Chapter 3: Batteries

The electrodes are the conductors by which the current leaves or returns to the electrolyte. In the simple cell, they are carbon and zinc strips that are placed in the electrolyte; while in the dry cell (Figure 2), they are the carbon rod in the center and zinc container in which the cell is assembled.

The electrolyte is the solution that acts upon the electrodes. The electrolyte, which provides a path for electron flow, may be a salt, an acid, or an alkaline solution. In the simple galvanic cell, the electrolyte is in a liquid form. In the dry cell, the electrolyte is a paste.

The container which may be constructed of one of many different materials provides a means of holding (containing) the electrolyte. The container is also used to mount the electrodes. In the voltaic cell the container must be constructed of a material that will not be acted upon by the electrolyte.

A primary cell is one in which the chemical action eats away one of the electrodes, usually the negative electrode. When this happens, the electrode must be replaced or the cell must be discarded. In the galvanic-type cell, the zinc electrode and the liquid electrolyte are usually replaced when this happens. In the case of the dry cell, it is usually cheaper to buy a new cell.

A secondary cell is one in which the electrodes and the electrolyte are altered by the chemical action that takes place when the cell delivers current. These cells may be restored to their original condition by forcing an electric current through them in the direction opposite to that of discharge. The automobile storage battery is a common example of the secondary cell.

The construction of a common type of dry cell is shown in Figure 4.These dry cells are also referred to as Leclanche' cells. The internal parts of the cell are located in a cylindrical zinc container. This zinc container serves as the negative electrode (cathode) of the cell. The container is lined with a nonconducting material, such as blotting paper, to separate the zinc from the paste. A carbon electrode is located in the center, and it serves as the positive terminal (anode) of the cell. The paste is a mixture of several substances such as ammonium chloride, powdered coke, ground carbon, manganese dioxide, zinc chloride, graphite, and water.

This paste, which is packed in the space between the anode and the blotting paper, also serves to hold the anode rigid in the center of the cell. When the paste is packed in the cell, a small space is left at the top for expansion of the electrolytic paste caused by the depolarization action. The cell is then sealed with a cardboard or plastic seal.

Since the zinc container is the cathode, it must be protected with some insulating material to be electrically isolated. Therefore, it is common practice for the manufacturer to enclose the cells in cardboard and metal containers.

The dry cell (Figure 4) is basically the same as the simple voltaic cell (wet cell) described earlier, as far as its internal chemical action is concerned. The action of the water and the ammonium chloride in the paste, together with the zinc and carbon electrodes, produces the voltage of the cell. Manganese dioxide is added to reduce polarization when current flows and zinc chloride reduces local action when the cell is not being used.

A cell that is not being used (sitting on the shelf) will gradually deteriorate because of slow internal chemical changes (local action). This deterioration is usually very slow if cells are properly stored. If unused cells are stored in a cool place, their shelf life will be greatly preserved. Therefore, to minimize deterioration, they should be stored in refrigerated spaces.

The blotting paper (paste-coated pulpboard separator) serves two purposes—(1) it keeps the paste from making actual contact with the zinc container and (2) it permits the electrolyte from the paste to filter through to the zinc slowly. The cell is sealed at the top to keep air from entering and drying the electrolyte. Care should be taken to prevent breaking this seal.

The mercuric-oxide zinc cell (mercury cell) is a primary cell that was developed during World War II. Two important assets of the mercury cell are its ability to produce current for a long period of time and a long shelf life when compared to the dry cell shown in Figure 4. The mercury cell also has a very stable output voltage and is a power source that can be made in a small physical size.

With the birth of the space program and the development of small transceivers and miniaturized equipment, a power source of small size was needed. Such equipment requires a small cell which is capable of delivering maximum electrical energy at a constant discharge voltage. The mercury cell, which is one of the smallest cells, meets these requirements.

Present mercury cells are manufactured in three basic types as shown in Figure 5. The wound- anode type, shown in Figure 5 view A, has an anode composed of a corrugated zinc strip with a paper absorbent. The zinc is mixed with mercury, and the paper is soaked in the electrolyte which causes it to swell and press against the zinc and make positive contact. This process ensures that the electrolyte makes contact with the anode.

In the pressed-powder cells, shown in Figure 5 views B and C, the zinc powder for the anode is mixed prior to being pressed into shape. The absorbent shown in the figure is paper soaked in the electrolyte. The space between the inner and outer containers provides passage for any gas generated by an improper chemical balance or impurities present within the cell.

If the anode and cathode of a cell are connected together without a load, a SHORT CIRCUIT condition exists. Short circuits (shorts) can be very dangerous. They cause excessive heat, pressure, and current flow which may cause serious damage to the cell or be a safety hazard to personnel.

There are many different types of primary cells. Because of such factors as cost, size, ease of replacement, and voltage or current needs, many types of primary cells have been developed. The following is a brief description of some of the primary cells in use today.

The Manganese Dioxide-Alkaline-Zinc Cell is similar to the zinc-carbon cell except for the electrolyte used. This type of cell offers better voltage stability and longer life than the zinc-carbon type. It also has a longer shelf life and can operate over a wide temperature range. The manganese dioxide- alkaline-zinc cell has a voltage of 1.5 volts and is available in a wide range of sizes. This cell is commonly referred to as the alkaline cell.

