Characterization of all zinc chloride zinc carbon cells containing zinc cans made from no lead added zinc alloys

There is considerable interest among consumer battery manufacturers to continue to eliminate toxic metals from battery products. Cadmium and mercury free battery products are now common place in the consumer market. As yet, lead remains in the zinc alloy of the zinc can used in the zinc carbon style cells. Anticipating the eventual need to remove lead from the zinc can of the zinc carbon cell, many types of “no lead added” zinc alloy cans have been evaluated for performance, leakage and cell gassing relative to two types of lead alloy zinc cans. Lead-free cans from the drawn and extruded manufacturing processes are compared. An improved drawn can concept was studied and compared relative to the other processes on significant performance and quality parameters. Significant differences are noted and reported between the various can types. The impact on performance of iron contamination in the zinc alloy is reported. An alloy additive was found that demonstrates significant promise for eliminating the bad effects of iron on corrosion and performance