Batteries and Cells

A battery stores energy as chemistry and releases it as electricity on demand. This article covers what happens inside one, why each chemistry has its own voltage, the common types, what capacity figures mean, how each type is charged, and how to keep lithium batteries from starting fires.

Article 9 treated a battery as a circuit element with internal resistance, capacity and short-circuit dangers. This article opens the case.

About the analogies. Everyday comparisons appear only in shaded "Analogy" boxes beside the real physics, and each box says where the comparison stops working.

Two hazards to know first. A damaged, abused or badly charged lithium battery can catch fire or explode (section 11). A swallowed coin cell can burn through a child's throat in as little as two hours (section 12).[1] If a child may have swallowed one, go to an emergency room immediately and call the National Battery Ingestion Hotline at 800-498-8666.[1]

1. A short recap

2. Cell or battery?

A cell is a single chemical unit: two electrodes and an electrolyte that together produce a voltage.[2] Strictly, a battery is a set of cells connected to give more voltage or current than one cell can.[2] In everyday speech an AA cell is called a battery too.

The voltage of a cell is set by its chemistry alone; its size makes no difference.[2] To get more voltage, cells are connected in series and their voltages add.[2]​[3] A car battery has six lead-acid cells of 2.0 V each, giving 12 V.[2] A rectangular 9 V battery holds six small cells in series,[4] 6 × 1.5 V = 9 V (calculated) (Figure 1).

A single cell and two batteries made of cells in series Three rows of cell symbols. Top: one alkaline cell of 1.5 volts. Middle: a 9 volt battery drawn as six 1.5 volt cells in series, 6 times 1.5 equals 9 volts. Bottom: a 12 volt car battery drawn as six 2.0 volt lead-acid cells in series, 6 times 2.0 equals 12 volts. The long plate of each cell symbol is its positive side. One alkaline cell 1.5 V + − = 1.5 V 9 V battery 1.5 V 1.5 V 1.5 V 1.5 V 1.5 V 1.5 V + − = 6 × 1.5 V = 9 V 12 V car battery 2.0 V 2.0 V 2.0 V 2.0 V 2.0 V 2.0 V + − = 6 × 2.0 V = 12 V
Figure 1. A cell and two batteries. One alkaline cell gives 1.5 V. Six in series make a 9 V battery, and six 2.0 V lead-acid cells make a 12 V car battery. Totals calculated.

3. How a cell works

Most cells have four main parts (Figure 2):

Metal current collectors carry electrons to the terminals. In an alkaline AA, the anode is a zinc-powder gel, the cathode is manganese dioxide with carbon, the electrolyte is potassium hydroxide, and the steel can and a brass pin are the collectors.[7]

Redox, plainly. The chemistry is a redox reaction (reduction and oxidation). Oxidation means losing electrons; reduction means gaining them.[6] In a cell the two halves happen in different places, oxidation at the anode and reduction at the cathode, so the freed electrons must travel out through your circuit to get from one to the other.[5] That flow is the current that does the work. Inside, ions drift through the electrolyte to keep the charges balanced.[5]​[6] Break the outside circuit and the reaction almost stops, which is why a primary battery can be stored for several years.[8]

Inside a cell during discharge A rectangular cell case containing a solid anode slab on the left and a dashed-outline cathode slab on the right, with a dotted porous separator between them in the electrolyte. Small dots are ions; two arrows show ions moving from the anode side across the separator toward the cathode. Metal current collectors rise from each electrode out of the case to a wire with a load resistor. Dashed arrows above the wire show electrons flowing from the anode through the outside circuit to the cathode. Labels: anode (negative) gives up electrons (oxidation); cathode (positive) takes in electrons (reduction); electrolyte, in which ions move; current collector; separator; cell case. electrons flow through the outside circuit load (your circuit) anode (−) gives up electrons (oxidation) cathode (+) takes in electrons (reduction) electrolyte ions move through it current collector separator: porous; keeps the electrodes apart but lets ions through cell case
Figure 2. Inside a cell during discharge. Electrons leave the anode, flow through the outside circuit and return at the cathode. Inside, ions move through the electrolyte and the porous separator. Simplified; the materials depend on the chemistry.

Analogy: two towns, a bridge and a ferry. Cars (electrons) can cross the river only by a long bridge, the outside circuit, doing useful work on the way. Foot passengers (ions) cross only by ferry, the electrolyte. Close the bridge and soon the ferry stops too.

Where it breaks down: electrons and ions are different particles, not one crowd taking two routes, and ions drift through the liquid rather than ride in anything. Nor does a closed "bridge" stop the chemistry completely: every cell slowly loses charge on its own, called self-discharge.[8]

4. Why the chemistry sets the voltage

Some materials hold on to their electrons more loosely than others. Chemists measure this as a standard electrode potential in volts, compared with a reference, the standard hydrogen electrode, set at exactly 0 V.[9] Put in order, these values form the electrochemical series (Figure 3).

