Energizer Pp355 Users Manual

PP355 ZincAirPrismaticHandbook

PP355 to the manual aae34916-d738-4839-adff-460196b6dee4

: Energizer Energizer-Pp355-Users-Manual-540432 energizer-pp355-users-manual-540432 energizer pdf

Open the PDF directly: View PDF .
Page Count: 17



Energizer

ZincAirPrismatic

Handbook



IncludingperformanceanddesigndataforthePP355

Page|2



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

EnergizerZincAirPrismaticHandbook



1.BatteryOverview.............................................................................................................................3

1.1ZincAirChemistry...............................................................................................................................3

1.2Construction........................................................................................................................................3

1.3FeaturesofZincAirPrismatic.............................................................................................................4

1.4ZincAirPrismaticBatterySizes...........................................................................................................6

2.PP355PerformanceCharacteristics..................................................................................................7

2.1PerformanceatStandardConditions..................................................................................................7

2.2PerformanceatOtherEnvironmentalConditions..............................................................................8

2.3PulseCapability...................................................................................................................................9

2.4ServiceMaintenance.........................................................................................................................10

2.5ActivationTimeandAirRequirements.............................................................................................11

3.ApplicationandDesignConsiderations..........................................................................................12

3.1AirManagement...............................................................................................................................12

3.2ElementsofAirManagement...........................................................................................................13

3.3BatteryCompartment.......................................................................................................................14

3.4Multi‐BatteryApplications................................................................................................................16

3.5RecommendedCutoffVoltage..........................................................................................................16

3.6FuelGauging......................................................................................................................................16

4.HandlingProcedures......................................................................................................................17

4.1RecommendedOperatingandStorageConditions..........................................................................17

4.2PolarityMarkings..............................................................................................................................17

4.3Safety................................................................................................................................................17

4.4BatteryDisposal................................................................................................................................17

Page|3



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Section1:BatteryOverview





Forover35years,EnergizerhasmanufacturedminiatureZincAirbatteriesprimarilydesignedtoprovide

powertominiaturehearingaids.ZincAirchemistryprovidesthehighestavailableenergydensity

comparedtoothercommerciallyavailablebatteries.EnergizerZincAirPrismaticbatteriesemploy

technologysimilartowhatisusedinhearingaidbatteries,butwithathinprismaticformfactor

providingpowerforabroadrangeofapplications.



1.1‐‐ZincAirChemistry



ZincAirbatteriesarebasedonthealkalinechemistry(Zn/MnO2)usedinstandardAAandAAAprimary

batteries.ThehighenergydensityofZincAirresultsfromreplacingthemanganesedioxide(MnO2)

cathodewithathinairelectrode.Thisairelectrodecontainscarbonwhichcatalyzesoxygentoallowit

toreactwithzinc.Thethinairelectrodeeliminatestheneedtocontainbothreactantsinthebattery,so

themajorityofthebatterycanbefilledbythezincanode.AsaresultZincAirprovidesthehighest

availableenergydensitycomparedtocommerciallyavailablebatteries.



Thetypicalopencircuitvoltage(OCV)ofZincAiris1.4V.Underload,theoperatingvoltageisgenerally

between1.10and1.30volts.ThehalfcellandoverallreactionsforaZincAirbatteryareasfollows:



Anode: 2Zn+4OH‐→2ZnO+2H2O+4e‐

Cathode: O2+2H2O+4e‐→4OH‐

Overall: 2Zn+O2→2ZnO



1.2‐‐Construction



Airholesaredesignedintothebatterycontainertoallowoxygentoflowintothebattery.Because

exposuretotheenvironmentcandegradebatteryperformanceovertime,theairholesaresealedbya

tabpriortoconsumeruse.Thetabmustberemovedbeforethebatteryisplacedintoadevice.Once

airenterstheholes,itflowsthroughanairdistributionlayer.Thislayerhelpstodistributeairacrossthe

entireairelectrode.Figure1showsacrosssectionofanEnergizerZincAirprismaticbattery.

