Over 200 years ago Alessandro Volta invented
the first battery. He discovered that by placing
copper and zinc discs on top of each other,
and separating each with a brine soaked cloth,
he could create an electrical power source.
His invention was called the Voltaic Pile
in honour of the inventor and because it was,
well, a pile of materials.
The basic principle of battery construction
has not changed to this day.
Batteries are made up of cells. Each cell
has a positive cathode and a negative anode.
The anode and cathode are kept physically
apart with a separator but, for the cell to
work, both are placed in contact with each
other via electrolyte.
In this state the cell is almost inactive,
it only has the potential to create electricity.
When connected to an appliance a chemical
reaction takes place within the materials
which causes electrons to flow through the
circuit.
The materials which make up the cathode, the
anode, the separator and the electrolyte vary
depending on the type of battery or, as it's
known, the battery chemistry. There are numerous
chemistries. And numerous types within each
chemistry.
In this video we'll look at how Zinc Carbon
batteries are made
The process starts with an empty zinc can
which is both the case, the negative anode
and the negative electrode.
A paper disc with a crown is placed at the
very bottom of the can. A second flat paper
separator rolled into a cyclinder is then
inserted. These two elements will prevent
the positive cathode material which will be
placed inside from making contact with the
negative anode case.
The can is then filled with a damp powdered
mixture of ammonium chloride electrolyte and
Manganese Oxide. This is the cathode material.
A carbon rod for collecting electricity is
inserted into this cathode material. This
is the positive electrode.
A plastic gasket is placed over the top to
ensure the internal elements don't dry out
and to prevent any leakage.
The battery is then placed in a resin tube.
Because the bottom of the casing is usually
flat a metal negative terminal is added and
fixed into place by shrink wrapping the resin
tube.
At the positive end of the battery a metal
terminal is also added and also held in position
by the shrink wrapped resin tube.
For marketing or labelling purposes a plastic
outer foil is usually added
Now you know how a Zinc Carbon battery is
made remember to check out our other videos
about Lead Acid, Alkaline, Lithium and Nickel
battery types.
And for more information on all battery related
topics simply search "BatteryGuy Knowledge
Base" of visit us at batteryguy.com forward
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