The gel electrolyte significantly influences gel valve-regulated lead acid battery performance. To address this, the paper describes the preparation of novel polymer gel electrolytes using poly (vinyl alcohol) (PVA) and tetraethylorthosilicate (TEOS) for valve-regulated lead–acid batteries. FTIR technique is used to confirm the chemical reaction between PVA and TEOS. Electrochemical analyses such as cyclic voltammetry and electrochemical impedance spectroscopy were applied to optimize the concentration of PVA-TEOS polymer gel electrolyte. The optimum concentration of polymer gel electrolyte was determined as 20 wt% of TEOS in PVA (PE-1) with higher anodic peak and lower Rs and Rct values. The Galvanostatic charge–discharge tests were performed on the optimized gel system prototype battery. The highest capacity of 6.86 × 10−5 Ah at a current density of 0.2 mA cm−2 was achieved with an excellent capacity retention ratio of 85.7% over 500 cycles. The exceptional cycle performance and high capacity make PVA-TEOS gel electrolyte a promising candidate for practical battery application.

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