Page|4



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure1:CrossSectionViewofZincAirPrismaticBattery

















EnergizerZincAirPrismaticbatteriesaredesignedtoallowairtoentertheairholesandtopreventthe

transportofliquidelectrolyteoutofthebattery.Agasketisusedtosealbetweentheanodecupand

thecathodecan.Thegasketalsoelectricallyinsulatesthenegativecupfromthepositivecan.Anair

electrodeandalooselayerofTeflonarecompressedontoabandofsealantonthebottomofthecan.

ThisTeflonlayerallowsgassestoenterthebatterywhilepreventingliquidfrompassingthrough.



1.3‐‐FeaturesofZincAirPrismatic



Energizer’sZincAirPrismaticbatteriesoffera5mmthin,prismaticconstructiondesignedtoworkwitha

varietyofapplications.Thisshapeisconsistentwiththelowprofiledesignoftoday’sdevices,often

requiringathinnerbatterysolution.ThethinnestroundcellavailableistheAAAAbatteryat

approximately8mm,andmanyLithiumIonrechargeablesolutionshaveathicknessof5mm.



EnergizerZincAirPrismaticbatteriesalsooffertheopportunitytosignificantlylowermanufacturer

costs.ItislikelythatthecostofaZincAirPrismaticbatterysolutionwillbelessthanthecostofa

LithiumIonbattery.AddingtothecostofaLithiumIonsolutionisthecostofcircuitryforchargeand

dischargecontrol,whichisnotneededwithZincAirPrismaticbatteries.FurthermoreZincAirPrismatic

batteriesarereadytobeusedoutofthepackage.Thereisnoneedforchargeadaptors.



EnergizerZincAirPrismaticbatteriescanlastupto3Xlongerthancomparablevolumebatterysystems.

ThisserviceadvantageisduetoZincAirtechnologyofferingthehighestenergydensityfornon‐

rechargeableandrechargeableconsumerbatteries.Figure2demonstratesthisadvantageoverAlkaline

andLithiumIonbatteriesofsimilarvolume.

Page|5



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure2:RuntimeforEquivalentVolumeAAAABatteriesin50mWDevices



0

10

20

30

40

50

A

AAA Alkaline Lithium Ion ZAP PP355

12 14

38



ThehighenergydensityofZincAirismadepossiblebyusingathinairelectrodewherethecathode

reactiontakesplaceandbyusingatmosphericoxygenasthecathodereactant.Theresultisgreater

internalvolumeforzinc,theactiveanodematerial.Morezinctranslatesintolongerruntimeinsimilar

overallvolume.Figure3demonstratesthehigherenergydensityofZincAircomparedtoother

consumerbatterysystems.ThechartontheleftdisplaysvolumetricenergydensityinunitsofWh/L,

andthechartontherightshowsgravimetricenergydensityinunitsofWh/kg.Thisdataisbasedonthe

volumeofaAAsizedbatteryforallsystemsandacontinuous50mAcurrentdraintoa0.9voltcutoff.



Figure3:ComparisonofZincAirversusOtherBatteryTechnologies



156

450

565

396 371

522

343

890

0

100

200

300

400

500

600

700

800

900

1000

Carbon

Zinc

Alkaline Lithium LiIon LithiumIon

Polymer

Lithium

MnO2

NiMH Zinc

Air

EnergyDensity(Wh/L)

87

151

307

153

171

218

95

345

0

50

100

150

200

250

300

350

400

Carbon

Zinc

Alkaline Lithium LiIon LithiumIon

Polymer

Lithium

MnO2

NiMH Zinc

Air

SpecificEnergy(Wh/kg)





EnergizerZincAirPrismaticbatterieshaveanoperatingvoltagesimilartoAlkaline,whichisbetween

1.10and1.30voltsdependingonthedrainrateofthedevice.Thedischargeprofilehoweveris

relativelyflatsimilartorechargeableNickelMetalHydridebatteries.Figure4containsexamplesof

dischargecurvesforZincAir,Alkaline,NickelMetalHydride,andLithiumIronDisulfidebatteries.Even

thoughtheZincAirPP355batteryhasthesameexternalvolumeastheAAAAbattery,itdeliversupto

3Xtheruntimeata50mWdischarge.

