Battery casings enclose the functional parts and chemicals of batteries. Lead-acid battery casings are made from polypropylene copolymers, while smaller batteries use lightweight metal or aluminum enclosures. Battery cases protect the enclosed battery and can be made from various materials.
Battery casings, also called battery compartments, are the shells or walls that enclose the battery’s functional parts and chemicals. Batteries, sometimes called cells, are electricity storage devices and are classified as ‘primary’ if they are disposable and ‘secondary’ if they are rechargeable.
The typical 12 volt DC automotive battery, also known as a lead-acid battery, contains lead, cell plates, straps, acid, and distilled water. All these components are enclosed by the casing in a compact, convenient and, above all, safe device capable of efficiently supplying the high current necessary to start a car.
Most heavy-duty lead-acid battery casings are made from polypropylene copolymers—essentially, plastic with an attitude—that resist the corrosive effects of battery acid. There is currently a trend away from the use of halogen-based flame retardant materials and towards non-halogen-based materials in the production of heavy enclosures. Halogenated material, although flame resistant, has been found to release highly corrosive and toxic gases in the event of a fire.
“A”, “C” or “D” cells, nickel cadmium (NiCd) and lithium ion (l-ion) batteries are at the opposite end of the battery spectrum. Much smaller than lead-acid batteries, these powerful mites usually power things like flashlights, digital cameras, mp3 players, cell phones, and so on. The battery casings for these types of batteries therefore do not have to be particularly durable or resistant to corrosion. The effects of broken casings are, of course, far less catastrophic in the event of a damaged or misused flashlight or other small battery than they would be for a lead-acid battery. Thin, lightweight metal or aluminum enclosures are sufficient to house the minor reactions and considerably less toxic materials consistent with these proportionately less potent cells.
Battery cases are not to be confused with battery cases. A case is designed to contain and protect the battery enclosed in the casing. The case may be the size of a small suitcase to hold a larger lead-acid battery, or it may be the size of a matchbox to hold a couple of tiny hearing aid cells.
Battery cases can be made from a variety of materials including plastic (co-polymer or not), wood, metal, aluminum, even cloth, leather or cardboard. Needless to say, the wraps are a different story. It simply would not be appropriate to produce a casing, or even a casing, in the case of a lead-acid battery, using non-durable materials such as cloth and cardboard.
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