PASTING MACHINE

The machine is configured to run continuous cast grid strip, single or

double panel. It is also available for pasting expanded metal grid strip
(Customer to specify).
The internal hopper roller design allows adjustment to crush oxide particles
or lumps in the paste. Hopper design requires changeover of the upper
orifice plate for a change in pasted plate heights. Variable speed drive for
the hopper to provide controlled paste feed. It includes paper roller system.
Stainless steel belt with precision roller support to ensure pasted plate
thickness

THE WIRTZ machine

General Specifications

• Pasting tolerance of plus or minus 2 grams.

• Plate thickness of plus or minus 0.002” (0.54mm).
• Increased plate and battery performance.
• Increased productivity, machine speeds up to 200 feet per minute.
• Cleans up environmental problems.
• PLC Control with operator interface.
• No cloth pasting belts.
• No shovel back of paste into the hopper.
• Every plate consistent in size reduces production problems.

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• Plate thickness can be adjusted while pastor is operating +/- 0.015”
(0.38mm) from nominal

Thickness setting.

Change over time for grid/plate height 15 minutes.

Grid Size Range Capability

Overall length, over panel frames: 4.0” to 12.0”(101.6mm to 304.8mm)
Maximum overall length: 14.0” (355.6mm)
Grid strip thickness range: 0.010” to 0.100” (0.25mm to 2.54mm)
Pasting Range 0.006 to 0.040” above nominal grid strip thickness (0.15mm
to 1.0mm).

Pasting Tolerances
Weight: Nominal plus or minus 2 grams(0.0044lb)
Thickness: Nominal plus or minus 0.002” (0.054mm)

Required Paste Parameters

Moisture: 10 to 14 %
Density: 62 to 74 grams / cubic inch Cube Wt: (3.78 to 4.51 grams
/ cu cm) Penetration: 20 to 30
Fiber Additives: Maximum length 0.06” (1.52mm) of “non-balling”
type fiber

Typical Machine up Time

90%+ of disposable time per shift.

Tooling Changeover Time

Change in grid/plate height: 15 minutes

Change in grid/plate thickness: 0 minutes for change of +/- .030”
(0.76mm) from nominal thickness setting. 10 minutes for change
greater than +/- 0.030” (0.76mm) from nominal setti

Physical Dimensions

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Paste Machine
Overall Length: 123.25” (3131mm)
Overall Width: 33.7” (856mm)
Height, floor to top of hopper in down position: 60.69” (1542mm)
Floor to top of hopper in up position: 71.50” (1816mm)
Floor to top of belt: 36.38” (924mm)
Floor space: 17.5 sq. ft. (1.63 sq. meters)

Utility Requirements
Electrical Power Input: 460V, 60 hz, 3-phase standard 200v - 575v, 50hz or
60hz, 3-phase available on request
Approximate power consumption: 20 KVA.
All wiring conforms to NFPA. Build to special or IEC (CE) codes available.
Compressed Air Supply pressure to be 65 to 85 PSI (4.48 to 5.86 bars) Air
consumption is approximately 1 cubic foot per hour (for intermittent hopper
tilt and hopper latch cylinder operation)
Process Water Supply pressure to be 20 to 50 PSI (1.38 to 3.45 Bars)
Maximum consumption rate during machine operation is 6 GPH, for metal
belt and roller cleaners (22.7 liters/hour). A solenoid valve limits water
spray application to periods of machine operation only. Requires clean
water source with minimum mineral solids content connected to 1/2 inch
NPT inlet cartridge filter.

Note:
1) Drainage required at Paster for process water and machine wash-down
water.
2) Daily machine wash-down is recommended using highpressure water.
(900 - 1200 PSI or 62 to 82 Bars, at about 2 gallons or 7.57 liters / minute
rate)

.
Factors and conditions affecting the pasting processes
Paste Preparation

The first stage in LABs. manufacturing is the paste formation. It is prepared

from industrial leady oxides using sulphuric acid and water in proportions ranging
between 5&10% depending 53 on the PbO: H2O ratio. The variation of the acid
proportions : water lead oxide has some effects on the properties of the produced
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 plates. Pastes containing 5-7% H2SO4 were reported 54 to give the best results.
Some additives may also be added 55-57 to the paste. The added to the positive plates
were silica gel and sodium lignin sulphonate. On the other hand, expender
materials were added to the negative plates such as humic acid, barium sulphate,
lignosulphonates , carbon black and -naphtholsulphonic acid formaldehyde
phenol copolymer (BNF).