Page|6



ENERGIZERBATTERYMANUFACTURING

VERSION1.2



Figure4:ComparisonofDischargeCurvesat50mWContinuous



0.4

0.6

0.8

1.0

1.2

1.4

1.6

0 5 10 15 20 25 30 35 40 45

Voltage(V)

DischargeTime(hrs)

Lithium

AAA

Alkaline

AAA

Alkaline

AAAA

ZincAir

PP355

NiMH

AAA





TheimpedanceofEnergizerZincAirPrismaticbatteriesishigherthansimilarvolumeAlkalinebatteries,

anditdecreasesslightlythroughthelifeofthebattery.Theimpedanceshouldnotimpactbattery

performanceatlowtomoderatedischargerates.Athigherratedischarges,thishigherimpedancewill

reduceoperatingvoltageanddeliveredenergy.

1.4‐‐ZincAirPrismaticBatterySizes



EnergizerZincAirPrismaticbatteriesprovideanidealformfactorfordeviceswithathinprofile.The

familyofbatterysizesisshowninFigure5,rangingfromAAAAlkalinevolumeequivalentto½theAAAA

Alkalinevolumeequivalent.EnergizerZincAirPrismaticbatterynomenclatureisdeterminedbytheIEC

standard.Thefirst‘P’indicatesZincAirchemistry,thesecond‘P’indicatestheprismaticformfactor,

thefirsttwodigitsrepresentthediagonalinmm,andthelastdigitisthebatteryheightinmm.For

examplethePP355hasa35mmdiagonaldistanceandaheightof5mm.



Figure5:ZincAirPrismaticBatterySizes



PP425 PP355 PP255

Length(mm) 36.0 32.2 22.6

Width(mm) 22.0 14.7 10.3

Thickness(mm) 5.0 5.0 5.0

Volume(cm

3

)3.96 2.37 1.16

CellWeight(g) 11.7 6.8 3.4

ContinuousRateCapability <200mW <100mW <50mW

CapacityRated(mAh) 3600 1800 720



Page|7



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Section2:PP355PerformanceCharacteristics





ThissectiondescribestheperformanceofthePP355battery.Standarddischargecurves,performance

atavarietyofenvironmentalconditions,pulsecapability,andservicemaintenancedataarepresented.



2.1‐‐PerformanceatStandardConditions



StandardconditionsforEnergizerZincAirPrismaticbatteriesaredefinedas21°Cand50%relative

humidity(RH).Undertheseconditions,thePP355batteryisdesignedtoprovidecontinuousdischarge

capabilityupto100mW.Whilebestperformanceisobtainedinstandardconditionsandcontinuous

dutycycles,EnergizerZincAirPrismaticBatteriesperformwelloverawiderangeofenvironmental

conditionsandinintermittentapplicationsaswell.Figure6containstypicaldischargecurvesforthe

PP355understandardconditionsandconstantpowerloadsof25,50,75,and100mW.



Figure6:PP355DischargeCurvesatContinuousConstantPower



0.8

0.9

1.0

1.1

1.2

1.3

1.4

0 500 1000 1500 2000 2500

Voltage(V)

DischargeEnergy(mWh)

100mW

75 mW

50 mW

25mW





EnergizerZincAirPrismaticbatteriessignificantlyoutperformexistingAlkalinecylindricalsolutionsof

equivalentvolume.Todemonstratethisadvantage,Figure7showshowPP355andAAAAAlkaline

batteriesperformonthesamecontinuouspowertests.ThePP355lastslongerthanthealkalineAAAA

eventhoughthevolumesofbothbatterytypesareapproximatelythesameat2.37ccand2.2cc,

respectively.



Page|8



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure7:ComparisonofPerformanceunderContinuousConstantPower



AAAA PP355

25 mW 24 88

50 mW 11 38

75 mW 6 24

100 mW 4 15

Continuous Discharge Time (hrs)







2.2‐‐PerformanceatOtherEnvironmentalConditions



WhenaZincAirbatteryisexposedtoanon‐standardenvironment,adrivingforceforwatertransportin

oroutofthebatteryexists.Movementofwatervaporintothebatterycanfillvoidspaceintheanode

cavityunderhighhumidityenvironments,andmovementofwatervaporoutofthebatterycandryout

theelectrolyteinlowhumidityenvironments.Eithersituationcandecreasebatteryperformanceover

time.



