Energizer PP355 User manual

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Energizer
ZincAirPrismatic
Handbook
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IncludingperformanceanddesigndataforthePP355

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ENERGIZERBATTERYMANUFACTURING
VERSION1.2
EnergizerZincAirPrismaticHandbook
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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

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ENERGIZERBATTERYMANUFACTURING
VERSION1.2
Section1:BatteryOverview
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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.
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1.1‐‐ZincAirChemistry
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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.
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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:
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Anode: 2Zn+4OH‐→2ZnO+2H2O+4e‐
Cathode: O2+2H2O+4e‐→4OH‐
Overall: 2Zn+O2→2ZnO
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1.2‐‐Construction
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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.

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ENERGIZERBATTERYMANUFACTURING
VERSION1.2
Figure1:CrossSectionViewofZincAirPrismaticBattery
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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.
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1.3‐‐FeaturesofZincAirPrismatic
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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.
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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.
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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.

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ENERGIZERBATTERYMANUFACTURING
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Figure2:RuntimeforEquivalentVolumeAAAABatteriesin50mWDevices
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0
10
20
30
40
50
A
AAA Alkaline Lithium Ion ZAP PP355
12 14
38
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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.
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Figure3:ComparisonofZincAirversusOtherBatteryTechnologies
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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)
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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.

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ENERGIZERBATTERYMANUFACTURING
VERSION1.2
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Figure4:ComparisonofDischargeCurvesat50mWContinuous
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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
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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
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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.
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Figure5:ZincAirPrismaticBatterySizes
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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
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ENERGIZERBATTERYMANUFACTURING
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Section2:PP355PerformanceCharacteristics
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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.
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2.1‐‐PerformanceatStandardConditions
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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.
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Figure6:PP355DischargeCurvesatContinuousConstantPower
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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
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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.
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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.

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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.

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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
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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
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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
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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.