Maintenance free thin plate developments for motive power applications

Agenda for
5-9 September

Raju Kurian
EnerSys, United States
Modern maintenance free material handling systems used in motive power Class 1,2,3 and AGV’s demand batteries to perform continuously in multiple shifts operation involving shorter frequent plug-ins in between operational periods.

TPPL (Thin Plate Pure Lead) technology has been developed in 2V cells and 12V blocs and applied to such applications, as its high electrode surface area and low internal resistance allow rapid charging of the battery pack with high in-rush current, enabling to achieve full or near full SoC with short duration charging compared to their traditional flooded counterpart. In addition, advances in active materials, charging, design and advanced materials allow the batteries to efficiently operate in Partial State of Charge with periodic extended charging steps to ensure the battery returns to full SoC.

At EnerSys, we continuously innovate all aspects of the battery pack and system. EnerSys proprietary adaptive charging algorithms ensure the batteries for each application site is optimised to maximise the charging efficiency, energy throughput, duty cycle and overall cycle life.


Dr. Raju Kurian gained his PhD in Physical Chemistry from Indian Institute of Science, Bangalore, India in 1990. He has carried out Post doctoral research in Surface Science and Electrochemistry at Cardiff University, Wales, UK before joining the battery R&D group in EnerSys in 1997 focussing on Electrochemical, materials and process developments of Thin Plate pure lead batteries. Currently he has the global responsibility of the electrochemical designs for Motive power, Reserve power and Speciality including aviation and defence batteries.