The major technical changes with respect to the previous edition are: – the order of the Annexes was changed to the order in which they appear in the document and a caption was added to
General
Design
Primary batteries are primarily marketed to consumers and have evolved significantly in recent years Advances in chemistry and construction have enhanced their capacity and rate capability, addressing the increasing demands of modern battery-powered devices.
When designing primary batteries, it is essential to ensure dimensional conformity and stability, along with reliable physical and electrical performance Additionally, the batteries must operate safely under both normal usage and anticipated misuse conditions.
Additional information on equipment design can be found in Annex B.
Battery dimensions
The dimensions for individual types of batteries are given in IEC 60086-2 and IEC 60086-3.
Terminals
Terminals shall be in accordance with Clause 6 of IEC 60086-2:−
Their physical shape shall be designed in such a way that they ensure that the batteries make and maintain good electrical contact at all times
They shall be made of materials that provide good electrical conductivity and resistance to corrosion
Where stated in the battery specification tables or the individual specification sheets in IEC 60086-2, the following applies:
A force of 10 N applied at the center of each contact area of a steel ball with a diameter of 1 mm for 10 seconds will not result in any noticeable deformation that could hinder the proper functioning of the battery.
NOTE See also IEC 60086-3 for exceptions
This terminal is designed for batteries that conform to the dimensions outlined in Figures 1 to 7 of IEC 60086-2, ensuring that the cylindrical side of the battery is insulated from the terminals.
This terminal is designed for batteries that adhere to the dimensions outlined in Figures 8, 9, 10, 14, 15, and 16 of IEC 60086-2, where the cylindrical side of the battery serves as part of the positive terminal.
This contact consists of a threaded rod in combination with either a metal or insulated metal nut
These are essentially flat metal surfaces adapted to make electrical contact by suitable contact mechanisms bearing against them
These contacts comprise flat metal strips or spirally wound wires which are in a form that provides pressure contact
These are made up of a suitable assembly of metal contacts, mounted in an insulated housing or holding device and adapted to receive corresponding pins of a mating plug
These contacts are composed of a combination comprising a stud (non-resilient) for the positive terminal and a socket (resilient) for the negative terminal
They shall be of suitable metal so as to provide efficient electrical connection when joined to the corresponding parts of an external circuit
This terminal features a stud for the positive connection and a socket for the negative connection, constructed from nickel-plated steel or other appropriate materials It is engineered to ensure a reliable physical and electrical connection when paired with compatible components in an electrical circuit.
Wire leads may be single or multi-strand flexible insulated tinned copper The positive terminal wire covering shall be red and the negative black
4.1.3.11 Other spring contacts or clips
Contacts are typically utilized on batteries when the specific components of the external circuit are uncertain They should be made of spring brass or a material with comparable properties.
Classification (electrochemical system)
Primary batteries are classified according to their electrochemical system
Each system, with the exception of the zinc-ammonium chloride, zinc chloride-manganese dioxide system, has been allocated a letter denoting the particular system
The electrochemical systems that have been standardized up to now are given in Table 1
Letter Negative electrode Electrolyte Positive electrode
No letter Zinc (Zn) Ammonium chloride,
Zinc chloride Manganese dioxide (MnO 2 ) 1,5 1,73
B Lithium (Li) Organic electrolyte Carbon monofluoride (CF) x 3,0 3,7
C Lithium (Li) Organic electrolyte Manganese dioxide (MnO 2 ) 3,0 3,7
E Lithium (Li) Non-aqueous inorganic Thionyl chloride (SOCl 2 ) 3,6 3,9
F Lithium (Li) Organic electrolyte Iron disulfide (FeS 2 ) 1,5 1,83
G Lithium (Li) Organic electrolyte Copper (II) oxide (CuO) 1,5 2,3
L Zinc (Zn) Alkali metal hydroxide Manganese dioxide (MnO 2 ) 1,5 1,68
P Zinc (Zn) Alkali metal hydroxide Oxygen (O 2 ) 1,4 1,59
S Zinc (Zn) Alkali metal hydroxide Silver oxide (Ag 2 O) 1,55 1,63
W Lithium (Li) Organic electrolyte Sulphur dioxide (SO 2 ) 3,0 3,05
Y Lithium (Li) Non-aqueous inorganic Sulfuryl chloride (SO 2 Cl 2 ) 3,9 4,1
Z Zinc (Zn) Alkali metal hydroxide Nickel oxyhydroxide (NiOOH) 1,5 1,78 NOTE 1 The value of the nominal voltage is not verifiable; therefore it is only given as a reference
NOTE 2 The maximum open-circuit voltage (3.15) is measured as defined in 5.5 and 6.8.1
NOTE 3 When referring to an electrochemical system, common protocol is to list negative electrode first, followed by positive electrode, i.e lithium-iron disulfide.
