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I. Battery Basics
The Science of
Batteries
Batteries convert chemical energy into
electricity by using one or more galvanic cells. Within each cell are
two electrodes, each made from a different type of metal (or metallic
compound) and an electrolyte solution. The positively charged
electrode is called a cathode. The negatively charged electrode is
called an anode. The electrolyte solution conducts the electric
current inside the cell.
When you switch on a
battery-powered device, such as a flashlight, electrons (negatively
charged subatomic particles) begin to move quickly within each
battery. Metal ions from the anode are “dissolved” into the
electrolyte solution while hydrogen molecules from the electrolyte are
deposited onto the cathode. Switching on the flashlight amounts to
completing an electric circuit (pathway) that includes the battery
terminals and the bulb. The current circulates through the battery and
the flashlight, making the bulb work.
When the
anode has been fully “dissolved” or the cathode is fully reduced, the
battery is considered to be discharged. Until this happens, a
battery's active life depends on the amount of energy required to
power the device as well as the type of metals used for its
electrodes. Every metal or metallic compound has an electromotive
force, which is the ability of the metal to gain or lose electrons in
relation to another type of metal. The large the difference between
the electromotive forces of the anode and cathode, the greater the
amount of energy will be produced by the cell.
Table 1.1 The
Electromotive Series for Some Battery Components
|
Anode Materials
(Listed from worst [most positive] to
best [most negative]) |
Cathode Materials
(Listed from best [most positive] to
worst [most negative]) |
|
Gold |
Ferrate |
|
Platinum |
Iron Oxide |
|
Mercury
|
Cuprous Oxide |
|
Palladium
|
Iodate |
|
Silver
|
Cupric Oxide |
|
Copper
|
Mercuric Oxide |
|
Hydrogen
|
Cobaltic Oxide |
|
Lead
|
Manganese Dioxide |
|
Tin
|
Lead Dioxide |
|
Nickel |
Silver Oxide |
|
Iron
|
Oxygen |
|
Chromium |
Nickel
Oxyhydroxide |
|
Zinc |
Nickel Dioxide
|
|
Aluminum |
Silver
Peroxide |
|
Magnesium |
Permanganate |
|
Lithium |
Bromate |
Since a battery is one or
more galvanic cells connected in series or in parallel, batteries can
be made with almost any current at almost any voltage level. A battery
composed of two 1.5V cells will produce 3V. A typical 9V battery is
simply six 1.5V cells connected in a series. This type of
series
battery, however, will produce a current equivalent to just one of the
galvanic cells.
A battery composed of two
1.5V cells connected in parallel will still produce a voltage
of 1.5V but the current can be double the current of just one
cell – thereby providing a current twice as long as a single cell.
Basic Battery Terminology
Disposable or Primary are terms used for the
most common type of battery for every day use. These batteries are
designed to be cycled (fully discharged) only once and then discarded.
Rechargeable or Secondary
are terms used most often with specific devices such as laptop
computers, answering machines or cell phones. These batteries can be
re-charged and re-used when the chemical charge is exhausted. How? The
electrodes contain chemicals that can be “revived” by reversing the
electrochemical reaction that produces power. When such a battery is
placed into a recharging unit, the charger sends a reverse current
through the electrodes. The reverse current is delivered at a higher
voltage, which is used to re-form the chemicals at each electrode.
Once the battery voltage is increased to its charged state, it can be
removed and used again.
Wet Cell is a term that
describes the battery’s electrolyte fluid which, in this case is
thinner and more liquid in form. Wet cell batteries are often
sensitive to the battery’s orientation and if positioned incorrectly,
may not be able to produce a current if gas pockets form around an
electrode. Vehicle batteries are almost always wet cells.
Dry Cell is a term that
describes a more solid, paste-like or powdery electrolyte material in
a battery. Orientation is not a factor in dry cell batteries.
Acid batteries get their
name because of the type of electrolyte used in their construction.
Acid-based batteries most often use sulphuric acid as the major
component and are most often found used in vehicles.
Alkaline batteries
typically use sodium hydroxide or potassium hydroxide as the main
component in the electrolyte make up. Alkaline batteries are mostly
used where high-energy output is needed, such as cell phones, portable
CD player, radios, pagers and cameras.
Types of Disposable Batteries
1. Alkaline (aka Zinc-Manganese Dioxide)
batteries comprise about 30% of all household batteries in the world.
This type of battery has electrodes made of zinc and manganese-oxide.
