> Subject: Batteries: why do they die and how to prevent it?
> In-Reply-To: <[EMAIL PROTECTED]>
>
> Subject says it all.
>

This short question could lead to an infinitely long answer. To keep it brief, I'll 
limit the discussion to just rechargeable batteries.

Rechargeable batteries work because their underlying chemical reactions are nominally 
reversible. You might think, then, that they should have a nearly infinite lifetime. 
Unfortunately, the reversibility applies only to the chemical reactions, and not 
necessarily to the physical/mechanical changes that accompany charge-discharge cycles. 
As you
discharge a cell, physical transport of material generally takes place. Recharging 
generally moves the stuff back, but not necessarily to their exact, original 
locations. So, you might build up peaks and valleys over time. Eventually, some of 
those peaks can puncture insulation and cause shorts, or the valleys can effectively 
create regions of high
resistance (or even open circuits). A constant challenge of battery designers is to 
minimize these sorts of consequences.

The famous (and misnamed) "memory" effect in nickel-based cells is an example of a 
problem caused by physical changes. In this case, overcharging (most commonly caused 
by continuing to charge -- even at a low level -- a NiCd or NiMH (yes, really) battery 
even after it's been topped up) can cause the growth of surprisingly large crystals 
within the
battery (with an ordinary microscope, you can readily see the difference in crystal 
size for a virgin battery, compared with one that has been consistently overcharged -- 
but be aware that nickel-based compounds are toxic, so don't cut open batteries unless 
you know what you're doing). As they grow, the cell resistance increases, reducing the
cell's ability to deliver energy to a load. Eventually, the crystals will grow large 
enough to puncture insulation and cause a short. Sometimes, you can fix this by 
applying a huge current for a short time (e.g., from a big fat capacitor).

To prevent "memory" is easy: Don't recharge NiCd cells before you've really drained 
them. Using them just a bit, and then popping them back into the charger turns out to 
be a terrible thing for NiCd/NiMH batteries.

If memory problems do arise, a couple of thorough discharge-charge cycles will help 
break down the crystals. Many battery chargers/reconditioners attempt to perform this 
function. However, they generally operate on an entire battery pack. If there's a 
shorted cell inside, reconditioning will generally fail. Even worse, discharging such 
a pack can
result in the application of reverse voltages across one or more cells, and this will 
destroy them fairly quickly. So, if you do decide to recondition cells, you really 
need to do it on an individual cell basis. That generally means popping open battery 
packs, or drilling/melting access holes, etc. You have to be pretty determined to want 
to go
through that trouble, but that's the best way to keep those cells going for a long 
time.

Lead-acid batteries also suffer degradation from physical changes, but they manifest 
themselves differently. Here, you must *avoid* deep discharges, because the lead-acid 
system produces a chemical, lead sulfate, which is an insoluble insulator. Deep 
discharges create a layer of this insulator that is too thick, and the cell resistance 
increases
more or less permanently. That's why you will often seriously wound or even kill a car 
battery if you leave your headlights on overnight. For these batteries, you want to 
treat them more or less the opposite way you would treat NiCd cells. Keep lead-acid 
batteries fully charged as much as possible, don't discharge them deeply, and never 
store them
in a discharged state.

Hope that this is what you were looking for.

--
Prof. Thomas H. Lee
Center for Integrated Systems, CIS-205
420 Via Palou Mall
Stanford University
Stanford, CA 94305-4070
http://www-smirc.stanford.edu
650-725-3709 ph, -3383 fax




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