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A method of making a lead alloy grid for use in a plate for a lead acid battery that enables thin battery plates with a high surface area. The method of the present invention includes forming the lead alloy, such as by direct casting, to a very small thickness, then work hardening the cast strip to

A method of making a lead alloy grid for use in a plate for a lead acid battery that enables thin battery plates with a high surface area. The method of the present invention includes forming the lead alloy, such as by direct casting, to a very small thickness, then work hardening the cast strip to create a grid by forming indentations and protrusions in the thinly cast alloy strip, which in addition to strengthening the strip, provides a desirable surface topography for paste adhesion and interface characteristics. The work hardening, for example embossing, may further include splitting the strip at a high point of the protrusions and indentations to create perforated protrusions and indentations. The grid may then be used to make a plate by pasting an active mass onto the grid, steaming the pasted grid, and curing the pasted grid to provide a plate having a thickness of about 0.05 inch or less. There is further provided a lead alloy grid for use in a plate of a lead acid battery, the grid comprising a cast lead-tin-calcium alloy having spaced protrusions and indentations on each opposing surface of the grid. The protrusions and indentations may further include a perforation. The grid has a higher surface area than punched or expanded grids, thereby providing a lower resistance and better adherence at the paste/grid interface.

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1. A method of making a lead alloy grid for use in a plate of a lead acid battery, comprising the steps of:forming a strip of a lead-tin-calcium alloy; andforming a plurality of indentations in a surface of the strip,wherein the alloy is formed to a thickness in the range of about 0.005-0.015 inch.

1. A method of making a lead alloy grid for use in a plate of a lead acid battery, comprising the steps of:forming a strip of a lead-tin-calcium alloy; andforming a plurality of indentations in a surface of the strip,wherein the alloy is formed to a thickness in the range of about 0.005-0.015 inch. 2. The method of claim 1 wherein the alloy is Pb-1.5Sn-0.08Ca. 3. The method of claim 1 wherein forming the strip includes direct casting the alloy. 4. The method of claim 3 wherein the alloy is direct cast to a thickness in the range of about 0.005-0.015 inch. 5. The method of claim 1 further comprising forming perforations within the indentations. 6. The method of claim 1 wherein the plurality of indentations are formed in each of the opposing surfaces of the strip. 7. The method of claim 1 further comprising, prior to forming the indentations, rolling the strip to reduce its thickness. 8. The method of claim 7 wherein the rolling reduces the strip to a thickness in the range of about 0.005-0.015 inch. 9. The method of claim 1 wherein forming the indentations includes embossing the surface to form pyramid-shaped indentations each having a central indented area surrounded by four angled surfaces. 10. The method of claim 9 wherein the embossing further includes splitting the strip in the central indented areas to form perforated indentations. 11. The method of claim 1 wherein the work hardening includes embossing the surface to form diamond-shaped indentations each having a central indented point surrounded by four angled surfaces. 12. The method of claim 11 wherein the embossing further includes splitting the strip at the central indented points to form perforated indentations. 13. The method of claim 1 wherein work hardening includes embossing the surface to form hemispherical-shaped indentations. 14. The method of claim 1 wherein work hardening includes knurling the surface. 15. A method of making a plate for a lead acid battery comprising the steps of applying an active mass paste to a lead alloy grid formed by the method of claim 1 to form a pasted grid, then steaming the pasted grid, and curing the pasted grid. 16. A method of making a plate for a lead acid battery comprising the steps of applying an active mass paste to a lead alloy grid formed by the method of claim 4 to form a pasted grid, then steaming the pasted grid, and curing the pasted grid, wherein the cured pasted grid has a thickness of about 0.05 inch or less. 17. A method of making a lead alloy grid for use in a plate of a lead acid battery, comprising the steps of:direct casting a strip of a lead-tin-calcium alloy onto a drum to form a cast strip of thickness in the range of about 0.005-0.015 inch; andembossing opposing surfaces of the cast strip to form a pattern on each surface of protrusions and indentations. 18. The method of claim 17 wherein the alloy is Pb-1.5Sn-0.08Ca. 19. The method of claim 17 wherein the embossing further includes splitting the strip at a high point of the protrusions and indentations. 20. The method of claim 17 wherein the embossing forms pyramid-shaped protrusions and indentations each having a central area surrounded by four angled surfaces. 21. The method of claim 20 wherein the embossing further includes splitting the strip in the central areas to form perforated protrusions and indentations. 22. The method of claim 17 wherein the embossing forms cone-shaped protrusions and indentations each having a central point surrounded by an angled surface. 23. The method of claim 22 wherein the embossing further includes splitting the strip at the central points to form perforated protrusions and indentations. 24. The method of claim 17 wherein the embossing forms hemispherical-shaped protrusions and indentations. 25. A method of making a plate for a lead acid battery comprising the steps of applying an active mass paste to a lead alloy grid formed by the method of claim 17 to form a pasted grid, then steaming the pasted grid, and curing t he pasted grid, wherein the cured pasted grid has a thickness of about 0.05 inch or less. 26. A method of making a plate for a lead acid battery comprising the steps of applying an active mass paste to a lead alloy grid formed by the method of claim 19 to form a pasted grid, then steaming the pasted grid, and curing the pasted grid, wherein the cured pasted grid has a thickness of about 0.05 inch or less. 27. A lead alloy grid for use in a plate of a lead acid battery, the grid comprising a cast lead-tin-calcium alloy having on each of opposing surfaces a pattern of space protrusions and indentations, wherein the grid between the spaced protrusions and indentations has a thickness of about 0.005-0.015 inch. 28. The grid of claim 27 wherein the protrusions and indentations are evenly spaced apart at a distance of about 0.01-0.03 inch. 29. The grid of claim 27 wherein the alloy is Pb-1.5Sn-0.08Ca. 30. The grid of claim 27 further including a perforation at a high point of each of the protrusions and indentations. 31. The grid of claim 27 wherein the protrusions and indentations are pyramid-shaped, each having a central area surrounded by four angled surfaces. 32. The grid of claim 31 further including a perforation in each central area. 33. The grid of claim 27 wherein the protrusions and indentations are diamond-shaped, each having a central point surrounded by four angled surfaces. 34. The grid of claim 33 further including a perforation at each central point. 35. The grid of claim 27 wherein the protrusions and indentations are hemispherical-shaped. 36. A plate for a lead acid battery comprising a cured active mass on the lead alloy grid of claim 27, wherein the plate has a thickness of about 0.05 inch or less. 37. A plate for a lead acid battery comprising a cured active mass on the lead alloy grid of claim 27, wherein the plate has a thickness of about 0.005 inch or less.