The Magnesium-Manganese Dioxide Cell uses magnesium as the anode material. This allows a higher output capacity over an extended period of time compared to the zinc-carbon cell. This cell produces a voltage of approximately 2 volts. The disadvantage of this type of cell is the production of hydrogen during its operation.

The Lithium-Organic Cell and the Lithium-Inorganic Cell are recent developments of a new line of high-energy cells. The main advantages of these types of cells are very high power, operation over a wide temperature range, they are lighter than most cells, and have a remarkably long shelf life of up to 20 years.

The lead-acid cell is the most widely used secondary cell. The previous explanation of the secondary cell describes exactly the manner in which the lead-acid cell provides electrical power. The discharging and charging action presented in electrochemical action describes the lead-acid cell.

You should recall that the lead-acid cell has an anode of lead peroxide, a cathode of sponge lead, and the electrolyte is sulfuric acid and water.

The nickel-cadmium cell (NICAD) is far superior to the lead-acid cell. In comparison to lead-acid cells, these cells generally require less maintenance throughout their service life in regard to the adding of electrolyte or water. The major difference between the nickel-cadmium cell and the lead-acid cell is the material used in the cathode, anode, and electrolyte. In the nickel-cadmium cell the cathode is cadmium hydroxide, the anode is nickel hydroxide, and the electrolyte is potassium hydroxide and water.

The nickel-cadmium and lead-acid cells have capacities that are comparable at normal discharge rates, but at high discharge rates the nickel-cadmium cell can deliver a larger amount of power. In addition the nickel-cadmium cell can:

Due to their superior capabilities, nickel-cadmium cells are being used extensively in many military applications that require a cell with a high discharge rate. A good example is in the aircraft storage battery.

The silver-zinc cell is used extensively to power emergency equipment. This type of cell is relatively expensive and can be charged and discharged fewer times than other types of cells. When compared to the lead-acid or nickel-cadmium cells, these disadvantages are overweighed by the light weight, small size, and good electrical capacity of the silver-zinc cell.

The silver-zinc cell uses the same electrolyte as the nickel-cadmium cell (potassium hydroxide and water), but the anode and cathode differ from the nickel-cadmium cell. The anode is composed of silver oxide and the cathode is made of zinc.

The silver-cadmium cell is a fairly recent development for use in storage batteries. The silver- cadmium cell combines some of the better features of the nickel-cadmium and silver-zinc cells. It has more than twice the shelf life of the silver-zinc cell and can be recharged many more times. The disadvantages of the silver-cadmium cell are high cost and low voltage production.

The electrolyte of the silver-cadmium cell is potassium hydroxide and water as in the nickel- cadmium and silver-zinc cells. The anode is silver oxide as in the silver-zinc cell and the cathode is cadmium hydroxide as in the nicad cell. You may notice that different combinations of materials are used to form the electrolyte, cathode, and anode of different cells. These combinations provide the cells with different qualities for many varied applications.

Assume that a load requires a power supply of 6 volts and a current capacity of 1/8 ampere. Since a single cell normally supplies a voltage of only 1.5 volts, more than one cell is needed. To obtain the higher voltage, the cells are connected in series as shown in Figure 8.

Figure 8 view B is a schematic representation of the circuit shown in Figure 8 view A. The load is shown by the resistance symbol and the battery is indicated by one long and one short line per cell.

In a series hookup, the negative electrode (cathode) of the first cell is connected to the positive electrode (anode) of the second cell, the negative electrode of the second to the positive of the third, etc.

The positive electrode of the first cell and negative electrode of the last cell then serve as the terminals of the battery. In this way, the voltage is 1.5 volts for each cell in the series line. There are four cells, so the output terminal voltage is 1.5 × 4, or 6 volts. When connected to the load, 1/8 ampere flows through the load and each cell of the battery. This is within the capacity of each cell. Therefore, only four series-connected cells are needed to supply this particular load.

In this case, assume an electrical load requires only 1.5 volts, but will require 1/2 ampere of current. (Assume that a single cell will supply only 1/8 ampere.) To meet this requirement, the cells are connected in parallel, as shown in Figure 9 view A and schematically represented in Figure 9 view B. In a parallel connection, all positive cell electrodes are connected to one line, and all negative electrodes are connected to the other. No more than one cell is connected between the lines at any one point; so the voltage between the lines is the same as that of one cell, or 1.5 volts. However, each cell may contribute its maximum allowable current of 1/8 ampere to the line. There are four cells, so the total line current is 1/8 × 4, or 1/2 ampere. In this case four cells in parallel have enough capacity to supply a load requiring 1/2 ampere at 1.5 volts.

Figure 10 depicts a battery network supplying power to a load requiring both a voltage and a current greater than one cell can provide. To provide the required 4.5 volts, groups of three 1.5-volt cells are connected in series. To provide the required 1/2 ampere of current, four series groups are connected in parallel, each supplying 1/8 ampere of current.