Understandingtheenvironmentalconditionsthatabatterymightencounteriscriticaltoestimating

batteryperformance.AstudywasdoneatEnergizertodeterminerealisticextremeconditionsfor

batterytesting,usingclimatedatafrom61citiesacrosstheglobe.Thesecitiesrepresentthemajor

marketsforbothdevicesandbatteries.Combinationsofdailymorningandafternoontemperatureand

humiditywerecompiledandanalyzedtodeterminereasonabletemperatureandhumidityextremes.



HotandHumidConditions:

ZincAirPrismaticbatteriescantakeonwaterwhenexposedtohotandhumidconditions.Thiscanlimit

batteryperformancebytakingupvoidvolumeintheairelectrodeandanodecompartment.At35°C

and75%RHconditions,thereisadrivingforceforwatergainlargerthan99%ofconditionsseenin

combinedindoorandoutdoordatafromthetop61citiesglobally.ServicetestswiththePP355under

theseconditionsshowverygoodserviceevenat1hrperdayintermittency.



HotandAridConditions:

ZincAirPrismaticbatteriescanlosewaterwhenexposedtohotandaridconditionswhichcanlimit

batteryperformancebydryingoutthebattery.Under35°Cand25%RHconditions,thereisadriving

forceforwaterlosslargerthan99%ofconditionsseenincombinedindoorandoutdoordatafromthe

top61citiesglobally.ServicetestingwiththePP355attheseconditionsshowsverygoodserviceeven

at1hrperdayintermittency.





Page|9



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

LowerTemperatureConditions:

Airholdslessmoistureastemperaturedecreases,andthedifferencebetweenlowandhighrelative

humiditybecomeslesssignificant.At0°C,thedifferencebetweenthehumidityofthePP355andthe

environmentisnegligible.WhiletheserviceobtainedfromaPP355attemperatureslowerthan

standardconditionsisless,thelossissimilartoAlkalinebatteries.Ingeneralthe“upto3X”service

advantageforZincAirbatteriesoverAlkalinebatteriesismaintained.



Figure9:ServiceSummaryforZincAirPrismaticBatteriesatVariousEnvironmentalConditions



Humid

(35°C / 75% RH) Typical

(21°C / 50% RH) Arid

(35°C / 25% RH) Cold

(0°C)

50 mW

Continuous 45 hrs

(2 days) 38 hrs

(2 days) 40 hrs

(2 days) 12 hrs

(0.5 days)

50 mW

1h per 12hr 38 hrs

(19 days) 36 hrs

(18 days) 30 hrs

(15 days) 16 hrs

(8 days)

50 mW

1h per 24hr 25 hrs

(25 days) 30 hrs

(30 days) 17 hrs

(17 days) -

AAAA

Alkaline

50 mW 5 hrs

(0.25 days)

PP355

generally about 12 hrs (0.5 days)

for these temperatures and all intermittencies



Eachbatterywasexposedtothespecifiedconditionsfortheentiretestduration.





Figure9demonstratestheserviceobtainedfromaPP355batteryat35°C/75%RH,35°C/25%RH,and

0°Cconditions.Thedatapresentedwithunitsofhoursrepresenttheruntimethatthebattery

delivered,whilethevaluesinparenthesesindicatethedurationofthetestindays.Insummary,the

PP355batterysustainsasignificantperformanceadvantageoversimilarvolumeAlkalinebatterieswith

varyingintermittencyinextremetemperatureandhumidityconditions.



2.3‐‐PulseCapability



ThepulsecapabilityofZincAirbatteriesisdependentontheinstantaneousamountofoxygenavailable

attheairelectrodeatagiventime.WhilethePP355batterycancontinuouslydischargeatratesupto

100mA,thebatterycanprovidesignificantlymorecurrentinshortbursts.Figure8demonstratesthata

freshPP355batterycanprovidepulsesofupto1500mA,dependingonthedurationofthepulse.The

pulsecapabilityofaZincAirbatterycanalsobeaffectedbythefrequencyofthepulses.Pulsecapability

willdropovertimewithoutsufficienttimeformoreoxygentoentertheairelectrode.



