plate thickness in AGM batteries is .045 to .064 inches. Lifeline deploys a plate that is between .095 and .105 inches thick. The thickness of the plate helps to enable it to hold together longer. Te extra thick plates allow the lifeline battery to provide a much longer and deeper discharge in the battery. You could just say the lifeline battery is able to offer more electrical power longer and more fully before that battery needs to be charged back up.

This by no means explains all of the contributing factors nor all the detailed differences in the manufacturing processes and or material selection used by Lifeine battery company, but this gives you a good overview summary view with enough details to asses the lifeline difference. This is what it takes to be the best AGM deep cycle battery manufacturer anywhere!

Lifeline Batteries can be found online at www.powerstridebattery.com.

 

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