Evolution of internal resistance during formation of flooded lead-acid batteries

This study employs experimental techniques to measure the changing internal resistance of flooded, flat-plate lead-acid batteries during container formation, revealing a novel indicator of formation completeness. In order to measure internal resistance during formation, d.c. current pulses are superimposed over the constant formation current at set intervals, while change in voltage is measured. The resulting “pulsed” internal resistance is divided into ohmic and interfacial components by measuring the ohmic resistance with short d.c. pulses as well as with a.c. injection. Various constant-current container formations are carried out using different current levels, plate thicknesses, and pulsing techniques, yielding an array of resistance trends which are explained using Butler-Volmer kinetic theory. Ohmic and interfacial resistance trends are shown both theoretically and experimentally to eventually decay to a predictable steady-state value as the formation proceeds, suggesting that this internal resistance method can be used to detect the completion of the formation. The same principles are shown to apply to recharge cycles as well, but with potentially limited practical implications in comparison to formation.