Page|10



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure8:PulseCapabilityofPP355Batteries

0.0001

0.001

0.01

0.1

1

0 200 400 600 800 1000 1200 1400 1600

MaximumPulseDuration(s)

Current(mA)

1.1VCutoff

1.0VCutoff

0.9VCutoff

0.8VCutoff



2.4‐‐ServiceMaintenance



ZincAirbatteriesarestoredwithadhesivebackedtabspriortouse.Thesetabssealtheairholesagainst

oxygenandwateringress.Toobtainthefullbatteryperformance,thetabshouldberemovedonly

immediatelypriortouse.Whenthebatteryissealedbythetab,servicelossduetoselfdischargeis

approximately5%peryear.Figure10illustratestheratesatwhichcapacityislostwiththetabonand

thetabremoved.



Figure10:ServiceMaintenanceofEnergizerZincAirPrismaticBatteries

80%

85%

90%

95%

100%

01234

Rated Capacity (%)

Shelf Life (yr)

unsealed

(tab removed)

sealed

(on tab)





Page|11



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

2.5‐‐ActivationTimeandAirRequirements



Whenbatteriesarestoredwiththeadhesivetabintact,theyhavealoweropencircuitvoltage(OCV)

sincetheoxygencontainedinthebatteryisconsumedduringstorage.Whenthetabisremovedthe

OCVwillriseasoxygenactivatestheairelectrode.Withmultipleairholesforaddedratecapability,the

PP355maytakeacoupleofsecondstoairupenoughtosustaina50mWloadabove1volt.Basedon

thetimeitwilltakeaconsumertoremovethetab,insertthebatteryintothedevice,closethebattery

compartment,thebatteryshouldbereadytosupportthedeviceloadwhentheuserturnsonthe

power.



FormaximumperformanceofaPP355undera50mWcontinuousload,aminimumairflowrateof2‐3

ccofairperminuteisneeded.Forhigherpowerdemanddevices(100mW),aminimumof4‐6ccofair

perminuteisneeded.Inmostdevicesthisamountofaireasilyleaksintothebatterycompartment.

Page|12



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Section3:ApplicationandDesignConsiderations





ExcessiveexposuretoaircanhaveanadverseaffectonZincAirbatteryoperation,primarilydueto

carbondioxidereactingwiththeelectrolyteintheairelectrode.Thebatterycanalsoabsorbwateror

dryoutdependingonambientconditions.Balancingtheairrequirementofthebatteryduringdischarge

versustheneedtominimizeexposureduringrestiscalledairmanagement.Airmanagementmightbe

assimpleasremovingthetabfromthebatteryandinsertingitintoadevice,oritmightincludeasystem

toopenandcontrolairaccesstothebatteryasneeded.Airmanagementisapplicationspecific,and

mostdeviceswillrequiresomedegreeofairmanagementtooptimizebatteryperformance.



3.1‐‐AirManagement



Thereareseveraltypesofairmanagement.Thesimplestmethodofairmanagementisremovingthe

tabandputtingthebatteryinthedevice.Thisishowminiaturezincaircellsareusedinhearingaids

sincethetotalbatterylifeistypicallyexpectedtobe6‐8weeks.Asthedeviceusagebecomesmore

intermittent,othermethodsofairmanagementareneededtodeliveroptimalbatteryperformance.



Throttlingisatechniquetopermanentlyrestrictairaccesstoonlywhatisneededbythebatteryina

specificapplication.Throttlingismostappropriateindevicesthatrequireasmallportionofthe

maximumcurrentthatabatterycansustain.Forexample,adevicemightrequire10mAofcurrent

comparedtothemaximumof100mAthataPP355cansustain.Thistechniqueworksbestfordevices

thathavealowaveragedrainratewithlittleincreasedpowerneeds.Byrestrictingtheairaccesstothe

battery,theperformancelifecanbeextended.



