Material composition study and computational evaluation toward the fabrication of tubular positive electrodes for high-capacity lead-acid batteries

Abstract

This study investigates the material composition and structural characteristics of tubular positive electrodes in high-capacity lead–acid batteries, combining experimental analysis with theoretical design calculations. Advanced characterization techniques, including X-ray diffraction (XRD), scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM–EDS), and infrared (IR) spectroscopy, were employed to identify phase composition, elemental constituents, and organic additives. Results indicate that the positive active mass primarily consists of tetragonal PbO₂ with minor orthorhombic PbSO₄, along with carbonaceous and polymeric conductive additives. The tubular sheath was found to be a polyester-based composite containing ester, alcohol, and anhydride functional groups, with silica-derived Si–O–Si structures. SEM analysis revealed a highly porous fine-particle morphology, suitable for binder-free filling into tubular casings. Computational design determined key structural and mass parameters of the positive active material (PAM), leading to an optimized electrode configuration with a theoretical battery capacity of 17,189 Ah. These findings provide a scientific basis for the domestic production of high-performance tubular lead–acid batteries.