Designation
The designation of primary batteries is based on their physical parameters, their electrochemical system as well as modifiers, if needed
A comprehensive explanation of the designation system (nomenclature) can be found in Annex C.
Marking
All batteries, except for small ones, must display specific information, including their designation (either IEC or common), the expiration date or the year and month/week of manufacture (which may be coded), the polarity of the positive (+) terminal, the nominal voltage, the manufacturer's or supplier's name or trademark, and any cautionary advice.
NOTE Examples of the common designations can be found in Annex D of IEC 60086-2:−
4.1.6.2 Marking of small batteries (see Table 2) a) Batteries designated in the IEC as small, mainly category 3 and category 4 batteries have a surface too small to accommodate all markings shown in 4.1.6.1 For these batteries the designation 4.1.6.1a) and the polarity 4.1.6.1c) shall be marked on the battery All other markings shown in 4.1.6.1 may be given on the immediate packing instead of on the battery b) For P-system batteries, 4.1.6.1a) may be on the battery, the sealing tab or the package.4.1.6.1c) may be marked on the sealing tab and/or on the battery 4.1.6.1b), 4.1.6.1d) and 4.1.6.1e) may be given on the immediate packing instead of on the battery c) Caution for ingestion of swallowable batteries shall be given Refer to IEC 60086-4:2014 (7.2 a) and 9.2) and IEC 60086-5:2011 (7.1 l) and 9.2) for details
Marking Batteries with the exception of small batteries
P-system batteries a) Designation, IEC or common A A C b) Expiration of a recommended usage period or year and month or week of manufacture The year and month or week of manufacture may be in code
A B B c) Polarity of the positive (+) terminal A A D d) Nominal voltage A B B e) Name or trade mark of the manufacturer or supplier A B B f) Cautionary advice A B a B a
A: shall be marked on the battery
B: may be marked on the immediate packing instead on the battery
C: may be marked on the battery, the sealing tab or the immediate packing
D: may be marked on the sealing tab and/or on the battery a Caution for ingestion of swallowable batteries shall be given Refer to IEC 60086-4:2014 (7.2a) and 9.2) and IEC 60086-5:2011 (7.1l) and 9.2) for details
4.1.6.3 Marking of batteries regarding method of disposal
Marking of batteries with respect to the method of disposal shall be in accordance with local legal requirements.
Interchangeability: battery voltage
Primary batteries standardized in the IEC 60086 series are classified by their standard discharge voltage (\$U_s\$) The interchangeability of a new battery system by voltage is evaluated using the formula: \$n \times 0.85 U_r \leq m \times U_s \leq n \times 1.15 U_r\$, where \$n\$ represents the number of cells in series based on the reference voltage (\$U_r\$), and \$m\$ denotes the number of cells in series based on the standard discharge voltage (\$U_s\$).