A cell's voltage is the difference between its two electrodes' potentials:[9]

Ecell = Ecathode − Eanode

Zinc's potential is −0.76 V and copper's is +0.34 V,[10] so a zinc-copper cell gives 0.34 − (−0.76) = 1.10 V (calculated). The lead-acid pair (lead dioxide at +1.69 V, lead at −0.35 V in sulfuric acid)[10] gives 2.04 V (calculated), which matches the 2.0 V nominal lead-acid cell. Lithium sits at the very bottom of the list, at −3.04 V,[10] which is part of why lithium cells reach 3 V or more.[6]

Part of the electrochemical series A vertical scale of standard electrode potentials from about plus 1.9 to minus 3.25 volts. Marked points from top to bottom: lead dioxide to lead sulfate plus 1.69 volts; silver plus 0.80; copper plus 0.34; the hydrogen reference 0.00; lead sulfate to lead minus 0.35; zinc minus 0.76; lithium minus 3.04 volts at the bottom. Materials near the top hold electrons tightly and make good cathodes; those near the bottom give them up easily and make good anodes. A bracket from zinc to copper is labeled zinc-copper cell 1.10 volts, and a bracket from lead sulfate to lead dioxide is labeled lead-acid cell 2.04 volts, both calculated. +1.0 V 0.0 V −1.0 V −2.0 V −3.0 V standard electrode potential holds electrons tightly (good cathode) gives up electrons easily (good anode) PbO₂ / PbSO₄ +1.69 V Ag⁺ / Ag (silver) +0.80 V Cu²⁺ / Cu (copper) +0.34 V H⁺ / H₂ (reference) 0.00 V PbSO₄ / Pb (lead) −0.35 V Zn²⁺ / Zn (zinc) −0.76 V Li⁺ / Li (lithium) −3.04 V lead-acid cell 2.04 V (calculated) zinc-copper cell 1.10 V (calculated)
Figure 3. Part of the electrochemical series (standard electrode potentials, from OpenStax Appendix L). The farther apart two electrodes sit, the higher the cell voltage. Differences calculated. Real cells differ a little from these standard values because their conditions differ.

Because chemistry fixes the voltage, every size of zinc-carbon cell from AAA to D gives the same voltage. A bigger cell holds more reacting material, so it can move more charge and lasts longer, but it does not push harder.[3]

5. Primary and secondary cells

Primary cells are single-use: their reaction cannot be practically reversed. Secondary cells are rechargeable: running current backward through them reverses the reaction.[3] Primary cells keep their charge far longer in storage.[8]

Never try to recharge a primary cell. Energizer warns not to recharge any battery unless it is marked "rechargeable", because charging a primary battery "could result in rupture or leakage".[7]

6. The main chemistries

Single-use (primary) cells

"Lithium battery" and "lithium-ion battery" are different things. Single-use lithium batteries contain lithium metal; lithium-ion batteries do not.[15]

Lead-acid

The oldest rechargeable (1859) uses lead and lead dioxide plates in sulfuric acid, at 2.0 V per cell.[19] It is cheap and can deliver the high current a starter motor needs.[3] Three main forms:[19]

Lead-acid is heavy, and lead is toxic.[19] Discharging coats both plates with lead sulfate, and charging turns it back.[3] Left discharged or repeatedly undercharged, the battery suffers sulfation: the sulfate stays and capacity falls.[19]​[20]

Nickel-cadmium and nickel-metal hydride

Both give 1.2 V per cell, a little less than an alkaline cell's 1.5 V.[21] NiCd is robust and long-lived but contains toxic cadmium. NiMH holds more energy and is considered non-toxic.[21] NiCd is not as common as it once was.[22] Energizer's NH15 rechargeable AA, for example, is a 2,300 mAh NiMH cell.[23]

Lithium-ion

The anode is usually graphite (a form of carbon) and the cathode a metal oxide; lithium ions shuttle to the cathode on discharge and back on charge.[6] The cathode names the family:[24]

LiPo ("lithium-polymer") usually means lithium-ion in a flexible foil pouch; to the user it is "essentially the same as lithium-ion". Pouch cells can swell from gas buildup and may be less durable than a metal can.[25]

A supercapacitor holds less energy than a battery of the same size, but delivers it faster and lasts longer (recap).

