Lead batteries are designed as either flooded or valve-regulated, depending on the needs of a particular application or the end user’s preference. Flooded batteries, also known as wet cell batteries, power a wide range of industrial and automotive applications. Here, we’ll discuss what flooded lead batteries are, their benefits, and what distinguishes them from sealed batteries.
Also referred to as wet cell batteries, flooded lead batteries feature a traditional design that consists of thick lead plates submerged in a liquid sulfuric acid electrolyte solution within the battery, which “floods” the plates so they’re entirely submerged. To prevent short circuits and safeguard the battery’s energy and cycle life, the lead plates are isolated from one another using separators. It’s also important to mount these batteries in an upright position to prevent the electrolyte from leaking out of the battery’s caps toward the top of the encasement.
These batteries have a low upfront cost in automotive and industrial truck applications. Although flooded batteries are cost-effective in specific applications, they also require regular maintenance in industrial applications to reach their full potential lifespan. Maintenance entails checking the battery on a regular basis and topping it off using distilled water.
Flooded batteries and sealed valve-regulated lead acid (VRLA) batteries share similarities in their weight and size, but they’re also different in several key ways.
The biggest difference between these batteries is their maintenance requirements. Flooded batteries require the occasional addition of distilled water, along with equalization in industrial applications. They also require users to measure the gravity of the electrolyte using a hydrometer. Additionally, flooded lead batteries may off-gas hydrogen under some circumstances, necessitating proper ventilation to release fumes.
However, depending on the application, flooded batteries can be considerably more cost-effective for upfront purchases than maintenance-free sealed batteries. Determine the total cost of ownership for your application when deciding to purchase a flooded or VRLA lead battery.
Flooded batteries and AGM batteries (VRLA) are two commonly used types of rechargeable lead acid batteries. They both require an electrolyte solution to create a chemical reaction and produce electrons. Here is an overview of their key differences.
While there are many types of lead acid batteries, flooded lead batteries, or “wet cell” batteries, are the most widely used. They feature a traditional design and have a long, proven history of use throughout many industrial applications. Flooded lead batteries come in a wide variety of shapes and sizes and are typically more cost-effective than AGM batteries.
In most cases, flooded batteries are not leak proof, and they do not recombine the gasses into liquids internally. Instead, any gasses that are produced internally are vented outside of the battery into the environment. The battery’s vents release condensation, steam, and acid, which depletes internal electrolyte levels over time.
The electrolytes that evaporate through the battery’s vents must be regularly replenished so that the lead plates never come into contact with the atmosphere. If they are exposed, they begin to oxidize, sulfate, and will eventually cause failure. Flooded batteries feature a weaker internal construction than AGM batteries and have higher internal resistance.
Absorbed glass mat (AGM) batteries are advanced lead batteries and are used for demanding applications. They feature a microfiber glass separator between the lead plates and wrappers to hold the electrolyte in place. The lead plates and AGM separator (with electrolyte) are held under pressure in a confined space, AGM separator has intimate contact with the electrodes and holds the electrolyte inside of the glass mat rather than in a free liquid form. For this reason, AGM batteries are spill-proof even if tipped over.
Since they are tightly packed, AGM batteries are more vibration-resistant than flooded batteries and feature low internal resistance. This low internal resistance allows high current charging for reduced charging times and fast capacity recovery. Unlike flooded batteries, AGM batteries are maintenance-free, as their electrolyte does not evaporate and doesn’t require monitoring or replenishment.
Flooded lead acid batteries come with several main advantages, including:
These benefits make flooded lead batteries highly versatile and compatible with a wide variety of applications, particularly as a solution for the automotive industry or industrial backup power, where both ventilation and maintenance are possible.
Flooded lead batteries are ideal for use in many applications across a wide range of industries. They can be a cost-competitive option enabling you to benefit from long-lasting energy. If you’re looking for the ideal flooded lead acid battery or VRLA battery solutions for your systems, turn to H&V. Our selection of flooded lead battery products includes Hi-Sep separators for high-temperature flooded batteries and PA10-6, a glass microfiber paste additive that enhances lead plate curing during processing and improves overall battery performance.
To learn more about our flooded lead battery products, contact us today.