Effect of acid concentration on the phase composition of the paste

The phase composition of the pastes prepared by using different acid concentrations was
reported58. The addition of 1% H2SO4 (H2SO4:PbO), sp. gr. 1.4 at 30°C gave a small amount of
3BS, while 6% H2SO4 gave 3BS with small amounts of -PbO and -PbO. The higher H2SO4
concentration, 12% favoured the presence of PbO.PbSO 4 (BS), 3BS with small amounts of -
PbO.
Zerroual et al. 50 studied the influence of the initial amount of sulphuric acid added to
leady oxide powder using XRD, SEM, IR and wet chemical analysis. It was observed that up to
5% sulphuric acid (H2SO4:PbO) and at 70°C, 3BS is the major phase which was formed in the
paste. Above 8% H2SO4, 3BS compound disappeared progressively and became PbO.PbSO 4.
Due to insufficient addition and poor mixing of acid to the leady oxide, the following species
were detected 60,61 in the paste : Pb, PbO , Pb3O4, PbOn.H2O , BS, 3BS and 4BS

Effect of time and Temperature on the phase composition of the

paste
The influence of stand time on the paste preparation was studied 60 using XRD and
SEM. The acid concentration used for pasting was 6% and sp.gr. 1.4.The mixing
temperatures and time for two pastes were 60°C, 30min. and 80°C, 60min.
respectively. They were selected so that the only basic lead sulphate present at the
lower temperature was 3BS and at the higher one 4BS. It was observed that a
continuous recrystallization process and a clear growth of crystal size were
achieved in 3BS pastes during standing. In the 4BS paste the crystal growth due to
rearrangement of the crystals finished after one hour of standing.
Pavlov and Kapkov 62 studied the paste preparation at 80°C using 6% H 2SO4 of
sp.gr.1.4. The XRD and SEM showed that lead oxide reacted with H 2SO4 forming
3BS first. The rate of this reaction was very high. Between the 5 th and the 15th min.,
part of -PbO was transformed into -PbO. Tetra basic lead sulphate formation
started between the 5th and 15th min. and went on until the 50th min.Up to the 5th
min. the Pb amount already in the paste decreased from 22 to 7% and the reaction
proceeded slowly there till the 60 th min., the paste contained 5% of lead. SEM
showed that the paste consisted of large prismatic 4BS and small -PbO & -PbO
ones. The 4BS crystals had well-pronounced walls, edges and apexes.

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 Process
Pasting machine

 Applying of paste into grid structure

 Applying of paper on all sides of grid ribbon

Pasting machine – Pasting paper specification

To cover normal plates during pasting

Specification:
Data No.
Grade Type BAT 15M 1
Substance (gr/m2) 12.5----- 15 2
Thickness (mm) at 100 Kpa 0.035 -or-0.045 3
Tensile Strength N/15mm MD 10------12 4
CD 4.4--------6

Wet Tensile N/15mm MD 3.5 5

Air Permeability I/Sm2 at 2 mbar 800----1700 6
Capillary (mm/10min) 20-----30 7
Moisture % 5 8

These values are obtained under test conditions (Temperature 23° C, humidity
50%HR)
Physical properties
Properties Effect Benefit
Purity Less short circuit by chemical Higher battery quality
reaction with lead Lower claim quote
Less discharge between positive and Higher life time
negative plates Excellent recyclability
Better water regulation of the battery
Less chemical residue in recycling
Porosity No need for needle punching Higher efficiency
Better paste adhesion Lower waste rate
Higher water absorption Faster drying
Possibility to work with several lead Higher flexibility
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 formulations
Thickness No cutting issues Lower claim quotes
Less bubbling during process Reduction of curing room
No peeling effect process
Reduction of fire hazard
Water Higher water absorption Higher efficiency
climb Faster saturation Better run ability

Impurities (max.):

pH 5-7
Ashes 0.02%
Cl 100 max. ppm
Fe 6 ---- 50 ppm
Mn 0.5 ----2 ppm
Cu 1 max. ppm
Zn 0.5 max. ppm
Ni 0.5 max. ppm

Identification:
Paper Composition according to automotive substances

5- Dimension characteristics
Paper Wide mm From 70 to 500 mm
Width tolerances mm
mm +1
Standard roll diameter mm Approx. 500
Inner Core Diameter mm Available 70 and 76

Parting machine

 Cuts continuous pasted ribbon into individual plates

 Cut plates in wire intersection of grids
 Plates are rolled at machine exit
 Individualises plates at machine exit by means of a faster running conveyor
section

Tunnel dryer
 Temperature:

7 Page 6 of
  100 -120 degrees Celsius
 Conveying speed: approx. 28 m/min
 Gas heated
 Protect exhaust system from clogging caused by paper shavings

Stacker
 Stack height both left and right: 120 plates
 Stacks are manual put into racks
 Adjust conveying speed to prevent twisted plates

Rack storage
 The racks are retrofitted with stainless steel overlays
 Racks setting: 5×2×4.
 Plate’s quantity per each rack: 3.000 pcs.
 Plates under treatment per cycle: 120.000.
 Maximum capacity: 22 tons for room (paste + grid).

Weight of Plate Before and After Flash

Type Grid Plate

Thickness Weight Thickness Weight Before Weight After
Flash Flash
+X 1.4 48 1.6 156 154
-X 1.25 44 1.45 136 134
+XW 1.4 43 1.6 136 134
-XW 1.25 39 1.45 123 121
+F 1.25 40 1.45 114 112
-F 1.15 40 1.35 107 105

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