A new method using lead coated glass fiber to produce continuous wire for battery grid of electric vehicles (EVs) and hybrid electric vehicles (HEVs) was introduced. Under equal flow, both the maximum and minimum theoretical value of gap size were studied and estimation equation was established. The experimental results show that the gap size is a key parameter for the continuous coating extrusion process. Its maximum value (Hmax) is 0.24 mm and the minimum one (Hmin) is 0.12 mm. At a gap size of 0.18 mm, the maximum of metal extrusion per unit of time and optimal coating speed could be obtained.
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