Seals zinc-carbon cells

The zinc chloride Leclanch cell is a special modification of the carbon-zinc cell. They differ principally in the electrolyte systems used. The electrolyte in a zinc chloride cell contains only zinc chloride, while in a carbon-zinc cell the electrolyte contains a saturated solution of ammonium chloride in addition to zinc chloride. The omission of ammonium chloride improves the electrochemistry of the cells but places greater demands on the cell seal. Zinc chloride cells therefore have either a new type of seal not previously used in carbon-zinc cells or an improved conventional seal so that their shelf life is equivalent to that of carbon-zinc cells. Electrode blocking by reaction products and electrode polarization at high... 

The electrolyte was a solution of ammonium chloride that bathed the electrodes. Like Plante s electrochemistry of the lead-acid battery, Leclanche s electrochemistry survives until now in the form of zinc-carbon dry cells and the use of gelled electrolyte.12 In their original wet form, the Leclanche electrochemistry was neither portable nor practicable to the extent that several modifications were needed to make it practicable. This was achieved by an innovation made by J. A. Thiebaut in 1881, who through encapsulating both zinc cathode and electrolyte in a sealed cup avoided the leakage of the liquid electrolyte. Modern plastics, however, have made Leclanche s chemistry not only usable but also invaluable in some applications. For example, Polaroid s Polar Pulse disposable batteries used in instant film packs use Leclanche chemistry, albeit in a plastic sandwich instead of soup bowls.1... 

The cell components are hermetically sealed in a steel shell that is in contact with the zinc and acts as the negative terminal of the battery. A fresh zinc-carbon dry cell generates a potential difference of 1.5 V. 

Practically every battery system uses carbon in one form or another. The purity, morphology and physical form are very important factors in its effective use in all these applications. Its use in lithium-ion batteries (Li-Ion), fuel cells and other battery systems has been reviewed previously [1 -8]. Two recent applications in alkaline cells and Li-Ion cells will be discussed in more detail. Table 1 contains a partial listing of the use of carbon materials in batteries that stretch across a wide spectrum of battery technologies and materials. Materials stretch from bituminous materials used to seal carbon-zinc and lead acid batteries to synthetic graphites used as active materials in lithium ion cells. 

Most battery systems employ carbon materials in one form or another, as noted in Table 10.1. The use of carbon materials in batteries stretches across a wide spectrum of battery technologies. The variety of carbon runs the gamut from bituminous materials, used to seal carbon-zinc and carbon black powders in lead acid batteries, to high performance synthetic graphites, used as active materials in lithium-ion cells. The largest use is as a conductive diluent to enhance the performance of cathode materials. In many instances, it is used as a conductive diluent for poorly conducting cathode materials where carbon blacks, such as acetylene black, are preferred. It is essential that... 

FIGURE 10.3 Construction of the carbon-zinc cells. The zinc chloride and Leclanche have the same construction except for the seal. The zinc chloride has a plastic-compression seal while the Leclanche has a poured hot bituminous seal instead of the plastic-compression seal shown. (Courtesy of Eveready Battery Co., St Louis, MO. With permission.)... 

However, the reaction with water can be made to be extremely slow. Because the alkaline electrolyte is corrosive toward human tissue as well as toward the materials in devices, it is more important to have a good seal toward preventing electrolyte leakage in an alkaline battery than in a carbon—zinc cell. The formation of a good seal is, however, incompatible with the formation of a noncondensable gas like hydrogen. 

The second battery (Fig. 10.17) is a series of six cells with bipolar (or duplex) electrodes. Each cell has the same components as the first cell, i.e. zinc can, separator, positive paste and carbon current collector. The latter is not a carbon rod but the bottom face of the duplex electrode. The whole set of cells is sealed in wax. In both cells the zinc electrode rapidly develops porosity as the corrosion process occurs while the performance is largely determined by the quality of... 

The flat cell is illustrated in Fig. 8.5. In this construction, a duplex electrode is formed by coating a zinc plate with either a carbon-filled conductive paint or laminating it to a carbon-filled conductive plastic film. Either coating provides electrical contact to the zinc anode, isolates the zinc from the cathode of the next cell, and performs the function of cathode collector. The collector function is the same as that performed by the carbon rod in cylindrical cells. When the conductive paint method is used, an adhesive must be placed onto the painted side of the zinc prior to assembly to effectively seal the painted surface directly to the vinyl band to encapsulate the cell. No expansion chamber or carbon rod is used as in the cylindrical cell. The use of conductive polyisobutylene film laminated to the zinc instead of the conductive paint and adhesive usually results in improved sealing to the vinyl however, the film typically occupies more volume than the paint and adhesive design. These methods of construction readily lend themselves to the assembly of multi-cell batteries. 

In the common dry cell the electrolyte is a concentrated ammonium chloride solution containing some zinc chloride and a small amount of mercury(II) chloride. The latter is reduced to mercury at the zinc surface, which reduces the corrosion (q.v.) rate and adds to the shelf life of the cell. The usual form of the cell is a zinc container, acting as anode, next to which is a layer of the electrolyte mixture made into a gelled paste by addition of starch or flour. Inside this is the Mn02-C mixture surrounding a central carbon rod the latter is fitted with a metal cap to act as positive terminal, and the cell is sealed with a bitumen layer. 

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