The names refer to the strong alkali solution, potassium hydroxide,
used in them as an electrolyte. Pros: They are affordable, have
a long shelf-life, and
are about five times more useful life than
Carbon-zinc batteries.
Cons: The energy supply can be drained quickly in high-power
devices.
2. Carbon-zinc batteries,
also called standard carbon batteries, have electrodes made of zinc
and carbon. An acidic paste between the electrodes serves as the
electrolyte. Pros: Least expensive and have a long
shelf life. Cons: Poor performance at lower
temperatures, and performance diminishes as power drains from the
battery. They have a propensity to leak because of the casing and can
ruin the devices they are in.
Note:
Household items such as flashlights, radios, and remote controls
typically use alkaline or carbon-zinc batteries. Because they last
from five to eight times longer, alkaline batteries may be more
economical than carbon-zinc batteries for devices that require high
amounts of currents.
3. Lithium batteries have
lithium metal anodes and produce more than twice the voltage of an
alkaline cell. They are used in cameras, pacemakers, watches, and
calculators because they have a very long service life in these low
power devices.
Lithium
batteries weigh less than alkalines, which saves you 1 ounce for every 4 AA batteries.
Pros:
Lithium batteries provide a high power output, long shelf-life, and
low temperature performance. They are small and light weight.
Cons: High cost and the energy
supply can be drained quickly in high-energy devices.
4. Air batteries have a
zinc anode and a potassium hydroxide electrolyte. Because an air
battery requires oxygen from the air or atmosphere for its
electrochemical reaction to occur, it can operate only where the
atmosphere is controlled. Air batteries are commonly used in hearing
aids because the humidity and temperature within the ear canal remain
constant. Pros: High energy output and long service life. They
can only operate in a controlled atmosphere, and provide low power.
Cons: Only designed for very small devices and usually are button
sized.
Benefits of
using disposable batteries:
-
Industry standards guarantee dependability
-
Affordable, usually costing less than $1 each
-
Widely obtainable at a variety of retail
locations
-
Long shelf-life (the ability to keep their
energy-producing capacity for years, if unused)
Drawbacks of using disposable batteries:
-
Despite their long shelf-life, they have a
rather short ACTIVE life
-
Long-term costs. Over the course of you
lifetime, you could spend hundreds and hundreds of dollars replacing
these batteries in all your devices.
Note:
Forget the hype about Super Titanium, E3 or any other new and
over-advertised alkaline technology. They cost more and once used,
still go in the garbage. Slightly longer active life is not offset by
the cost and in the end, the battery companies are just making a lot
of money off their strategic ad campaigns.
Types of Rechargeable Batteries
1. Nickel-cadmium batteries, also called Ni-Cad
batteries, have electrodes made of nickel-hydroxide and cadmium and
use potassium hydroxide as the electrolyte. They are less expensive
than NiMH and hold their charge longer.
Pros: Inexpensive,
long-lasting, and strong performance at high temperatures. NiCd
batteries use Cadmium, a highly toxic heavy metal that can damage the
environment if not disposed of properly.
Cons:
Low energy capacity, toxic, and decline quickly with use.
2. Rechargeable Alkaline
Batteries are made only by Rayovac and marketed to be rechargeable 25
times or more. Pros: The manufacturer states that its batteries
do not suffer from “memory loss” that NiCd batteries do and that the
shelf life is as long as disposable alkaline batteries. Cons: Unknown
at this time.
3. Nickle-metal-hydride
(Ni-MH) batteries use a nickle-hydroxide cathode, an alloy of a rare
earth metal (M) with nickel for its anode and a potassium hydroxide
solution for the electrolyte. These are a good replacement for
alkalines. They
are more expensive and have a shorter service life than NiCd.
Pros: They can store large
amounts of energy. Cons: Self-discharge quickly, and easily damaged
by overcharging.
4. Lithium-ion batteries
use an anode made of any one of a number of carbon-based materials.
The cathode is made of a cobalt, manganese, or nickel oxide that
includes lithium. They require special circuitry to help keep them
from exploding, which is why general-purpose Li-ion cells are not
commercially available in standard sizes
like AA , C or D cell.
Pros: Lithium offers the highest
energy-producing potential at the lightest weight.
Cons: They
have a high cost, diminishing performance as power drains from the
battery, and can explode if misused.
5. Nickel-Iron (Ni-I) are
sometimes called the Edison battery and are much less expensive to
build and to dispose of than nickel-cadmium cells. They are widely
used in industrial settings and in eastern Europe where iron and
nickel are readily available and inexpensive.
