How Is A Car Battery Made, And What Defines It As A Lead Acid Battery?

how is a car battery madeSo, how is a car battery made? Whether it is laptops, mobile phones, or vehicle batteries, they all operate on the same basic principles. The cell configuration has a positive and negative terminal, which allows the transport of electricity. This electricity is carried by negatively charged sub-atomic particles called electrons.

A vehicle’s battery allows electric current to flow through your car, and therefore, will enable it to come alive. Your battery powers various components, such as the central locking, your windshield wipers, and of course, your engine. Without a surge of energy, your engine would not work, and your car would not run.

How is a car battery made to produce electrical energy that powers your vehicle?

One of its most important components is sulfuric acid, which provides the necessary process that allows ions to drive an electronic reaction, and lead, which conducts electricity. When your battery discharges, the plates contain lead sulphate. As the battery is charged, a chemical response renders this coating as lead oxide.

An automotive battery can generate 12 volts and comprises six cells, each of which can produce 2 volts. Each cell contains a positively and negatively charged lead plate. They start as lead ingots and are quickly melted and malleable: they can be moulded, flattened, and shaped according to your needs, and they can freely conduct electricity.

Combining Lead, Sulfuric Acid And Polypropylene, How Is A Car Battery Made In The Production Line?

Lead ingots are melted down, and after several processing reactions, atomized. This spray of lead is combined with oxygen, producing a toxic metal called lead oxide. Resembling powdery dirt, lead oxide is extremely dangerous; it can poison all living systems. Workers need to protect themselves with face masks to avoid inhaling lead oxide.

A vehicle battery contains around 90-100 grids on which lead is mounted. The lead oxide is pressed onto these grids, creating a weighty component. These grids go through a flash drying process, which completely removes any moisture. Because of their weight, robotic machines are needed to stack the finished plates together, forming the battery’s basic cells.

The end product is a heavy automotive battery that contains around 20 pounds of lead. They are assembled on a conveyor belt: the outer polypropylene casing is fitted with the cells, and other components, such as terminals, are added to the battery. In the final process, they are filled with a mixture of 35% sulfuric acid and water and are charged before being shipped off to car manufacturers and battery retailers.


So, now that we have answered your question, “How is a car battery made?” you will learn to appreciate what an important component your battery plays in keeping both you and your vehicle mobile and safe.

We highly recommend a great resource on common frequently asked battery questions. (Opens in new window)

next how does a car battery work

Next Page: How Does A Car Battery Work