Asdeviceusebecomesmoreintermittentandasdevicepowerdemandsincrease,valved(openand

shut)airmanagementbecomesmoreappropriate.Valvedsystemsareeithermechanicalorelectronic.

Eachsystemrequiresasealedbatteryorbatterycompartment,intowhichairisintroducedbythevalve

whenthedeviceneedspower.Asealcanbeaccomplishedwithcommonmaterialssuchaso‐rings,

gaskets,over‐moldedortwo‐partinjectionmoldedmaterials,orothermethods.Amechanicalsolution

mightbeanON/OFFslideswitchwhichactsasasimpleairvalve.Otherdevicespecificmechanical

actionscouldalsobeusedtoopenandclosetheairaccess.Examplesincludechangingdevicesettings,

movingapieceorapartofthedeviceduringuse,pressingabutton,turningadial,ormanipulatinga

threadedcomponent.Anelectronicvalvewouldactinasimilarfashion,exceptthatthedevice

electronicswouldopentheairaccessautomatically.Avalvecouldbeopenedasafunctionofdevice

state(on=open,off=closed),oritmightbeafunctionoftheinstantaneouspowerneedsofthedevice.

Inavalvedairmanagementsolution,alowlevelofairaccessmightstillbeneededtobeabletoprovide

thequiescent,orbackground,powerrequiredtoactivatetheON/OFFvalve.Figure11showsgenerally

whereeachoftheseairmanagementtechniquesisappropriate.

Page|13



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure11:OverviewofDifferentAirManagementTechniques

high

low

continuous intermittent

noneorsmall

degreeofair

management

needed,sincecell

capacityisquickly

used

(1‐3months)

highdegreeofairmanagementneeded,

cellhashighairaccessbutisexpectedto

beinservicewithlongperiodsof“of f ”

time(>3months)

DutyCycle

DischargeRate

throttlingneededto

maximizeservice

time (>3months)





3.2‐‐ElementsofAirManagement



Twoelementsofasuccessfulin‐deviceairmanagementsystemareameansforallowingcontrolledair

accesstothebatteryandanairplenumforevenairdistribution.Anairplenumisanairgap,orvolume,

whichhasaccesstoalloftheairholesonthebattery.Theairplenumallowsformoreevenair

distributionoverthebatteryairholes,anditprovidesareserveofairimmediatelyavailabletothe

batterytohandlepeakpowerneeds.Controllingairaccesstothebatteryisaccomplishedbycreatingan

accesspathtothesealedvolumeofairwithinadevice.Theairaccesspathisdesignedtoallowa

desiredamountofairtoflowtothesealedvolumeofair,whichincludestheplenum,either

continuouslyorintermittently.Asealedvolumeofaircanbecreatedbysealinganentiredevice,a

portionofthedeviceincludingthebatterycompartment,orjustaplenumabovetheairholesideofthe

battery.Thepowerrequirementsofthedevicedeterminetherateatwhichairisrequiredtoflowtothe

battery.



Figure12illustratesasimple,costeffectiveairmanagementsolutiondesignedintoadevice.The

compartmentdoorcontainsano‐ringwhichsealsagainsttheairholesideofthebatterywhenthedoor

isclosed.Theairplenumvolumeisdefinedbythecompartmentdoorandthesidesoftheo‐ring.A

slideswitchislocatedinthecompartmentdoortocreateanairaccesspoint.Theslideswitchactsasa

valvewhichsealsthecompartmentwhenintheclosedpositionandallowsairtoflowtothebattery

whenintheopenposition.Theslideswitchcouldbemechanicallymanipulatedbytheuseror

electronicallycontrolledbythedevice.

Page|14



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Figure12:AirManagementDesignConcept











3.3‐‐BatteryCompartment



ThedesignofaZincAirPrismaticbatterycompartmentdependsonseveralfactorsincludingbattery

dimensions,batteryorientation,andairflowneededtomaintainpowertothedevice.Other

considerationsaretheeaseofbatteryinsertionandremoval,contactmaterials,reversalprotection,and

theshapeandlocationofdevicecontacts.Ingeneral,consumersshouldbeabletouseandreplaceZinc

AirPrismaticbatteriesinasimilarfashiontoAAandAAAreplaceablebatterieswithnoadditional

actionsrequiredotherthanremovingthetabfromtheZincAirPrismaticbatterypriortouse.