Currently, two voltage ranges that conform to the above formula have been identified They are identified by reference voltage U r , which is the midpoint of the relevant voltage range
Voltage range 1, U r = 1,4 V: Batteries having a standard discharge voltage m × U s equal to or within the range of n × 1,19 V to n × 1,61 V
Voltage range 2, U r = 3,2 V: Batteries having a standard discharge voltage m × U s equal to or within the range of n × 2,72 V to n × 3,68 V
The term standard discharge voltage and related quantities, as well as the methods of their determination, are given in Annex D
2 The standard discharge voltage U s was introduced to comply with the principle of experimental verifiability Neither the nominal voltage nor the maximum off-load voltage complies with this requirement
For single-cell batteries and multi-cell batteries made with cells of the same voltage range, the values of m and n will be the same However, in multi-cell batteries that use cells from a different voltage range than those of a standardized battery, m and n will differ.
Voltage range 1 encompasses all presently standardized batteries with a nominal voltage of 1,5 V, i.e "no-letter" system, systems A, F, G, L, P, S and Z
Voltage range 2 encompasses all presently standardized batteries with a nominal voltage of 3
Batteries operating within voltage range 1 and voltage range 2 exhibit notably different discharge voltages, necessitating their design to be physically non-interchangeable Prior to the standardization of a new electrochemical system, it is essential to establish its standard discharge voltage following the procedure outlined in Annex D to address potential interchangeability issues based on voltage.
Failure to adhere to this requirement may lead to significant safety risks for users, including fire, explosion, leakage, and potential damage to the device Compliance is essential for ensuring both safety and proper operation.
Performance
Discharge performance
Discharge performance of primary batteries is specified in IEC 60086-2.
Dimensional stability
Battery dimensions must consistently adhere to the specified measurements outlined in IEC 60086-2 and IEC 60086-3 throughout discharge testing, following the standard conditions detailed in this specification.
NOTE 1 An increase in battery height of 0,25 mm can occur with button cells of the B, C, G, L, P and S systems, if discharged below end-point voltage
NOTE 2 For certain button cells (coin cells) of the C and B systems, a decrease in battery height may occur as discharge continues.
Leakage
When batteries are stored and discharged under the standard conditions given in this specification, no leakage shall occur.
Open-circuit voltage limits
The maximum open-circuit voltage of batteries shall not exceed the values given in Table 1.
Service output
Discharge durations, initial and delayed, of batteries shall meet the requirements given in IEC 60086-2.
Safety
When designing primary batteries, safety under conditions of intended use and foreseeable mis-use as prescribed in IEC 60086-4 and IEC 60086-5 shall be considered
General
For the preparation of standard methods of measuring performance (SMMP) of consumer goods, refer to Annex E
A capacity of a primary battery may be established by electrical discharge tests as detailed in D.2.3 However, under consumer usage conditions, the capacities realised from electrical discharge test methods can vary
Several key factors significantly influence the optimal realization of capacity, including the current demand from external electrical circuits or devices, the frequency of that demand—whether continuous or intermittent, the minimum voltage required for satisfactory device operation (known as the cut-off voltage), and the operational temperature.
High current demand over extended periods, combined with a high cutoff voltage and low temperature, creates the worst-case scenario that leads to substantial capacity loss.
The capacity of a primary battery, whether derived electrically or chemically, cannot be reliably used to calculate its ultimate performance However, it is crucial to provide users with an understanding of battery life in typical devices It is important to note that designated 'application tests' (as defined in 60086-2) may not fully replicate every device or application due to the diverse electrical requirements in the market Additionally, battery performance can be influenced by various conditions.
The following has therefore been derived from ISO/IEC Guide 36:1982.
Discharge testing
General
The discharge tests in this standard fall into two categories:
In both categories of tests, discharge loads are specified in accordance with 6.4
The test methods of determining the load and test conditions are as given in 5.2.2
Application tests
5.2.2.1 General a) The equivalent resistance is calculated from the average current and average operating voltage of the equipment under load Constant current or constant power loads are also permitted for applications exhibiting these types of power demand patterns b) The functional end-point voltage and the equivalent resistance load, current load, or constant power values are obtained from typical application equipment measurements c) The median class defines the load value and the end-point voltage to be used for the discharge test d) If the data are concentrated in two or more widely separated groups, more than one test may be required
Application tests may be accelerated by discharge load, daily period duty cycle, or both The specified values for load and time intermittency should take the following factors into consideration:
– discharge efficiency of the battery relative to the application
– typical duty cycle use patterns for the application
– total time to conduct the test not to exceed 30 days
Certain fixed resistance tests have been selected for their straightforward design and reliability of the testing equipment, even though constant current or constant wattage tests might better reflect specific applications.
