Creating the cathode and anode from materials like lithium, nickel, or cobalt, adding a separator, and filling with an electrolyte solution before sealing are common steps in the battery production process. A copper and zinc electrode, an acid solution as the electrolyte, connected by wires, and a load to produce electrical current are all you need to manufacture a basic battery at home.
Italian Alessandro Volta started the battery-making journey in 1800. Volta experienced an electric shock after completing the battery creation process. His battery creation consisted of silver and zinc discs and mercury cups. He also used salt water, Lye and some alkaline solutions.
Later, Sir Humphrey Davy led further battery manufacturing experiments in 1813. Michael Faraday also contributed by discovering the principle of electromagnetic induction. This article will help you understand battery manufacturing methods using various raw materials. The materials used in the process are zinc, manganese, graphite, potassium etc.
Did you know?
The lead-acid battery used in the automobile was first invented by Martha C. Weston in 1859.
What are Battery Components?
A battery is a group of cells. There is no difference in creating electricity by a battery. But, there are different types of batteries in the market due to material variations. The battery's inside parts consist of an anode and a cathode. The combination of a cathode and oxygen is called an oxide. The anode releases electrons, and the cathode absorbs them. A cell can produce electricity when the anode and cathode are connected to the third substance that conducts electricity. An electrolyte is the third substance where the anode and the cathode are placed. Electrolytes are chemicals with alkaline properties. A cell cannot produce electricity unless placed in a circuit with a simple switch. Different batteries function differently in various situations. There are also other types of batteries, including lead acid batteries, lithium/manganese dioxide batteries and mercury batteries.
Battery Manufacturing Process
You will have to follow different manufacturing processes to create a variety of batteries. The battery material is also different. Here, you can learn the process of creating an alkaline battery.
1. The Process of Creating a Cathode
The materials, including manganese dioxide, graphite and electrolyte, are delivered and mixed at the production site. Then the mixture is pressed into cylinders called preforms. The number of reforms depends on the battery size.
The preforms are entered into a steel can of nickel plate in the next step. Combining the preforms and the steel creates the battery's cathode.
2. The Separator Process
After soaking it in the electrolyte solution, a paper separator is inserted into the can. It appears like a paper cup in the can.
3. The Creation of Anode
In the next step, the anode is inserted into the battery can. It consists of zinc powder, potassium hydroxide electrolyte etc. It is a chemical suspension that does not get filled to the top of the can, leaving space for the chemical reaction in the battery.
4. Seal of the Battery
Although the battery can produce electricity at this stage, the cell cannot be left open. Therefore, it is necessary to seal the battery. The battery is sealed using three components: brass, plastic and metal. The seal is made thin in some parts to avoid rupture of the entire battery.
5. The Battery Label
The battery is labelled to facilitate identification. The label includes size, type and other information. The label is often attached to the battery using glue.
How to Make Battery at Home?
Most people think that batteries can be created only in the factory. But, it is not true. People can create a battery at home using simple battery manufacturing methods. You can build the batteries using lemons, potatoes and lead.
Also Read- Drawing Process for Metals & Plastics: A Comprehensive Overview
1. Lemon Battery
The lemon battery-making process includes a lemon, a copper coin, a zinc-coated nail, two wires and a multimeter. First, you must insert the copper coin into one end and the zinc nail into the other end of the lemon. Then it would help if you connected the wires to the copper coin and zinc nail. After that, connect the multimeter to the wire. You will see the voltage reading on the multimeter.
2. DIY Lead-Acid Battery
It would be prudent to take safety measures to create a DIY lead-acid battery at home. The battery components required for making a DIY Lead-Acid battery are lead plates, sulfuric acid electrolytes, a plastic container with a lid, wire, a battery charger, and distilled water. You should wear goggles, gloves and protective clothing to be safe.
You will have to follow the steps below.
Step 1: You must cut the lead plates into the perfect size and shape to fit into the container.
Step 2: Clean the lead plates using a wire brush and distilled water.
Step 3: You must fill the plastic container with sulfuric acid based on the container size and the number of lead plates.
Step 4: Soak the lead plates in the electrolyte by covering them fully.
Step 5: You must connect the lead plates to the wires. Connect the positive plate to the positive point of the battery and the negative plate to the negative point.
Step 6: Charge the battery for a few hours unless it reaches around 2.3 V per cell.
Step 7: Use distilled water to bring the electrolytes to the proper level.
Step 8: Repeat the charging process until the battery is fully charged.
Step 9: You should keep the battery dry and cool.
Types of Battery
There are different types of batteries based on the materials used to create them. Some of the batteries are listed below.
1. Lithium Batteries
This is one of the most common battery types. These batteries offer the highest energy density by storing more energy. The sizes of these batteries are AA, AAA and 9V. It lasts longer, even after heavy use. Therefore, it is an ideal choice for heavy use.
2. Alkaline Batteries
Alkaline batteries are also popular because they are easy to use and economical. Since these batteries have a capacity of over 2,500 mAh, they are suitable for moderate to heavy use. This battery is considered ideal for almost all devices for its standard size and is available at a suitable price. These batteries are manufactured using eco-friendly materials; you can use them without harming the environment.
Also Read- Why Should You Start a Battery Business in India?
3. Silver Oxide Batteries
These batteries are used mainly in small devices like wristwatches, which operate longer and have greater energy capacity. Due to its flat size, it can be used in any compact device.
4. Lithium-ion Battery
Lithium-ion batteries are also called Li-ion batteries. This is also a popular battery type and is used regularly. Li-ion batteries are found in electronic devices like mobile phones and laptops. Since these are rechargeable batteries, you can recharge them again and again. The batteries have a high energy density, can be recharged quickly, and are environmentally friendly.
5. NiCD
NiCD batteries are used widely in toys, digital cameras and flashlights. These are available in standard sizes like AA, AAA, C and 9V. These batteries are available cheaply, and you can find them easily in the market.
Factors to Consider During the Battery Manufacturing Process
There are many things to remember during the battery manufacturing process, and these things will have a significant impact if followed properly.
1. Quality of the Battery
It is indispensable to maintain good quality while manufacturing the battery. The battery inside parts and materials should be of high quality. The battery should have the capacity to operate in any situation and a longer life. The batteries should be tested in every stage of the battery-making process. The battery should also be readily available in an easy-to-find manner.
2. Environment Friendly
Apart from good quality, the manufacturer also must make the battery environment-friendly. The manufacturer should remember that the material incorporated in the battery should not threaten the environment.
Zinc and manganese are safe for the environment. Therefore, the manufacturer should use these materials to manufacture the battery. Mercury is considered harmful to the environment. Therefore, this material should be avoided in battery manufacturing.
3. Efficiency
The battery should be efficient and last for a long time. It should also have a superior energy density, and the manufacturer should use those materials to increase battery efficiency.
4. Availability
The battery should be readily available in the market. When the sale increases, the demand for the battery automatically increases. Therefore, availability can be increased by improving battery quality.
5. Life Span
The battery should be durable, and the materials used should increase its durability. If the battery is rechargeable, the user should be able to recharge it conveniently.
Conclusion
Batteries are an indispensable part of our lives. With the increasing usage of various technological devices, battery usage has also increased. Batteries demand has also increased day by day. Battery manufacturing is an excellent business idea at present. But, one should follow the necessary guidelines before beginning the battery manufacturing process. If you are searching for any business idea, battery making at home or in a factory can be beneficial for starting a business. You can start a factory or manufacture at home. However, it would help if you took some necessary safety measures while manufacturing the battery.
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