EnergizerZincAirPrismaticbatteriesareelectricallyconductiveonallsurfaces,andflatbatterycontacts

arerecommended.Leafspringcontactsarepreferredovercoilspringsascoilspringsaremoreproneto

shorting.Positivecontactshouldbemadeatthepositive(+)cansidewallratherthanontheairhole

sideofthebatterytopreventunwantedairflowrestrictionstotheairholes.Negativecontactshould

becenteredonthenegative(‐)cupbottom(nonairholesideofbattery)insuchawayastominimize

potentialshortingbetweenthenegativecupandthepositivecansidewall.Figure13illustratesthe

recommendedcontactsurfacesforZincAirPrismaticbatteries.



Figure13:ZincAirPrismaticPolarity







Contactsurfacesareashouldbemaximizedtoreducecontactresistance.Sufficientcontactpressure

shouldalsobemaintainedtoensureconsistentelectricalconnectionbutnotsogreatastodeformthe

batterycontacts.Acontactforceintherangeofonehalftotwopoundsisrecommended.

Page|15



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

ContactMaterials:

Nickelplatedstainlesssteelisrecommendedbecauseitprovidesgoodconductivityandenvironmental

stabilityatareasonablecost.Nickelplatingmustbeadherent,continuous,andnon‐porous.Thenickel

platingmustalsoresistthewearthatoccursduringtheinsertionandextractionofbatteries.The

suggestedplatingthicknessis5‐6micrometers.



BatteryOrientation:

Howthebatteryissituatedinthecompartmentisanimportantdesignconsideration.Thelocationof

theairaccesspath,plenum,andsealaredeterminedbythefacingofthebatteryairholes.The

orientationoftheairholesideofthebatteryalsoinfluencesthelocationoftheelectricalcontacts.

Determiningthefacingofthebatteryairholesisgenerallyafunctionofdeviceuseandthepositionof

thebatterycompartmentwithinadevice.Figure14presentsanexampleofadevicewhichorientsa

ZincAirPrismaticbatterywiththeairholesfacingthecompartmentdoor.Thecoverholdsthebattery

inplaceanddoesnotrestrictairflowtobelowwhatisrequiredfordeviceoperation.



Figure14:BatteryOrientationandDeviceContacts







ReversalProtection:

Batteryreversalprotectionisrecommendedforbatteryoperateddevicestopreventagainstpossible

damagetoadeviceorbatteryifabatteryisinsertedincorrectly.Reversalprotectioncanbemechanical

orelectronic,dependingonthedevice.Anexampleofmechanicalreversalprotectionisadesign

featureinthebatterycompartmentthatonlyallowsthebatterytobeinsertedwiththecorrectpolarity.

Thiscanbeaccomplishedbyincludingaraisedliporridgethatconformstothebatterycontourwhen

insertedinthecorrectpolarity.TherecommendedlocationoftheribforEnergizerZincAirPrismatic

batteriesiswheretherecessededgearoundthenonairholesideofthebatteryfitsintothe

compartment.



BatteryDimensions:

Similartootherbatterysystems,ZincAirbatteriescanbulgeslightlyundernormaldischargeconditions

aszincisconvertedtozincoxideintheintendedreactions.Energizerrecommendsdesigningdevices

aroundstandardindustrydimensionswhereavailable.TypicaldimensionalspecificationsforEnergizer

ZincAirPrismaticbatteries,includingconsiderationforpossiblebulge,canbefoundontherespective

datasheets.

Page|16



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

3.4‐‐Multi‐BatteryApplications



Insomesituations,ahighervoltageoranincreasedperformancelevelisdesiredforacertain

application.ZincAirbatteriescanbearrangedinseriesorinparallelasneeded.Devicesthatusemore

thanoneZincAirPrismaticbatteryintroduceadditionaldesignconsiderations.Anairplenumandair

accessisrequiredforeachbattery,andthesecanbeindependentorshared.Additionally,stacked

batteriesrequirespaceabovetheairholesideofeachbattery.Iftwobatteriesarestackedwiththeair

holesidesfacingeachother,thenasingleairplenumcanbeused.