In the future, it may be essential to implement alternative or additional load conditions to accurately reflect the diverse applications in use As technology evolves, the load characteristics of specific equipment categories are expected to change over time.
Accurately determining the functional end-point voltage of equipment can be challenging, as discharge conditions often serve as a compromise to represent a diverse range of equipment with varying characteristics.
Nevertheless, in spite of these limitations, the derived application test is the best approach known for the estimation of battery capability for a particular category of equipment
NOTE In order to minimize the proliferation of application tests, the tests specified target to be those accounting for 80 % of the market by battery designation
5.2.2.2 Application tests with multiple loads
For application test with multiple loads, the load order during a cycle shall start with the heaviest load and move to the lightest load unless otherwise specified.
Service output tests
For service output tests, the value of the load resistor should be selected such that the service output approximates 30 days
If full capacity is not achieved within the specified timeframe, the service output can be extended for the shortest appropriate duration by choosing a discharge load with a higher ohmic value, as outlined in section 6.4.
Conformance check to a specified minimum average duration
To ensure battery compliance with IEC 60086-2 and 60086-3 discharge tests, conduct the following procedure: Test eight batteries and calculate the average service output without excluding any results If the average meets or exceeds the specified figure and no more than one battery falls below 80% of this figure, the batteries conform If the average is below the specified figure or more than one battery is below 80%, retest another sample of eight batteries If the average of this second test meets the criteria, the batteries conform; otherwise, they are deemed non-compliant, and no further testing is allowed Conditional acceptance may be granted after the initial discharge tests.
NOTE Discharge performance of primary batteries is specified in IEC 60086-2.
Calculation method of the specified value of a minimum average duration
This method is described in Annex F.
OCV testing
Open-circuit voltage shall be measured with the voltage measuring equipment specified in 6.8.1.
Battery dimensions
Dimensions shall be measured with the measuring equipment specified in 6.8.2.
Leakage and deformation
Once the service output is established under the given environmental conditions, the discharge process should continue until the closed circuit voltage first falls below 40% of the battery's nominal voltage, ensuring compliance with sections 4.1.3, 4.2.2, and 4.2.3.
NOTE For watch batteries, the visual examination for leakage is carried out in accordance with Clause 8 of IEC 60086-3:2011
Storage and discharge conditions
Storage and discharge testing must be conducted under clearly defined conditions, as outlined in Table 3 Unless stated otherwise, these conditions are referred to as standard discharge conditions.
Table 3 – Conditions for storage before and during discharge testing
Storage conditions Discharge conditions Temperature °C
Initial discharge test 20 ± 2 a 55 ± 20 60 days maximum after date of manufacture 20 ± 2 55 +20 / -40 Delayed discharge test 20 ± 2 a 55 ± 20 12 months 20 ± 2 55 +20 / -40
The storage temperature for batteries should ideally be maintained at 45 ± 2 °C and 55 ± 20 °C for a duration of 13 weeks, with a permissible deviation during short periods not exceeding 20 ± 5 °C High-temperature storage tests are conducted as needed, with performance requirements determined by mutual agreement between the manufacturer and the customer It is important to store batteries unpacked, except for the “P” system, which requires a relative humidity of 55 ± 10%.
Commencement of discharge tests after storage
The period between the completion of storage and the start of a delayed discharge test shall not exceed 14 days
During this period the batteries shall be kept at (20 ± 2) °C and (55 + 20 / -40) % RH (except for P-system batteries where the relative humidity shall be (55 ± 10) % RH)
At least one day in these conditions shall be allowed for normalization before starting a discharge test after storage at high temperature.