Pros: The cells
are rugged and reliable. Cons: They do not charge very well.
Benefits of using rechargeable batteries:
-
Compared to non-rechargeable carbon zinc or
alkaline batteries, rechargeable batteries last longer
-
Less expensive in the long run – usually
designed to be recycled anywhere from 100 to 1000 times!
-
More environmentally friendly –less waste
created by reusing
Drawbacks of using rechargeable batteries:
-
More expensive initially
-
Less
widely available
II. Battery
Size
Our
Battery Doctrine
Whether you chose disposable or
rechargeable batteries, we strongly support “battery size
standardization” for practicality, and choose AA as the most universal
size. By compiling gear powered exclusively by AA batteries, a soldier
can triage his/her gear and replace any/all batteries more quickly and
efficiently. All battery-powered gear on our site follows this
standardization doctrine.
Table
2.1 Battery Stats
|
Size |
Voltage
(V) |
Capacity
(mAh) |
Height inches
(mm) |
Width inches
(mm) |
Weight
(grams) |
Notes |
|
AAAA |
1.5 |
595 |
1.6 (42.5) |
0.32 (8.3) |
6.5 |
|
|
AAA |
1.5 |
1125 |
1.75 (44.5) |
0.41 (10.5) |
11.5 |
|
|
AA |
1.5 |
2600 |
1.98 (50.5) |
0.57 (14.5) |
23 |
|
|
AA Lithium |
1.75 |
2900 |
1.98 (50.5) |
0.57 (14.5) |
14.5 |
|
|
C |
1.5 |
8350 |
1.96 (50.0) |
1.03 (26.2) |
66.2 |
|
|
D |
1.5 |
18000 |
2.42 (61.5) |
1.34 (34.2) |
141.9 |
|
|
F |
1.5 |
26000 |
3.45 (87.8) |
1.27 (32.2) |
201 |
|
|
N |
1.5 |
1000 |
1.18 (30.2) |
0.47 (12.0) |
9 |
|
|
9v |
9 |
595 |
1.9 (48.5) |
1.04 (26.5) x
0.68 (17.5) |
45.6 |
Contains 6
AAAA |
|
Lantern |
6 |
26000 |
4.52 (115) |
2.62 (66.7) |
885 |
Contains 4 F
cells |
|
MN 21/23 |
12 |
40 |
1.12 (28.5) |
0.40 (10.3) |
7.5 |
Contains 8
LR932 |
|
123A |
3 |
1300 |
1.35 (34.5) |
0.66 (17.0) |
15.5 |
|
Why AA?
Compare
the size, weight, and capacity of the standard batteries listed in
Table 2.1. Relative to their weight, AA batteries have the best
characteristics when compared to these other battery sizes. Also,
there are adapters that hold AA batteries which enable you to use them
in devices that normally require larger batteries. It is estimated
that 90% of portable, battery-operated devices require AA, C, or D
battery sizes.
III. Battery Advice
Battery
Safety
Because batteries are so common, we may
forget that they are self-contained chemical reactors and that their
contents can be harmful under certain circumstances. The chemicals
that provide the battery's energy source are safely sealed within a
metal or plastic container at the factory. Over time, however, battery
casings may develop leaks because of abuse or degradation. Leaking
batteries should never be used and should be discarded as soon as
proper disposal can be arranged.
Certain types of batteries
may explode if they overheat. To protect yourself, never recharge a
disposable battery. Batteries should never be exposed to open flames,
disposed of in fires of incinerators, or stored in areas where the
temperature may exceed 37°C. Batteries should likewise be kept
free from moisture, which may cause a metal battery casing to corrode
and leak. You should never carry a battery loose in your pocket, as
contact with coins or other metal objects may cause the battery to
short-circuit and overheat.
If a manufacturer
recommends a particular type of battery for a battery operated device,
never use any other type of battery. Never Mix batteries from
different manufacturers. Never mix batteries of different capacities.
Never mix batteries of different chemistries. i.e. NiCD, NiMH,
Lithium,etc.
Batteries that are no
longer useful should not be stored together. While they may lack
sufficient charge to power their intended devices, drained batteries
nonetheless retain some energy. If they come into contact with one
another, they could generate enough heat to become a fire hazard.
Newer
NiMH battery chargers are designed to specifically charge NiMH and
NiCad chemistries. However most of the older NiCad chargers were not
designed to charge any other battery chemistries such as NiMH since
they were unavailable at that time these chargers were designed. That
is why many of the newer NiMH/NiCad chargers are capable of
automatically charging both types, while others have a switch.
