Battery Handbook

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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.
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BatteryOrientation
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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.
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Figure14:BatteryOrientationandDeviceContacts
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ReversalProtection
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Battery reversal protection is recommended for battery operated devi ces 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.
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BatteryDimensions
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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.