Discharge test conditions
General
To test a battery, it must be discharged according to IEC 60086-2 or IEC 60086-3 standards until the load voltage first falls below the specified end-point The service output can be quantified in terms of pulses, duration, capacity, or energy.
Compliance
When IEC 60086-2 or IEC 60086-3 specify service outputs for more than one discharge test, batteries shall meet all of these requirements in order to comply with this specification.
Load resistance
The value of the resistive load (which includes all parts of the external circuit) shall be as specified in the relevant specification sheet and shall be accurate to ± 0,5 %
When formulating new tests, the resistive load shall, whenever possible, be as shown in Table
4 together with their decimal multiples or sub-multiples
Table 4 – Resistive loads for new tests
Time periods
The periods on-discharge and off-discharge shall be as specified in IEC 60086-2
When formulating new tests, whenever possible, one of the following daily periods should be adopted from Table 5
Table 5 – Time periods for new tests
Other cases are specified in IEC 60086-2, if necessary.
Test condition tolerances
Unless otherwise specified, the tolerances given in Table 6 shall apply
Relative humidity +20 / -40 % RH except 'P' system ± 10 % RH Time “accuracy” Discharge time t d Tolerance
Activation of ‘P’-system batteries
A period of at least 10 min shall elapse between activation and the commencement of electrical measurement.
Measuring equipment
Voltage measurement
The measuring equipment must have an accuracy of ≤ 0.25% and a precision of ≤ 50% of the last significant digit's value Additionally, the internal resistance of the measuring instrument should be ≥ 1 MΩ.
Mechanical measurement
The accuracy of the measuring equipment shall be ≤ 0,25 % and the precision shall be ≤ 50 % of the value of the last significant digit
The use of sampling plans or product quality indices should be agreed between the manufacturer and the purchaser
Where no agreement is specified, refer to ISO 2859 and ISO 21747 for sampling and quality compliance assessment advice
A code of practice for battery packaging, shipment, storage, use and disposal can be found in Annex G
Criteria for the standardization of batteries
To be included or retained in the IEC 60086 series, batteries and electrochemical systems must meet specific criteria: they must be mass-produced and available in multiple global markets; they should be manufactured by at least two independent companies that comply with the ISO/IEC Directives regarding patented items; and production must occur in at least two different countries, or the batteries must be sourced by international independent manufacturers and sold under their own labels.
The items of Table A.1 shall be included in any new work proposal to standardize a new individual battery or electrochemical system
Table A.1 – Items necessary to standardize
Conformance statement to items a) to d) above Conformance statement to items a) and b) above Designation and electrochemical system Recommended designation letter
Dimensions (including drawings) Negative electrode
Minimum average duration(s) Nominal voltage
Maximum open circuit voltage Electrolyte
Technical liaison
Companies manufacturing battery-powered equipment should closely collaborate with the battery industry and consider the capabilities of current batteries from the design phase It is advisable to choose battery types that comply with IEC 60086-2 standards Additionally, the equipment must be clearly marked with the IEC designation, grade, and size of the battery to ensure optimal performance.
Battery compartment
General
Ensure that battery compartments are designed for easy insertion and secure retention of batteries The dimensions and design of these compartments and contacts must align with the specified standards to accommodate compliant batteries It is crucial for equipment designers to adhere to the tolerances outlined in these standards, regardless of any national standards or manufacturer specifications that may suggest tighter tolerances.
The design of the negative contact should make allowance for any recess of the battery terminal
Clearly indicate the type of battery to use, the correct polarity alignment and directions for insertion
To prevent reverse battery connections, it is essential to design battery compartments with distinct shapes and dimensions for the positive (+) and negative (–) terminals Ensuring that the positive and negative contacts are visibly different helps avoid confusion during battery insertion.