Table 1. Common chemistries compared (typical values; each maker and test condition differs)
ChemistryTypeVolts per cell (nominal)Energy per kilogram (Wh/kg)Cycle life (full discharges)Self-discharge or shelf life
Zinc-carbonPrimary1.5[12]about 110 at most (calculated from the 1215 datasheet: 1.5 V × 1.1 Ah ÷ 15 g)—over 90% of its service left after 1 year at 21 °C[11]
AlkalinePrimary1.5[26]200[27]—about 3% a year at 20 °C[7]
Lithium-manganese dioxide (CR2032 coin)Primary3.0[13]198[13]—about 1% a year[13]
Lithium-iron disulfide (lithium AA)Primary1.5[16]about 297[15]—25-year shelf life at 21 °C[16]
Silver oxide (button)Primary1.55[18]about 100 (calculated from the 357 datasheet: 1.55 V × 0.15 Ah ÷ 2.3 g)—over 90% left after 5 years at 21 °C[17]
Lead-acidSecondary2.0[19]30 to 50[19]150 to 200 (deep-cycle type)[19]about 5% a month[8]
NiCdSecondary1.2[21]45 to 80[21]1,000[21]10 to 15% in the first day, then 10 to 15% a month[8]
NiMHSecondary1.2[21]60 to 120[21]300 to 500[21]as NiCd[8]
Li-ion LCOSecondary3.6[24]150 to 200[24]500 to 1,000[24]about 5% in the first day, then 1 to 2% a month, plus about 3% a month for the protection circuit[8]
Li-ion NMCSecondary3.6 to 3.7[24]150 to 220[24]1,000 to 2,000[24]as LCO[8]
Li-ion LFPSecondary3.2 to 3.3[24]90 to 120[24]1,000 to 2,000[24]higher than other lithium-ion types[24]

Cycle-life figures assume each cycle empties the battery completely; shallower cycles generally last longer, and lead-acid lives longer if it is not discharged below 60% charge.[19]

7. Sizes and names

Sizes are standardized, so any brand fits (Figure 4):

Common battery sizes drawn to scale Outlines drawn to the same scale on a common baseline. From left: AAA cylinder, 10.5 by 44.5 millimeters; AA cylinder, 14.5 by 50.5 millimeters; 9 volt rectangular block, 48.5 by 26.5 by 17.5 millimeters, with two snap terminals on top; 18650 lithium-ion cylinder, 18.5 by 65.3 millimeters; 21700 cylinder, 21.7 by 70.2 millimeters, the tallest; CR2032 coin cell shown face-on as a 20 millimeter circle and edge-on as a thin 3.2 millimeter slab. A 10 millimeter scale bar is at top right. face edge AAA 10.5 × 44.5 mm AA 14.5 × 50.5 mm 9 V 48.5 × 26.5 × 17.5 mm 18650 18.5 × 65.3 mm 21700 21.7 × 70.2 mm CR2032 20 × 3.2 mm 10 mm Drawn to scale from maximum datasheet dimensions
Figure 4. Common battery sizes, drawn to the same scale from maximum datasheet dimensions. Each body is labeled from outside; the CR2032 is shown face-on and edge-on.

Decoding the codes. International Electrotechnical Commission (IEC) names use letters for chemistry and shape and numbers for size.[14] In CR2032, C marks a lithium chemistry (here lithium-manganese dioxide[13]), R means round, 20 is the diameter in millimeters and 32 is the height in tenths of a millimeter.[14] Datasheets show others: an alkaline AA is an LR6, a zinc-carbon AA is an R6, a lithium AA is an FR6, a NiMH AA is an HR6, a silver oxide button is an SR44, and a 9 V alkaline, with its six cells, is a 6LR61.[26]​[12]​[16]​[23]​[18]​[29]​[4]

8. Capacity in practice

Article 9 introduced amp-hours and watt-hours (recap). One amp-hour is 3,600 coulombs of charge.[2] A capacity figure means little without its conditions: the current, the temperature and the cutoff voltage at which the cell counts as empty. Energizer's AA alkaline example ran 25 hours at 100 mA down to 0.8 V, giving 2,500 mAh; counted only to 1.2 V, it gives less.[7]

Watt-hours compare different voltages. A CR2032 holds 3.0 V × 0.235 Ah = 0.7 Wh (calculated). A Panasonic NCR18650B holds 3.6 V × 3.35 Ah = 12.1 Wh (calculated, using the datasheet's nominal voltage and typical capacity).[32]

C-rate. Currents are often given as a multiple of capacity, the C-rate. A 1 Ah battery at 1C supplies 1 A for about an hour; at 0.5C, 0.5 A for two hours; at 2C, 2 A for 30 minutes, less in practice because of losses.[33]

Heavier loads give less capacity. Article 9 showed an alkaline AA giving about half its capacity at 500 mA compared with 25 mA (recap). Primary cells are rated at small currents and look less impressive at 1C.[4] For lead-acid this is Peukert's law: Victron's example is a 100 Ah battery, rated over 20 hours, that may give only 56 Ah if emptied in two. Lithium is affected less.[34]

Cold reduces capacity. Cold slows the reactions and raises internal resistance, so high currents cause large voltage drops.[7] A zinc-carbon AA is typically 0.5 Ω at 21 °C but 5.0 Ω at −21 °C;[12] at 100 mA that loses 0.05 V warm but 0.5 V cold (calculated). Lithium AA cells do much better in the cold.[7]​[15]

Discharge curves differ by chemistry (Figure 5). Alkaline slopes steadily from about 1.5 V toward a 0.8 V cutoff.[7] Lithium batteries give a nearly constant voltage as they discharge,[3] near 3.6 V for common lithium-ion types, and LFP is flatter still, near 3.2 V.[24] A flat curve keeps a device at full strength but makes it hard to judge the remaining charge from voltage.

