May 23, 2025

Sealed Lead-acid Battery Charging

CHARGING

Dr. Olson has particular expertise in charging lead-acid batteries. In particular, sealed (aka VRLA, AGM, Gel) batteries are difficult to charge properly. Dr. Bob Nelson called it a knife edge because overcharge leads to dramatically lower lifetimes, but undercharge is worse leading to a rapid degradation of capacity. To make things more complex, the optimum charge varies over the life of the battery. Charging large packs adds another layer of complexity to the optimization of charging.

Long Charge Times: Any lead-acid battery requires long charge times of about 16 hours for full charge. Dr. Olson has developed effective charge algorithms that can reduce this time to 3 – 4 hours.

Recovering Aged Batteries: Another important area is recovering aged batteries. Lead-acid batteries will become resistant to standard charging techniques if they have aged due to prolonged storage. These batteries develop ‘sulfation’ which is resistant to charging. Depending on the condition of the battery they may be recovered with aggressive charging techniques.

Thermal Runaway: A related topic for sealed lead-acid batteries is thermal runaway. Overcharging, particularly at higher temperatures, can lead to thermal runaway that can permanently damage the batteries. Dr. Olson understands the mechanisms and can help you avoid the risks of thermal runaway.