Button Battery Metal Layer Inhibits Hydrogen Swelling
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Solution Overview
Problem
Conventional button-type alkaline batteries using mercury-free zinc alloy anode active materials face issues with hydrogen gas generation, leading to swelling and capacity deterioration, especially during high-temperature storage, due to self-corrosion and local cell reactions.
Innovation Solution
A button-type alkaline battery design where a metal layer containing zinc and at least one of indium, bismuth, or tin is formed between the anode and anode sealing member, inhibiting hydrogen gas generation by segregating these metals in the base material, thereby preventing swelling and capacity degradation without requiring conventional plating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If mercury-free zinc alloy powder is used as anode active material, then environmental pollution is reduced, but hydrogen gas generation increases causing battery swelling and capacity deterioration
Solution Approach 1:
A metal layer comprising zinc and at least one of indium, bismuth, or tin is formed as an intermediary between the anode sealing member and the anode. This metal layer acts as a mediator that prevents direct contact between the zinc anode active material and the anode sealing member, thereby inhibiting local cell reactions and hydrogen gas generation while maintaining environmental compatibility by avoiding mercury
Solution Approach 2:
The metal layer is formed as a composite material comprising zinc and at least one of indium, bismuth, or tin. This composite structure combines the benefits of zinc (high hydrogen overpotential) with the corrosion-resistant properties of the alloying elements, creating a multi-functional barrier that simultaneously prevents hydrogen gas generation through both local cell reactions and self-corrosion
2Manufacturing precision
If conventional plating processes are used to form metal layer, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The metal layer is formed through a self-service mechanism where zinc ions from the anode active material naturally deposit onto the anode sealing member surface during battery assembly and initial operation. This self-formation process eliminates the need for complex external plating equipment and processes, achieving sufficient metal layer formation through the battery's own electrochemical environment
Solution Approach 2:
The invention changes the parameters of metal layer formation from external plating conditions (electrolyte composition, current density, temperature control) to internal battery conditions (electrolyte concentration, operating voltage, temperature). By utilizing the battery's own operational parameters to form the protective metal layer, the manufacturing process is simplified while maintaining adequate layer quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively inhibits both self-corrosion and local cell reactions, preventing hydrogen gas generation and associated swelling and capacity loss, even during high-temperature storage, while avoiding the need for specialized processes like plating.
Implementation Method 1
a metal layer which comprises zinc and at least one of indium, bismuth, and tin, wherein the at least one of indium, bismuth, and tin has segregated in the zinc
Implementation Method 2
a zinc-mercury alloy layer is formed through the solid phase diffusion of mercury in a zinc layer formed on the inner surface of the anode sealing member
Implementation Method 3
Zinc dissolves in an alkaline electrolyte while generating hydrogen gas
Implementation Method 4
When zinc and copper that is contained in the anode-side surface (the inner surface) of the anode sealing member come into contact with each other in the presence of an alkaline electrolyte, a local cell is formed. This local cell reaction decomposes water contained in the alkaline electrolyte and thereby generates hydrogen gas
Data Source
AI summary
A button-type alkaline battery in which an anode 3 containing an anode active material and an alkaline electrolyte is disposed in a sealed space formed by sealing a cathode housing 4 with an anode sealing member 5, with a gasket 6 being interposed between the cathode housing 4 and the anode sealing member 5. The anode active material includes mercury-free zinc or a mercury-free zinc alloy. The button-type alkaline battery includes a metal layer 7 that is disposed between and in contact with the anode sealing member 5 and the anode 3. The metal layer 7 includes a base material containing zinc, and at least one metal M selected from the group consisting of indium, bismuth, and tin, with the metal M having segregated in the base material.