3.5‐‐RecommendedCutoffVoltage



TherecommendedendoflifeforZincAirbatteriesisat0.9voltswhereessentiallyallavailablecapacity

hasbeenused.Below0.9voltsadditionalchemicalreactionsmaytakeplaceinthebatterywhichcan

leadtoincreasedpotentialforgassingandleakage.Energizerrecommendsthatdevicesaredesignedto

preventthebatteryfrombeingdischargedbelow0.9volts.Thiscanbeaccomplishedpreferablybya

completedisconnectofthebatterycircuitorbyusingalowvoltagebatterywarning.



3.6‐‐FuelGauging



ZincAirPrismaticbatterieshavearelativelyflatdischargecurvecomparedtoexistingAlkalinesolutions,

withthedischargecurveslopingmoreatincreaseddischargerates.ThiscanbeseeninFigure4and

Figure6.AlthoughtherelativelyflatdischargecurvemakestheZincAirsystemmorechallengingtofuel

gaugewithconventionalvoltage‐onlymeasurements,theflatvoltageprofilehelpsmakedevice

performanceconsistentthroughoutthelifeofthebattery.Amoresophisticatedalgorithm

incorporatingadditionalmeasurementsthataretailoredtothespecificapplicationmaybenecessary.

ThisissimilartowhatisrequiredforLithiumIronDisulfideandrechargeableNickelMetalHydride

batteries.

Page|17



ENERGIZERBATTERYMANUFACTURING

VERSION1.2

Section4:HandlingProcedures





4.1‐‐RecommendedOperatingandStorageConditions



Foroptimumperformanceandcapacityretention,ZincAirPrismaticbatteriesshouldbeusedina

temperaturerangeof‐10⁰Cto55⁰Candinarelativehumidityrangeof25%to80%.ZincAirbatteries

shouldbestoredbetween10°Cand30°Candat40%to70%relativehumidity.Batteriesshouldbe

storedwiththetabinplacetopreventperformancedegradationduetoenvironmentalexposure.As

withanychemicalsystem,hightemperaturestoragewillresultinincreasedlossofcapacity.



4.2‐‐PolarityMarkings



Theadhesivetabofthebatterycoversthepositivecancontactandismarkedwithapositivepolarity(+)

mark.Inaddition,anegativepolarity(‐)markingisetchedonthemetalcuptohelpuserscorrectly

insertthebatteryintothedevicebatterycompartment.



4.3‐‐Safety



EnergizerZincAirPrismaticbatteriesundergosafetyandabusetestingaccordingtoalkalineandzincair

industrystandards.Someofthetestsperformedincludemultipletemperaturecycling,deepdischarge,

directshort,thermalabuse,abusivecharge.Safetytestperformanceisconsistentwiththatofstandard

alkalineandindicatesnosafetyconcerns.Understandardconditions,minimalhydrogengascanbe

generatedasinotheralkalinecellsandcellthicknessmayincreaseslightly.Underabusiveconditions,

leakageismorelikelytooccurwithincreasedcellthickness.



Insituationswherethebatteryisoperatingorstoredintemperaturesandhumidityoutsidethe

recommendedrangesinSection4.1,orunderabusiveconditions,thebatterymayproduceasmall

amountofwhiteprecipitate(salting)onthecrimpofthebattery.Energizerrecommendsthatthe

batterybedisposedofifandwhensaltingisobserved.Exposedskinorclothingshouldbecleansedwith

coolsoapywater.



Becauseoftheirsize,ZincAirPrismaticbatteriesposeaswallowing/chokinghazard.Ifbatteriesare

swallowed,immediatelycontacttheNationalCapitalPoisonCentercollectat202‐625‐3333formedical

advice.



4.4‐‐BatteryDisposal



EnergizerdoesnotaddmercuryorcadmiumtoZincAirPrismaticbatteriesthereforetheyareexempt

fromanyspecialcollectionanddisposalregulationsafterdischarge.