Discharge curve shapes for three chemistries Cell voltage from 0 to 4.5 volts against the share of capacity used, 0 to 100 percent. Lithium-ion (LCO or NMC), solid line: starts at 4.20 volts, settles near 3.6 to 3.9 volts for most of the discharge, then falls to a 3.0 volt cutoff. LFP, dashed line: very flat at about 3.2 to 3.3 volts, then drops sharply to a 2.5 volt cutoff at the end. Alkaline, dotted line: starts near 1.55 volts and slopes steadily down to a 0.8 volt cutoff. Illustrative shapes. 0 1 2 3 4 0 25 50 75 100 share of capacity used (%) cell voltage (V) lithium-ion (LCO, NMC): 4.20 V full, 3.6 V nominal LFP: very flat, about 3.2 to 3.3 V alkaline: slopes steadily from about 1.5 V 3.0 V cutoff 2.5 V cutoff 0.8 V cutoff
Figure 5. Discharge curve shapes. Illustrative curves; the full-charge, nominal and cutoff voltages come from Energizer's alkaline handbook and Battery University's lithium summary. Real curves depend on current, temperature and the particular cell.

9. Charging

A charger is a DC supply that controls the voltage and current into a battery. A plug-in one first turns mains AC into low-voltage DC with building blocks from earlier articles: a transformer (recap), rectifier diodes (recap) and smoothing (recap). Chemistries differ in how hard to push and when to stop, so never use "chargers that are not designed for the specific battery type".[7]

Lithium-ion: constant current, then constant voltage

Lithium-ion uses two stages, CC/CV (Figure 6):[35]

  1. Constant current. The charger pushes a fixed current, often 0.5C to 1C, and the cell voltage rises.[35]
  2. Constant voltage. At the limit, typically 4.20 V per cell within ±50 mV, the charger holds the voltage and the current falls as the cell fills.[35]
  3. Stop when the current falls to 3 to 5% of the amp-hour rating.[35] (Panasonic's NCR18650B: 0.5C maximum, 4.20 V, 65 mA cutoff.[32]) Lithium-ion "cannot accept overcharge" and gets no trickle charge.[35]

LFP uses the same method with a 3.65 V limit and no float charge. Four LFP cells can replace a 12 V lead-acid battery's six, but lithium cannot tolerate a lead-acid charger's float stage unless the pack's BMS is designed to cope.[36]

Constant-current, constant-voltage charging of a lithium-ion cell Two curves against time. Solid line, cell voltage on the left scale from 3.0 to 4.4 volts: it rises from about 3.2 volts during stage 1 and levels off at 4.20 volts, where it is held during stage 2. Dashed line, charge current on the right scale from 0 to 1C: it is constant at 0.5C during stage 1, then tapers downward during stage 2 and the charger stops when it reaches a few percent of C; after that the current is zero and the voltage relaxes slightly. Vertical dashed lines mark the stage boundary and the stop point. Illustrative. 3.0 3.4 3.8 4.2 0 0.5C 1C cell voltage (V) charge current time Stage 1: constant current Stage 2: constant voltage off voltage rises held at 4.20 V current held at 0.5C current tapers stops at a few % of C Solid line: voltage (left scale). Dashed line: current (right scale). Illustrative.
Figure 6. CC/CV charging of a lithium-ion cell. The current is held constant while the voltage rises to 4.20 V; then the voltage is held and the current tapers until the charger stops. Illustrative shape based on Battery University's description and the NCR18650B datasheet.

Analogy: filling a glass from a jug. You pour quickly at first, then slow down near the top so it does not overflow, and stop when it is full.

Where it breaks down: the slowing happens on its own, because the voltage is held fixed and a fuller cell accepts less current. And "overfilling" a lithium cell does not spill harmlessly: overcharging can start a fire.[37]

Lead-acid: bulk, absorption and float

Lead-acid chargers use three stages (Figure 7):[20]​[38]

The three stages of charging a lead-acid battery Two curves against time. Solid line, volts per cell on the left scale from about 1.9 to 2.55: in the bulk stage it rises from about 2.05 volts; in the absorption stage it is held at about 2.40 volts (the range is 2.30 to 2.45 volts per cell); in the float stage it drops to a lower held voltage of about 2.27 volts (2.25 to 2.30). Dashed line, charge current on the right scale: at maximum during bulk, tapering during absorption, and small during float. Illustrative. 2.0 2.1 2.2 2.3 2.4 2.5 0 max volts per cell charge current time Bulk Absorption Float constant current voltage held, current tapers lower voltage held 2.30 to 2.45 V per cell 2.25 to 2.30 V maximum current voltage rises Solid line: voltage (left scale). Dashed line: current (right scale). Illustrative.
Figure 7. The three stages of a lead-acid charge, per cell. Illustrative shapes; voltage levels from Battery University. Multiply by six for a 12 V battery.

