This occurs when a battery stands in a partially or fully discharged state for long periods of time, or is continually undercharged. As a result of these conditions the active lead material on the plates becomes lead sulphate which also hardens the plates. Depending on the length of time the battery has been in this condition, the sulphation may be irreversible, in addition, if the electrolyte level in the battery is low, the exposed part of the plates will become inactive and sulphated. Therefore batteries with higher electrolyte levels will go a long way to reducing problems due to sulphation and assisting longer battery life. This is where there has been a complete failure of the intercell weld.
Weld quality is critical for reliable battery performance and good working life.
This problem is largely minimised by manufacturers like Century Yuasa Batteries and other leading manufacturers, due to accredited Quality Assured manufacturing processes. A broken busbar. This type of failure can be caused by excessive corrosion of the busbar due to low electrolyte level in the battery. Batteries with the capacity for higher electrolyte levels will help to ensure a longer battery life. It can also be a result of overcharging, cycling or elevated operating temperatures.