Automotive batteries of the AGM (Absorbent Glass Mat) type are modern energy carriers, in the design of which fiberglass separators play an important role. These components ensure high energy density, safety, and long battery life. The Edcon brand uses innovative technologies based on high-tech methods of forming active materials and the production of high-quality fiberglass separators, which makes it possible to create high-end products.
The main stages of Edcon AGM battery manufacturing technology
The process begins with the production of active electrode materials. An alloy of calcium and lead, which has high electrical conductivity and corrosion resistance, is used for negative plates, while lead oxides, stabilized to increase cyclic resistance, are used for positive plates. The molten components are processed in vacuum furnaces at temperatures above 1200 °C, after which they are quickly cooled and crushed. The resulting parts are formed into microporous components, which are then pressed and heat treated to fix the structure.
The treated plates are stabilized by heating under controlled conditions, which increases porosity and ensures good contact with the electrolyte. After that, they are cut, covered with protective layers and undergo additional stages of drying and profile processing.
At the same time, fiberglass separators for AGM are being created. This process begins with the melting of the original glass fiber in special furnaces at a temperature of about 1200 ° C. Then, thin strands of fiberglass strands are pulled out of the melt, which are assembled into fiber matrices. These matrices undergo standard bonding, molding, and drying processes to create high-strength microporous membranes.
To enhance the hydrophilic properties of the membranes, special coated materials are applied to them, increasing their ability to quickly absorb electrolyte. After applying the protective layers, the membranes are heated in furnaces at temperatures around 100-200 ° C, which helps to consolidate the structure and increase chemical resistance. During further heat treatment, the density and porosity of the membranes increases, which is important for their further operation.
The finished canvases are cut to standard sizes using automatic machines, which ensures the accuracy and repeatability of the shapes. At this stage, it is possible to process the edges and apply additional protective coatings to increase the durability of the separators.
Production samples undergo strict quality control: microporosity and hydrophilicity, resistance to electrolyte, mechanical strength and uniformity of structure are checked. This ensures that each separator meets the necessary requirements to ensure long-term and safe operation of the Edcon battery.
After manufacturing the active plates and separators, all components are assembled into a single battery pack. The plates are placed with separators in a plastic case, then the electrolyte, sulfuric acid, is automatically poured inside with water in precise concentrations. After that, the product is vacuum treated to remove air bubbles and moisture, which increases its tightness and durability. Final testing evaluates resistance, capacity, and tightness to ensure that products meet high standards.
Advantages of Edcon batteries manufactured using AGM technology compared to conventional batteries:
- convenience and safety in vehicles with lots of equipment. AGM batteries are a reliable power source for electronic systems;
- guaranteed engine start at extremely low temperatures;
- high output current during cold start;
- fast charging and resistance to deep discharges;
- three times longer cycle life compared to conventional batteries;
- protection against shocks and vibrations due to the use of shockproof housing and vibration-resistant materials, which is especially important when operating off-road;
- compliance with the requirements of Start-Stop systems, both basic and advanced (with regenerative braking);
- protection against electrolyte leaks due to the use of AGM technology — the electrolyte is contained in absorbent glass fiber;
- does not require refilling water — completely maintenance-free battery.