Batteries Storage Tips for Field Use
Keep batteries stored in a cool place
(like your refrigerator) until you're ready to use them. Warm up only
as many as you'll need. Lithium batteries won't need warming up unless
they've been in temperatures below -20°F. Protect dry cell batteries
by keeping them out of the cold and wind. Cover them with your
clothing. Put them in a vehicle or common shelter when possible.
Sheltering batteries behind a wind break is better than leaving them
out in the open. Putting them next to your body is best of all. Never
stow batteries next to a heater or stove. That's too much warmth for
most batteries and they could vent or rupture.
Do not throw away dead or weak batteries.
Heat can speed-up any remaining chemical reaction. Small batteries can
gain life by warming them in your arm pit or between your legs. A
larger battery can gain life by sleeping with the battery next to the
body. Additional life can also be gained by placing batteries in the
sun.
Keep spare batteries
handy so you can make a switch when the ones in your gear start
to fade. When you remove batteries from your gear, put them in
an inside shirt pocket to warm up. After a while, they'll regain
their punch.
If you won't be using your
gear right away, don't install the batteries. Keep them warm as long
as you can. If you warm batteries in a heated place, watch for
sweating. Wipe off any moisture or it will freeze when you go back
into the cold. Finally, if your gear has plastic pins in the battery
compartment, take care when installing the battery. Cold pins become
brittle. They'll break if handled too roughly.
AA batteries of different
chemistry are not compatible. Also, if you replace one battery,
replace them all. A weak battery not pulling its load will cause the
others to drain more rapidly.
Common
to all types of rechargeable batteries is a thing called "self
discharge" where the battery actually loses power even though the
device it's in is turned off. We don't know the exact rate of self
discharge (it varies between capacity and battery chemistry) - but it
is something you should be aware of. If you leave your camera sitting
in a bag for long periods of time the NiMH batteries will not have
much power left.
Fast vs. Standard Chargers
There are some factors to consider when comparing fast charging versus
standard charging units. A typical NiMH fast charger will have a
charge time of 15-60 minutes. While a standard charger will have a
charge time of 60-180 minutes. Quality is important since we have
heard of units that actually fry the batteries instead of charging
them. For this reason, we suggest a name brand unit. Otherwise, it
boils down to your specific needs: do you prefer not needing an AC
adapter? Do you require a 12V input for charging off your car’s
cigarette lighter? These features may be more important than the
charging speed.
Basically, fast
charging units supply the batteries with more power at higher rates.
The batteries thereby charge faster but may suffer more wear and tear.
On the other hand, standard charging units charge batteries with less
power at slower rates, thereby causing less wear and tear on the
batteries. In the end, there is no noticeable difference in the
battery performance. Nor can we determine a difference in the number
of charges you can expect from each unit.
IV.
Our Recommendations
Disposables
We
strongly encourage the exclusive use of Lithium batteries for gear
that has a low power draw (like LED flashlights). This will reduce the
number of times you'll have to change batteries. Lithium batteries
are: much lighter; last longer; more resistant to cold; have better
shelf-life; and withstand heavier current draws. They are five times
as expensive, but when you really need them, believe us, it will be
worth it. Alkaline batteries are fine and dandy for home use, but
switching to Lithium before taking your light source to the field will
increase the battery life10-25%.
Rechargeables
We
encourage the exclusive use of rechargeable nickel-metal-hydride (Ni-MH)
batteries for use in your high power draw devices. This will reduce
the number of batteries you'll be throwing in the trash and save you
money. Most new battery chargers can use Ni-MH or Ni-Cad batteries
interchangeably. Primary batteries, secondary Ni-Cad, or secondary
alkaline batteries are good enough for home use, but switching to Ni-MH
before taking your GPS to the field will increase the battery life
5-15%.