NiMH: watching for the voltage dip

As a fast-charged NiMH cell fills, its voltage peaks and dips very slightly. Chargers watch for this negative delta V (−ΔV), 5 mV per cell or less, along with temperature rise and timers, whichever comes first (Figure 8).[39]

NiMH "dislikes overcharge", so a trickle charge left on should be tiny: about 0.05C per Battery University, under 0.025C per Energizer, which prefers very small trickles to limit overcharge harm.[39]​[40] A NiMH in an old NiCd charger would overheat.[39]

Fast-charging a NiMH cell and the negative delta V signal Solid line, volts per cell from 1.2 to 1.6: it rises through the charge, flattens, reaches a peak near full charge and then dips slightly. A vertical dashed line just after the peak marks where the charger stops because it has seen the negative delta V dip. Dashed line, cell temperature on the right: nearly flat for most of the charge, then rising sharply as the cell becomes full. Illustrative; the dip is exaggerated, as the real one is about 5 millivolts per cell or less. 1.2 1.3 1.4 1.5 1.6 volts per cell cell temperature charge time (fast charge) charger stops: −ΔV seen peak, then a slight dip voltage temperature rises sharply near full Illustrative. The dip is drawn far larger than its real size (about 5 mV per cell or less).
Figure 8. Fast-charging a NiMH cell. The voltage peaks and then dips slightly as the cell fills and warms; the charger stops at the dip. Illustrative; the dip is drawn far larger than its real size of a few millivolts.

Temperature while charging

The U.S. Fire Administration says not to charge lithium-ion below 0 °C (32 °F) or above 40 °C (105 °F).[41] Sub-freezing charging is a stress that can lead to cell failure.[42] Panasonic allows 0 to 45 °C for the NCR18650B, with reduced current below 10 °C.[32]

10. Why lithium needs a BMS

Battery University calls protection circuits for lithium-ion packs "mandatory".[43] A battery management system (BMS) is the electronics that watches the cells and disconnects the pack if limits are exceeded or a fault occurs.[44] It guards against (Figure 9):

A simplified battery management system for a four-cell pack Four cells stacked in series on the left. Beside each cell is a balancing branch: a small resistor and a switch across that cell. Thin sense wires run from every junction between cells to a BMS controller block in the middle; a temperature sensor beside the cells also connects to it. The pack positive runs along the top through a fuse to the pack plus terminal. The pack negative runs along the bottom through a current-sense resistor and then two electronic switches in series, a discharge switch and a charge switch, to the pack minus terminal. Dashed control lines run from the controller to both switches and from the sense resistor to the controller. Label: the BMS controller measures each cell, the current and temperature, opens a switch if a limit is crossed, and runs balancing. Block diagram only. + four cells in series balancing resistor and switch, per cell cell voltage sense wires temperature sensor fuse pack + pack − current-sense resistor discharge switch (transistor) charge switch (transistor) BMS controller: measures each cell, current and temperature; opens a switch if a limit is crossed; runs balancing pack + and pack − connect to the charger or load dashed lines: control signals
Figure 9. A simplified BMS for a four-cell series pack. The BMS reads each cell's voltage, the pack current (through a sense resistor) and a temperature sensor. It controls the balancing resistors and two electronic switches that can cut charge or discharge; a fuse backs it up. Block diagram, not a circuit to build.

Home and solar systems. Battery University says LFP is used primarily for energy storage.[46] Stationary batteries were among the first with supervisory systems monitoring each cell.[44] The U.S. Consumer Product Safety Commission (CPSC) recommends that battery packs have "proper Battery Management Systems, including charge control, short-circuit protection and cell balancing", and that cells, packs, chargers and product be tested together as a system.[47] A home battery feeds the house through an inverter that turns DC into AC (recap; solar systems). For any particular system, the maker's and installer's documentation is the authority.

