Volta battery production process

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INTRODUCTION

Volta Batteries is a world leader in battery manufacturing, with numerous factories and units around the world. They have all types of Motorcycle Batteries ranging from 04 Amp to 10 Amp & Automotive Batteries ranging from 32 Amp to 240 Amp. They take pride in being the only local manufacturer for all types of Maintenance Free Batteries, ranging from 32 Amp to 200 Amp. They are the only local manufacturer of Tubular Batteries ranging from 12 volts 80 Amp to 160 Amp, specialized battery for Solar Panels and Stand By Power.

We have state of the art manufacturing unit to produce quality products with more than 1000 employees. Our head office is in Islamabad and is supported by 7 regional offices across the country, enabling us to cater to the needs of our valued customer s effectively.

PRODUCT LINE

1. Dry Charge Batteries

2. Motorcycle batteries

3. VRLA Batteries

4. Tubular Batteries

RAW MATERIAL

In an alkaline battery, the cylinder that contains the cells is made of nickel-plated steel. It is lined with a separator that divides the cathode from the anode and is made of either layered paper or a porous synthetic material. The canister is sealed at one end with an asphalt or epoxy sealant that underlies a steel plate, and at the other with a brass nail driven through the cylinder. This nail is welded to a metal end cap and passed through an exterior plastic seal. Inside the cylinder, the cathode consists of a mixture of manganese dioxide, graphite, and a potassium hydroxide solution; the anode comprises zinc powder and a potassium hydroxide electrolyte.

THE MANUFACTURING PROCESS

➢ THE CATHODE

1 In an alkaline battery, the cathode actually doubles as part of the container. Huge loads of the constituent ingredients—manganese dioxide, carbon black (graphite), and an electrolyte (potassium hydroxide in solution)—are

Mixing the constituent ingredients is the first step in battery manufacture. After granulation, the mixture is then pressed or compacted into preforms—hollow cylinders. The principle involved in compaction is simple: a steel punch descends into a cavity and compacts the mixture. As it retracts, a punch from below rises to eject the compacted preform delivered by trucks and mixed in very large batches at the production site. The mixture is then granulated and pressed or compacted into hollow cylinders called preforms. Depending on the size of the battery being made, several preforms may be stacked one on top of another in a battery. Alternatively, the series of preforms can be replaced by an extruded ring of the same material.

The preforms are next inserted into a nickel-plated steel can; the combination of the preforms and the steel can make up the cathode of the battery. In a large operation, the cans are made at the battery factory using standard cutting and forming techniques. An indentation is made near the top of the can, and an asphalt or epoxy sealant is placed above the indentation to protect against leakage.

➢ THE SEPARATOR

A paper separator soaked in the electrolyte solution is then inserted inside the can against the preforms; the separator is made from several pieces of paper laid at crossgrains to each other (like plywood). Looking down at an open can, one would see what looks like a paper cup inserted into the can. The separator keeps the cathode material from coming into contact with the anode material. As an alternative, a manufacturer might use a porous synthetic fiber for the same purpose.

➢ THE ANODE

The anode goes into the battery can next. It is a gel composed primarily of zinc powder, along with other materials including a potassium hydroxide electrolyte. This gel has the consistency of a very thick paste. Rather than a solution, it is chemically a suspension, in which particles do not settle (though an appropriate filter could separate them). The gel does not fill the can to the top so as to allow space for the chemical reactions that will occur once the battery is put into use.

➢ THE SEAL

Though the battery is able to produce electricity at this point, an open cell is not practical and would exhaust its potential rapidly. The battery needs to be sealed with three connected components. The first, a brass "nail" or long spike, is inserted into the middle of the can, through the gel material and serves as a "current collector." The second is a plastic seal and the third a metal end cap. The nail, which extends about two-thirds.

The container of a typical alkaline battery, consisting of preform inserted into a steel can, also doubles as the cathode. The anode in the middle is a gel composed primarily of zinc powder. The separator between the anode and cathode is either paper or synthetic fiber that has been soaked in an electrolyte solution. In the finished battery, a plastic seal, a steel nail, and a metal top and bottom have been added. The nail is welded to the metal bottom and extends about two-thirds of the way into the can, through the anode of the way into the can, is welded to the metal end cap and then passed through the plastic seal.This seal is significantly thinner in some places than in others, so that if too much gas builds up in the can, the seal will rupture rather than the entire battery. Some battery designs make use of a wax-filled hole in the plastic; excess gas pushes through the wax rather than rupturing the battery. The seal assembly meets the indentation made in the can at the beginning of the process and is crimped in place. Theopposite end of the can (the positive end of the battery) is then closed with a steel plate that is either welded in place or glued with an epoxy-type cement.

➢ THE LABEL

Before the battery leaves the factory, a label is added identifying the type of battery, its size, and other information. The label is often paper that is simply glued to the battery. One large manufacturer has its label design printed on plastic shrink wrap: a loose fitting piece of heat-sensitive plastic is wrapped around the battery can and then exposed to a blast of heat that makes the plastic shrink down to fit tightly around the can.

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