Electronics > Projects, Designs, and Technical Stuff
New Alkaline Battery Leakage Testing
Prehistoricman:
More anecdotes:
I've found that smoke detector batteries have a high chance of leaking/exploding. They must have a light load to get the lifetime high.
Electro Detective:
--- Quote from: graybeard on March 26, 2020, 07:34:46 pm ---
Put the batteries in a valuable piece of equipment since those are the ones that always seem to leak. ;)
--- End quote ---
You can bet on that :clap:
DJ may have to choose an expensive or irreplaceable 'sacrifice' :'( if the current testing isn't going anywhere :horse: |O
graybeard:
From the Energizer publication: Alkaline Manganese Dioxide Handbook and Application Manual
On page 13: Do store batteries in a cool, dry place at normal room temperature. Remove batteries from devices that will be stored for extended periods. -- this suggests that moisture intrusion and elevated temperatures is an issue.
On page 14: Don’t mix old and new batteries, or mix different types or makes of batteries. This can cause rupture or leakage, resulting in personal injury or property damage -- this suggests that to get them to leak you should mix batteries in different states of discharge.
From this Duracell publication: Alkaline-Manganese Dioxide
On page 11 section 7.1: Batteries should be stored at temperatures between 50°F (10°C) and 77°F (25°C), with relative humidity not exceeding 65 percent. Refrigeration of alkaline batteries is not necessary because of their very good capacity retention. Excessive temperature cycling and storage at temperatures greater than 77°F (25°C)should be avoided to maximize shelf life. -- this suggests the both extreme temperatures and high humidity should be avoided. Although this is not stated as being a cause of leakage it certainly could be a contributing factor.
Duracell publication: Alkaline Manganese Dioxide Battery Product Safety, Transportation and Disposal This also suggest limiting temperature and humidity.
This in an interesting paper from University of Babylon in Hillah, Iraq: ALKALINE-MANGANESE DIOXIDE BATTERIES -- this is a good summary of cell sizes, construction methods and materials
This paper on a US DOE web site describes in detail the chemical mechanism of battery leakage: Understanding the Dynamics of Primary Zn-Mn02 Alkaline Battery Gassing with Operando Visualization and Pressure Cells -- "It is shown that steep concentration gradients emerge during the cell discharge through a redox electrolyte mechanism, leading to the formation of high surface area Zn deposits that experience rapid corrosion when the cell rests to its open circuit voltage. Such corrosion is paired with the release of hydrogen and high cell pressure" —eventually leading to cell rupture" -- to me the paper suggests that fast high current discharge followed an open circuit may be best way to get leakage. It also has some interesting electron microscope photos.
magic:
--- Quote from: graybeard on March 28, 2020, 07:10:40 am ---This paper on a US DOE web site describes in detail the chemical mechanism of battery leakage: Understanding the Dynamics of Primary Zn-Mn02 Alkaline Battery Gassing with Operando Visualization and Pressure Cells -- "It is shown that steep concentration gradients emerge during the cell discharge through a redox electrolyte mechanism, leading to the formation of high surface area Zn deposits that experience rapid corrosion when the cell rests to its open circuit voltage. Such corrosion is paired with the release of hydrogen and high cell pressure" —eventually leading to cell rupture" -- to me the paper suggests that fast high current discharge followed an open circuit may be best way to get leakage. It also has some interesting electron microscope photos.
--- End quote ---
Good find. It seems that what it takes is a fast discharge and then open circuit.
Not sure if deep discharge increases chances of leaking or if it's enough to just get to the point of rising ESR as formation of "black Zn" (blamed for leaking) appears to be correlated with "cell passivation" (blamed for ESR).
mzzj:
I was sorting out some random batteries I had lying around benches by measuring the short-circuit current of them and found out that every one of them had leaked 6mo later. (but most were chinese Ikea batteries)
I replace probably 200 AA batteries per year at work and the old ones go to collection bin. Last time I was emptying it 99% of the batteries that had been sitting there probably up to 3 years after use were still looking ok.
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