Valve-regulated lead-acid (VRLA) batteries have been commercially available for more than 20 years and have been enthusiastically embraced by users of uninterruptible power supplies (UPS) because of the anticipated reduction in installation and operating costs, smaller footprint and fewer environmental concerns. In Japan, communication networks are demanding reduced costs and longer life from their batteries. Among the factors limiting the life of VRLA batteries, the corrosion of positive grid material has been proven to cause elongation of the plates, loss of electrical contact and shorter lifetime. The content of Sn is also a key factor and addition of Sn in the grid alloy results in better performance in creep resistance, tensile strength and corrosion resistance [R. David Prenagaman, The Battery Man, vol. 39, September 1997, p. 16. I. Mukaitani, T. Sakamoto, T. Kikuoka, Y. Yamaguchi, H. Tsubakino, Proceedings of the 40th Battery Symposium in Japan, 1999, p. 99]. A key point is what the ratio of Sn to Ca should be, since too much Sn may lead to even worse elongation of the plates [I. Mukaitani, T. Sakamoto, T. Kikuoka, Y. Yamaguchi, H. Tsubakino, Proceedings of the 40th Battery Symposium in Japan, 1999, p. 99]. We have determined that microstructure control with a composition of lead-calcium-tin (Pb-Ca-Sn) alloy is optimal for better performance of the plates [I. Mukaitani, T. Sakamoto, T. Kikuoka, Y. Yamaguchi, H. Tsubakino, Proceedings of the 40th Battery Symposium in Japan, 1999, P. 99]. We developed a "simulation of current collector corrosion elongation" which is a technique of estimating corrosion elongation from the current collector design [I. Mukaitani, K. Hayashi, I. Shimoura, H. Takabayashi, M. Terada, A. Takemasa, I. Takahashi, K. Okamoto, Proceedings of the 44th Battery Symposium in Japan, 2003, p. 652]. Corrosion elongation occurs as the corrosion material layer grows out of the current collector metal. We resolved this problem using generally CAD software "Solid Works" and computer aided engineering (CAE) software "ANSYS" with corrosion elongation transformed into thermal elongation. We established a current collector corrosion elongation forecast and found that the microstructure controlled the Pb-Ca-Sn alloy; thus newly designed VRLA batteries (MU-series [A. Takemasa, I. Mukaitani, Y. Yoshiyama, K. Fukuri, T. Sakamoto, T. Kuwano, M. Fukuda, H. Misaki, K. Uwatari, Shin-Kobe Technical Report 9 (1999) 111 for telecommunication and LL-series [H. Takabayashi, T. Shibahara, Y. Mastuda, K. Fukui, S. Hazui, Y. Matsumura, S. Kondo, Shin-Kobe Tech. Rep. 11 (2001) 351 for electric energy storage) which are lightweight and have long life are introduced here. (c) 2004 Elsevier B.V. All rights reserved.