Table
2.2 AA Battery Stats
|
|
Size |
Voltage
(V) |
Capacity
(mAh) |
Weight
(grams) |
Life Cycles |
Charge Times
(hrs) |
Shelf Life |
Price
(ea) |
|
Primary Batteries |
Alkaline |
1.5 |
2600 |
23 |
N/A |
N/A |
5-7 years |
$0.95 |
|
Lithium |
1.75 |
2900 |
13-15 |
N/A |
N/A |
10-12 years |
$3.50 |
|
Carbon-Zinc |
1.5 |
950 |
15-18 |
N/A |
N/A |
3 years |
$0.85 |
|
Secondary Batteries |
Rechareable Alkaline |
1.5 |
2000 |
20-22g |
25-500 |
3-10 |
5 years |
$1.75 |
|
Nickel-cadmium |
1.2 |
600-800 |
18-24 |
600-900 |
16 |
100 days |
$1.25 |
|
Nickl-metal-hydride |
1.2 |
1600-2500 |
14-30 |
500-1000 |
1-3 |
30-60 days |
$2.95 |
Chargers
Ideally, we recommend a
AA NiMH fast charger with folding prongs on the back (often called a
travel charger) capable of handling 120-240V (for international
charging) and a 12V input. This will allow you to charge from a wall
outlet in almost any country or from a vehicle, with the least amount
of adapters. We also recommend “smart” charger features such as
trickle charge and overcharge protection. This will keep your
batteries fully charged when left charging and will keep the batteries
from getting fried.
Keeping "Current"
New M1 Nanophosphate batteries recharge
in minutes instead of an hour, and lasts for decades instead of a
couple of years. Traditional lithium-ion batteries use bits of metal
oxide to store energy, but it takes a while for lithium ions to
diffuse into these relatively large particles. The M1 developed by
A123Systems, charges faster by instead using tiny specs of iron
phosphate to quickly absorb ions. The easier movement of ions means
less wear and tear and a longer lifetime for the battery. Plus, it's
less prone to exploding. While charging, standard lithium-ion
batteries heat up and release oxygen - fuel for fire - at around
300F. The M1's iron phosphate has been tested at about 480 (far
hotter than the batteries are likely to get) without shedding any
oxygen. M1's are currently used in power tools and hybrid/electric
vehicles. There are currently no batteries available for consumer
electronic devices.
In this modern day of portable electronic
devices, the biggest limiting factor is battery life. As the field of
material engineering continues to grow, so will the limits of battery
life. Check this site often for updates to battery life technology.
V.
The Power Frontier
Oxyrides
Panasonic has come out with a new bread of disposable batteries
called Oxyrides. They deliver twice the performance of high-end
alkalines for the same price. AA and AAA rechargeables are still the
most cost-effective way to power many such devices, but lots of
people use disposables anyway, perhaps because of the high initial
investment that rechargeables require.
Panasonic says it uses a patented
process and a combination of new and improved electrolytes to
manufacture the new AA and AAA cells. After eight years in development,
they finally reached store shelves in Japan in 2007. Oxyrides face some
competition in the disposable arena from long-lived AA
and AAA lithium disposable batteries. But these batteries also cost
about three times as much as alkalines. Given their relatively low price
and their sizable power boost. Oxyrides should hold greater appeal for
many battery buyers. There's one slight catch: At least for now, you can
get the batteries only from Panasonic; the company has no plans at
present to license its technology to others.
Capacitors
Capacitors are better than batteries in almost every way, except in the
amount of energy they store. Unlike batteries, which produce voltage
from a chemical reaction, capacitors store electricity between a
pair of metal plates. The larger the area of the plates, and the smaller
the space between them, the more energy a capacitor can hold. Recent
experiments to increase the surface area of the plates by covering the
plates with millions of microscopic filaments known as carbon nanotubes.
With nanotubes it is possible to store an amount of energy that is
comparable to what batteries store.
A capacitor-powered gadget could be
charged in minutes or seconds instead of hours. And since capacitors can
be reused indefinitely, environmental waste from discarded batteries
would become a thing of the past.
Delta Gear predicts that battery free
bliss will be here by 2015.
Germs & Viruses
MIT
researchers are developing a new breed of lithium-ion battery that's
razor-thin, transparent and more potent than current power cells. This
battery looks like a piece of tape. A light, see-through battery could
open the door to less-cumbersome computers, MP3 players and other
gadgets. The secret to its slimness... a virus called M13. Most
batteries store energy in electrodes made of bulky carbon or metal. To
cut weight and increase power, a virus is used as a cathode to attract metal ions and
then bathed them in a solution of cobalt oxide and gold, metals known
for their superior energy-storage properties. Coating the viruses in an
iron phosphate before attaching to carbon nanotubes onto a
charged polymer film created an electrode 40 times as thin as a human
hair. Tests conducted earlier this year showed that it stored three
times the energy of a conventional electrode. The new battery is
currently in the prototype stage, but expect the technology to
go commercial by 2014.
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