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Why batteries come in so many sizes and shapes
๐ Abstract
The article discusses the history, development, and various types of batteries, including lead-acid, alkaline, and lithium-ion batteries, and the factors that shape their design and manufacturing.
๐ Q&A
[01] The History and Development of Batteries
1. What were some of the early demonstrations and inventions of batteries?
- The first batteries were made in the 1800s and were quite simple, such as a series of metal discs soaked in brine, which Italian scientist Alessandro Volta found created an electric current.
- The first lead-acid battery was made of a few pieces of lead in a jar of sulfuric acid, and the modern versions are not that different, just easier to manufacture and containing various additives to improve performance.
2. How do batteries work in general?
- Batteries perform in the same manner: a voltage difference between two dissimilar electrodes produces an electric current, which can be discharged to power a device. Rechargeable batteries can then reverse this current to charge back up.
- Inside the battery, the electric current is accompanied by the flow of ions through a liquid, the electrolyte, and the passage of each electron in the current is accompanied by the transport of one ion through the electrolyte.
[02] Lead-Acid Batteries
1. What are the key characteristics of lead-acid batteries?
- Lead-acid batteries were the first rechargeable battery, invented in 1859 by Gaston Plante, and they need to be large enough to provide enough charge to start a car.
- They also need to be usable in cold climates and last many years, and since the electrolyte is a corrosive acid, the external casing has to be tough to protect people and car parts.
[03] Alkaline Batteries
1. How do alkaline batteries differ from lead-acid batteries?
- Household devices like calculators and digital scales can afford to use smaller batteries because they don't require a lot of charge, and these are primarily non-rechargeable alkaline batteries that have been used for decades.
- The standardized cell sizes are AAAA, AAA, AA, C and D, as well as button and coin cells, and the sizes are related to how much charge they store, with the bigger batteries holding more charge.
[04] Lithium-Ion Batteries
1. What were the advantages of lithium-ion batteries over previous rechargeable battery technologies?
- Nickel-cadmium batteries were the first widely used rechargeable batteries for household electronics but had issues with toxicity and "memory effect".
- Lithium-ion batteries, first commercialized by Sony in 1991, store more energy and last longer than nickel-cadmium batteries, making them popular for portable electronics like laptops and cellphones.
2. Why were cylindrical lithium-ion cells chosen for early production?
- Sony chose to make cylindrical cells because these were the easiest to manufacture, as they could repurpose their existing roll-to-roll manufacturing equipment for producing rolls of battery electrodes.
[05] Factors Shaping Battery Design
1. What factors influence the shapes and sizes of batteries?
- Batteries are made in certain sizes and shapes for reasons of cost and manufacturability, as well as due to legacy manufacturing processes.
- Market demand also plays a role, as seen with the adoption of cylindrical lithium-ion cells in electric vehicles by Tesla, which were already being mass-produced for portable electronics.
- The future of battery shapes and sizes will depend on a mix of innovation and history, considering factors like energy density, manufacturing costs, and intended use.
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