The connections shown have been used to illustrate the various methods of combining cells to form a battery. Series, parallel, and series-parallel circuits will be covered in detail in the next chapter, "Direct Current."

Some batteries are made from primary cells. When a primary-cell battery is completely discharged, the entire battery must be replaced. Because there is nothing else that can be done to primary cell batteries, the rest of the discussion on batteries will be concerned with batteries made of secondary cells.

For a battery to work properly, its electrolyte (water plus active ingredient) must contain a certain amount of active ingredient. Since the active ingredient is dissolved in the water, the amount of active ingredient cannot be measured directly. An indirect way to determine whether or not the electrolyte contains the proper amount of active ingredient is to measure the electrolyte’s specific gravity. Specific gravity is the ratio of the weight of a certain amount of a given substance compared to the weight of the same amount of pure water. The specific gravity of pure water is 1.0. Any substance that floats has a specific gravity less than 1.0. Any substance that sinks has a specific gravity greater than 1.0.

The active ingredient in electrolyte (sulfuric acid, potassium hydroxide, etc.) is heavier than water. Therefore, the electrolyte has a specific gravity greater than 1.0. The acceptable range of specific gravity for a given battery is provided by the battery’s manufacturer. To measure a battery’s specific gravity, use an instrument called a HYDROMETER.

A hydrometer, shown in Figure 14, is a glass syringe with a float inside it. The float is a hollow glass tube sealed at both ends and weighted at the bottom end, with a scale calibrated in specific gravity marked on its side. To test an electrolyte, draw it into the hydrometer using the suction bulb. Draw enough electrolyte into the hydrometer to make the float rise. Do not draw in so much electrolyte that the float rises into the suction bulb. The float will rise to a point determined by the specific gravity of the electrolyte. If the electrolyte contains a large amount of active ingredient, its specific gravity will be relatively high. The float will rise higher than it would if the electrolyte contained only a small amount of active ingredient.

To read the hydrometer, hold it in a vertical position and read the scale at the point that surface of the electrolyte touches the float. Refer to the manufacturer’s technical manual to determine whether or not the battery’s specific gravity is within specifications.

Note: Hydrometers should be flushed with fresh water after each use to prevent inaccurate readings. Storage battery hydrometers must not be used for any other purpose.

The routine maintenance of a battery is very simple. Terminals should be checked periodically for cleanliness and good electrical connection. The battery case should be inspected for cleanliness and evidence of damage. The level of electrolyte should be checked and if the electrolyte is low, distilled water should be added to bring the electrolyte to the proper level. Maintenance procedures for batteries are normally determined by higher authority and each command will have detailed procedures for battery care and maintenance.

All types of batteries should be handled with care:

In the event electrolyte is splashed or spilled on a surface, such as the floor or table, it should be diluted with large quantities of water and cleaned up immediately.

If the electrolyte is spilled or splashed on the skin or eyes, IMMEDIATELY flush the skin or eyes with large quantities of fresh water for a minimum of 15 minutes. If the electrolyte is in the eyes, be sure the upper and lower eyelids are pulled out sufficiently to allow the fresh water to flush under the eyelids. The medical department should be notified as soon as possible and informed of the type of electrolyte and the location of the accident.

When a new battery is shipped dry, the plates are in an uncharged condition. After the electrolyte has been added, it is necessary to charge the battery. This is accomplished by giving the battery a long low- rate initial charge. The charge is given in accordance with the manufacturer’s instructions, which are shipped with each battery. If the manufacturer’s instructions are not available, reference should be made to the detailed instructions for charging batteries found in current Navy directives.

A normal charge is a routine charge that is given in accordance with the nameplate data during the ordinary cycle of operation to restore the battery to its charged condition.

An equalizing charge is a special extended normal charge that is given periodically to batteries as part of a maintenance routine. It ensures that all the sulfate is driven from the plates and that all the cells are restored to a maximum specific gravity. The equalizing charge is continued until the specific gravity of all cells, corrected for temperature, shows no change for a 4-hour period.

In a floating charge, the charging rate is determined by the battery voltage rather than by a definite current value. The floating charge is used to keep a battery at full charge while the battery is idle or in light duty. It is sometimes referred to as a trickle charge and is accomplished with low current.

A fast charge is used when a battery must be recharged in the shortest possible time. The charge starts at a much higher rate than is normally used for charging. It should be used only in an emergency, as this type charge may be harmful to the battery.

Normally, the charging rate of Navy storage batteries is given on the battery nameplate. If the available charging equipment does not have the desired charging rates, the nearest available rates should be used. However, the rate should never be so high that violent gassing (explained later in this text) occurs.

The charge must be continued until the battery is fully charged. Frequent readings of specific gravity should be taken during the charge and compared with the reading taken before the battery was placed on charge.

When a battery is being charged, a portion of the energy breaks down the water in the electrolyte. Hydrogen is released at the negative plates and oxygen at the positive plates. These gases bubble up through the electrolyte and collect in the air space at the top of the cell. If violent gassing occurs when the battery is first placed on charge, the charging rate is too high. If the rate is not too high, steady gassing develops as the charging proceeds, indicating that the battery is nearing a fully charged condition.