11. Lithium safety

Lithium-ion batteries pack a lot of energy into a small space. The National Fire Protection Association (NFPA) explains that if it is released uncontrollably, the heat can turn parts of the battery into flammable and toxic gases.[37]

Thermal runaway

Thermal runaway is a chain reaction in which heat makes a cell produce more heat. It can begin with a tiny internal short, such as microscopic metal particles gathering in one spot: current heats the spot and damages the separator, letting more current flow. The temperature can quickly reach 500 °C, and the cell catches fire or explodes.[42] A burning cell can heat its neighbors until they fail too; that is why cylindrical cells in packs are often spaced apart.[30] External protection circuits cannot stop a thermal runaway once it has started (Figure 10).[42]

The thermal runaway chain in a lithium-ion cell A flow diagram. A trigger (crush, puncture, overcharge, wrong charger, overheating or a manufacturing defect) leads to an internal short circuit, with current flowing inside the cell, which causes local heating faster than the heat can escape. That leads to the separator and other materials breaking down, which allows more current and more heat; an arrow loops back to show the process feeds itself. The breakdown turns electrolyte into flammable, toxic gases, leading to venting, fire or explosion at up to about 500 degrees Celsius, highlighted. From there an arrow shows neighboring cells heating up and failing too. Trigger: crush, puncture,overcharge, wrong charger,overheating or a defect Internal short circuit:current flows inside the cell Local heating(heat made faster thanit can escape) Separator and materialsbreak down; more current,more heat feeds itself Electrolyte breaks downinto flammable, toxic gases Venting, fire or explosion;up to about 500 °C Neighboring cells heatup and can fail too
Figure 10. The thermal runaway chain. Once heat is produced faster than it can escape, each step feeds the next. Based on Battery University and NFPA.

What causes it

NFPA lists four kinds of cause:[37] physical damage (crushing, puncture, water); electrical abuse (overcharging, or a charger not designed for the battery); extreme temperatures; and manufacturing defects. The Federal Aviation Administration (FAA) adds that thermal runaway "can occur without warning".[48] Very thin separators, used to pack in more energy, make cells more sensitive to impurities.[42] Never use packs modified by unqualified people or rebuilt with used cells.[49]

Warning signs

Stop using a battery if you notice any of these:[37]​[41]​[50]

Never charge, open or repair a damaged battery.[37] Stop using one that swells enough to press on its compartment.[30]

Safe charging and storage

If a battery overheats or catches fire

  1. Stop using or charging it immediately.[50]
  2. If it is safe to do so, move the device away from anything that can catch fire and call 9-1-1.[50]
  3. If there is fire or heavy smoke, get out ("Get out quickly", in the U.S. Fire Administration's words) and call 9-1-1 from outside.[41] The smoke and gases are toxic, and cells can explode.[37]

NFPA notes that firefighters should use water on lithium-ion fires: the lithium is in salts that do not react with water as lithium metal does.[37]

Air travel and shipping

On U.S. flights, the FAA requires:[48]

To find watt-hours, multiply voltage by amp-hours.[48] A power bank marked 3.6 V and 20,000 mAh holds 3.6 × 20 = 72 Wh (calculated), under the limit. Shipping is regulated too: since 2016 lithium batteries cannot travel as cargo on passenger aircraft, and lithium-ion shipped on its own must be at no more than 30% charge.[52]

12. Coin cells and children

A swallowed coin cell is an emergency. These batteries can burn through a child's throat or esophagus in as little as two hours. From 2011 through 2021, the CPSC knew of 27 deaths and an estimated 54,300 emergency-room-treated injuries from swallowed or inserted button and coin batteries.[1] More than 3,500 people of all ages swallow button batteries in the United States every year.[53]

The CR2032 datasheet warns that swallowing one may lead to serious injury or death in as little as two hours, from chemical burns and possible perforation of the esophagus.[13] If you suspect a child has swallowed one:[1]​[53]

Prevention. Since Reese's Law (2022) and the standard UL 4200A-2023, products with coin or button batteries must have battery compartments that need a tool such as a screwdriver or coin, or two independent movements at once, to open, and the batteries must come in child-resistant packaging.[1] At home, the CPSC advises keeping products with unsecured compartments away from children, checking toys' compartments, and never letting children handle coin batteries.[1]

13. Testing a battery

Open-circuit voltage is a rough guide only. Measuring a battery with nothing connected, its open-circuit voltage (OCV), "can be misleading" as a guide to remaining life. A better test measures the voltage while the battery drives a load for one or two seconds, the closed-circuit voltage.[7] A worn battery can read nearly full yet collapse under load (recap), and flat-curve chemistries barely change voltage until nearly empty.

Internal resistance. Measure the open-circuit voltage, apply a known load briefly, measure again, and divide the drop by the current, the DC load method.[54] For example, if a cell reads 1.55 V open and 1.45 V while supplying 0.5 A, its internal resistance is 0.10 V ÷ 0.5 A = 0.2 Ω (calculated, example values). A fresh Energizer AA alkaline has 150 to 300 mΩ,[26] and resistance rises as a battery ages or runs down.

Capacity. The most dependable test is still charge, discharge, recharge.[55] Discharge at a known constant current to the cutoff and multiply current by hours, as in Energizer's 100 mA × 25 h = 2,500 mAh.[7]

14. Disposal and recycling

The U.S. Environmental Protection Agency (EPA) says:[22]

Batteries in the trash can start fires in collection trucks, landfills and recycling plants.[56]​[37] Many stores that sell batteries take them back,[37] and The Battery Network (formerly Call2Recycle) has a drop-off locator.[57] For a damaged lithium battery, ask the maker, the fire department or the local waste authority.[22]​[37]

The whole story in brief

Coming up in this section: 14 LEDs and Optoelectronics.

