How A Battery Is Made
The alkaline cathode is a mixture of manganese dioxide, graphite and an electrolyte.
The mixture is granulated, aged, and then compacted into a pressed tablet assembly.
Next, these tablets are inserted into a steel can. The steel can and the mixture thus become the cathode of the alkaline battery. An indentation is then made near the top of the can and the sealant is placed just above it. These two steps help safeguard the battery against leakage.
As with the zinc chloride battery, the cathode and the anode portions of the alkaline battery must be kept from coming into contact with one another. Therefore, we must insert a paper separator, which is soaked with an electrolyte that promotes ionic, or electrolyte, conductivity once the battery is in use.
We now insert the anode. In alkaline batteries, the anode is actually a gel made up of mostly zinc powder and several other materials. This gel is inserted into the steel can against the separator paper.
With the anode and cathode in place, we now have a usable alkaline battery. However, because it is unsealed, the battery would not have a long shelf life. Therefore, a seal must be used to ensue the high quality and performance of the alkaline battery.
The seal is made up of a brass nail, which acts as the current collector, a plastic gasket, a steel washer and a metal end cap. The four items are pre assembled and inserted into the middle of the steel can, up against the indentation which was formed earlier.
A top is welded to the other end of the can to provide the positive polarity safety feature.
The batteries are then stored, given a second voltage test, and a decorative outer label is applied.