Although the active materials
in alkaline cells are basically the same as in zinc carbon cells,
the significant differences are in the electrolyte and cell construction.
Its more sophisticated design, combined with the alkaline electrolyte,
accounts for its superior performance. The following descriptions
of construction of Alkaline Manganese Dioxide cells and batteries
are specific to the products manufactured or distributed by Duracell.
Cylindrical Cell Construction
A typical cell is designed with active materials and alkaline
electrolyte contained in a nickel plated steel can. The following
drawing shows a cutaway of a DURACELL® cylindrical
alkaline cell.
Multicell Construction
Multicell DURACELL® alkaline batteries are designed
with two or more alkaline cells in series or parallel connection.
All series and parallel connections, as well as cell-to-terminal
connections, are welded using a nickel-plated steel tab material.
This all-welded construction enhances the reliability of the battery’s
performance in comparison to pressure-type contacts. The battery
assembly cases are typically made of injection molded plastic or
steel.
Button Cell Construction
The button cell construction consists of an anode subassembly,
cathode subassembly and a separator to form a layered design. The
anode subassembly includes the cell top, which is made of a bimetal
laminate of nickel-plated steel and either copper or tin; a plastic
grommet, used to insulate the positive and negative terminals; a
pelleted zinc anode, which is placed inside the top; and an absorbent
material saturated with electrolyte.
The cathode subassembly includes the cell can; the manganese dioxide
cathode consolidation; and a barrier/ separator, which allows current
to flow but blocks any migration of material.
The cathode subassembly is placed over the anode subassembly and
is sealed by crimping the edge of the can over the grommet.