Sources

All links were checked in October 2026. External links open in a new tab.

  1. U.S. Consumer Product Safety Commission, "Making Families Safer from Button Cell or Coin Battery Dangers: Reese's Law Leads to New Federal Mandatory Safety Standard" (2023): https://www.cpsc.gov/Newsroom/News-Releases/2023/Making-Families-Safer-from-Button-Cell-or-Coin-Battery-Dangers-Reeses-Law-Leads-to-New-Federal-Mandatory-Safety-Standard
  2. Tony R. Kuphaldt, Lessons In Electric Circuits, Volume I (DC), chapter 11, "Batteries and Power Systems": https://www.ibiblio.org/kuphaldt/electricCircuits/DC/DC_11.html
  3. OpenStax, Chemistry 2e, section 17.5, "Batteries and Fuel Cells": https://openstax.org/books/chemistry-2e/pages/17-5-batteries-and-fuel-cells
  4. Battery University, "BU-106: Advantages of Primary Batteries": https://batteryuniversity.com/article/bu-106-advantages-of-primary-batteries
  5. OpenStax, Chemistry 2e, section 17.2, "Galvanic Cells": https://openstax.org/books/chemistry-2e/pages/17-2-galvanic-cells
  6. Battery University, "BU-204: How do Lithium Batteries Work?": https://batteryuniversity.com/article/bu-204-how-do-lithium-batteries-work
  7. Energizer, Alkaline Manganese Dioxide Handbook and Application Manual (PDF): https://data.energizer.com/pdfs/alkaline_appman.pdf
  8. Battery University, "BU-802b: What does Elevated Self-discharge Do?": https://batteryuniversity.com/article/bu-802b-what-does-elevated-self-discharge-do
  9. OpenStax, Chemistry 2e, section 17.3, "Electrode and Cell Potentials": https://openstax.org/books/chemistry-2e/pages/17-3-electrode-and-cell-potentials
  10. OpenStax, Chemistry 2e, Appendix L, "Standard Electrode (Half-Cell) Potentials": https://openstax.org/books/chemistry-2e/pages/l-standard-electrode-half-cell-potentials
  11. Energizer, Eveready Carbon Zinc Battery Handbook and Application Manual (PDF): https://data.energizer.com/pdfs/carbonzinc_appman.pdf
  12. Energizer, Eveready 1215 AA Super Heavy Duty (zinc-carbon) product datasheet (PDF): https://data.energizer.com/pdfs/1215.pdf
  13. Energizer, CR2032 lithium coin product datasheet (PDF): https://data.energizer.com/pdfs/cr2032.pdf
  14. Microbattery.com, "ANSI and IEC battery standardization nomenclature": https://www.microbattery.com/battery-standardization-nomenclature
  15. Energizer, Cylindrical Primary Lithium Handbook and Application Manual (Li/FeS2) (PDF): https://data.energizer.com/pdfs/lithiuml91l92_appman.pdf
  16. Energizer, L91 AA Ultimate Lithium product datasheet (PDF): https://data.energizer.com/pdfs/l91.pdf
  17. Energizer, Silver Oxide (Zn/Ag2O) Application Manual (PDF): https://data.energizer.com/pdfs/silveroxide_appman.pdf
  18. Energizer, 357/303 silver oxide product datasheet (PDF): https://data.energizer.com/pdfs/357-303.pdf
  19. Battery University, "BU-214: Summary Table of Lead-based Batteries": https://batteryuniversity.com/article/bu-214-summary-table-of-lead-based-batteries
  20. Battery University, "BU-403: Charging Lead Acid": https://batteryuniversity.com/article/bu-403-charging-lead-acid
  21. Battery University, "BU-215: Summary Table of Nickel-based Batteries": https://batteryuniversity.com/article/bu-215-summary-table-of-nickel-based-batteries
  22. U.S. Environmental Protection Agency, "Used Household Batteries": https://www.epa.gov/recycle/used-household-batteries
  23. Energizer, NH15-2300 AA NiMH product datasheet (PDF): https://data.energizer.com/pdfs/nh15-2300.pdf
  24. Battery University, "BU-216: Summary Table of Lithium-based Batteries": https://batteryuniversity.com/article/bu-216-summary-table-of-lithium-based-batteries
  25. Battery University, "BU-206: Lithium-polymer: Substance or Hype?": https://batteryuniversity.com/article/bu-206-lithium-polymer-substance-or-hype
  26. Energizer, E91 AA alkaline product datasheet (PDF): https://data.energizer.com/pdfs/e91.pdf
  27. Battery University, "BU-106a: Choices of Primary Batteries": https://batteryuniversity.com/article/bu-106a-choices-of-primary-batteries
  28. Energizer, E92 AAA alkaline product datasheet (PDF): https://data.energizer.com/pdfs/e92.pdf
  29. Energizer, 522 9V alkaline product datasheet (PDF): https://data.energizer.com/pdfs/522.pdf
  30. Battery University, "BU-301a: Types of Battery Cells": https://batteryuniversity.com/article/bu-301a-types-of-battery-cells
  31. Molicel, INR-21700-P42A product data sheet (PDF): https://www.molicel.com/wp-content/uploads/INR21700P42A-V4-80092.pdf
  32. Panasonic (Sanyo), NCR18650B lithium-ion cell datasheet (PDF, hosted by BatterySpace): https://www.batteryspace.com/prod-specs/NCR18650B.pdf
  33. Battery University, "BU-402: What Is C-rate?": https://batteryuniversity.com/article/bu-402-what-is-c-rate
  34. Victron Energy, SmartShunt manual, "Battery capacity and Peukert exponent": https://www.victronenergy.com/media/pg/SmartShunt/en/battery-capacity-and-peukert-exponent.html
  35. Battery University, "BU-409: Charging Lithium-ion": https://batteryuniversity.com/article/bu-409-charging-lithium-ion
  36. Battery University, "BU-409b: Charging Lithium Iron Phosphate": https://batteryuniversity.com/article/bu-409b-charging-lithium-iron-phosphate
  37. National Fire Protection Association (NFPA), "Lithium-Ion Battery Safety": https://www.nfpa.org/education-and-research/home-fire-safety/lithium-ion-batteries
  38. Victron Energy, Smart IP43 Charger manual, "Operation" (charge algorithm): https://www.victronenergy.com/media/pg/Smart_IP43_Charger_120-240V/en/operation.html
  39. Battery University, "BU-408: Charging Nickel-metal-hydride": https://batteryuniversity.com/article/bu-408-charging-nickel-metal-hydride
  40. Energizer, Nickel Metal Hydride (NiMH) Handbook and Application Manual (PDF): https://data.energizer.com/pdfs/nickelmetalhydride_appman.pdf
  41. U.S. Fire Administration (FEMA), "Battery Fire Safety": https://www.usfa.fema.gov/prevention/home-fires/prevent-fires/batteries/
  42. Battery University, "BU-304a: Safety Concerns with Li-ion": https://batteryuniversity.com/article/bu-304a-safety-concerns-with-li-ion
  43. Battery University, "BU-304: Why are Protection Circuits Needed?": https://batteryuniversity.com/article/bu-304-why-are-protection-circuits-needed
  44. Battery University, "BU-908: Battery Management System (BMS)": https://batteryuniversity.com/article/bu-908-battery-management-system-bms
  45. Battery University, "BU-803a: Cell Matching and Balancing": https://batteryuniversity.com/article/bu-803a-cell-matching-and-balancing
  46. Battery University, "BU-205: Types of Lithium-ion": https://batteryuniversity.com/article/bu-205-types-of-lithium-ion
  47. U.S. Consumer Product Safety Commission, "Batteries" (voluntary standards topic page): https://www.cpsc.gov/Regulations-Laws--Standards/Voluntary-Standards/Topics/Batteries
  48. Federal Aviation Administration, "PackSafe: Lithium Batteries": https://www.faa.gov/hazmat/packsafe/lithium-batteries
  49. U.S. Consumer Product Safety Commission, "Micromobility: E-Bikes, E-Scooters and Hoverboards": https://www.cpsc.gov/Safety-Education/Safety-Education-Centers/Micromobility-Information-Center
  50. FDNY Smart, "Lithium-Ion Batteries" safety sheet (PDF): https://www.fdnysmart.org/wp-content/uploads/2025/05/2024-09-20_FDNY-Lithium-Ion-batteries-6-8-objective-1.pdf
  51. U.S. Fire Administration, "Lithium-Ion Battery Safety for Electronic Devices" handout (PDF): https://www.usfa.fema.gov/downloads/pdf/publications/lithium-ion-battery-safety-handout.pdf
  52. Battery University, "BU-704a: Shipping Lithium-based Batteries by Air": https://batteryuniversity.com/article/bu-704a-shipping-lithium-based-batteries-by-air
  53. National Capital Poison Center (Poison Control), "Swallowed a button battery? Battery in the nose or ear?": https://www.poison.org/battery
  54. Battery University, "BU-902: How to Measure Internal Resistance": https://batteryuniversity.com/article/bu-902-how-to-measure-internal-resistance
  55. Battery University, "BU-904: How to Measure Capacity": https://batteryuniversity.com/article/bu-904-how-to-measure-capacity
  56. U.S. Environmental Protection Agency, "Lithium-Ion Battery Recycling": https://www.epa.gov/hw/lithium-ion-battery-recycling
  57. The Battery Network (formerly Call2Recycle), home page with drop-off locator: https://batterynetwork.org/