Battery compartments must be electrically insulated from the circuit to reduce the risk of damage and injury, ensuring that only the battery terminals make contact with the electric circuit It is crucial to select appropriate materials and design contacts that maintain effective electrical connections, even with batteries at the extremes of permitted dimensions Additionally, battery and equipment terminals should be made of compatible materials and exhibit low electrical resistance.
Battery compartments with parallel connections are not recommended since a wrongly placed battery will result in charging conditions
Equipment utilizing air-depolarized batteries from the "A" or "P" systems must ensure sufficient air access For optimal performance, "A" system batteries should be positioned upright during operation In the case of "P" system batteries, as outlined in Figure 9 of IEC 60086-2, the positive contact must be established on the battery's side to avoid obstructing air access.
Despite significant advancements in battery leakage resistance, occasional leaks can still happen To minimize potential damage, it's essential to position the battery compartment in a way that limits exposure to the equipment.
The battery compartment must be clearly marked to indicate the correct orientation for battery installation Incorrectly placing a battery can lead to serious issues such as leakage, explosion, or fire To reduce these risks, battery compartments should be engineered to ensure that a reversed battery does not complete the electrical circuit.
The associated circuitry should not make physical contact with any part of the battery except at the surfaces intended for this purpose
Designers are strongly advised to refer to IEC 60086-4 and IEC 60086-5 for comprehensive safety considerations.
Limiting access by children
Apparatus should be designed to prevent children from removing the battery by one of the following methods:
A tool, such as a screwdriver or coin, is required to open the battery compartment; or
The battery compartment door/cover requires the application of a minimum of two independent and simultaneous movements of the securing mechanism to open by hand
To ensure that screws or similar fasteners remain attached to the door or cover of the battery compartment, they should be designed as captive fasteners This requirement does not extend to side panel doors on larger devices, as these panels are essential for the equipment's operation and are unlikely to be removed or discarded.
Voltage cut-off
In order to prevent leakage resulting from a battery being driven into reverse, the equipment voltage cut-off should not be below the battery manufacturers' recommendation
General
The battery designation system provides a clear and precise identification of a battery's physical dimensions, shape, electrochemical system, nominal voltage, and, when applicable, details such as terminal type, rate capability, and special characteristics.
This annex is divided into two clauses:
– Clause C.2 defines the designation system (nomenclature) in use up to October 1990 – Clause C.3 defines the designation system (nomenclature) in use since October 1990 to accommodate present and future needs.
Designation system in use up to October 1990
General
This clause applies to all batteries which have been standardized up to October 1990 and will remain valid for those batteries after that date.
Cells
Cells are identified by a capital letter and a number, where the letters R, F, and S represent round, flat (layer built), and square cells, respectively Each cell type is associated with a specific set of nominal dimensions, indicated by the following number.
The maximum dimensions of a single-cell battery are specified in Tables C.1, C.2, and C.3, rather than the nominal dimensions of the cell It is important to note that these tables do not include electrochemistries, except for the no letter system, or other modifiers Additional components of the designation system are detailed in sections C.2.3, C.2.4, and C.2.5 These tables focus solely on the core physical designations for single cells or batteries.
NOTE The complete dimensions of these batteries are given in IEC 60086-2 and IEC 60086-3
When this system was implemented, numbers were assigned in a sequential order However, gaps in the sequence can occur due to deletions or the varying numbering methods that were utilized prior to the adoption of the sequential system.
Table C.1 – Physical designation and dimensions of round cells and batteries
Physical designation Nominal cell dimensions Maximum battery dimensions
Physical designation Nominal cell dimensions Maximum battery dimensions
NOTE The complete dimensions of these batteries are given in IEC 60086-2 and IEC 60086-3
Table C.2 – Physical designation and nominal overall dimensions of flat cells
Physical designation Diameter Length Width Thickness
NOTE The complete dimensions of these batteries are given in IEC 60086-2
Table C.3 – Physical designation and dimensions of square cells and batteries
Nominal cell dimensions Maximum battery dimensions
Length Width Height Length Width Height
NOTE The complete dimensions of these batteries are given in IEC 60086-2
In some cases, cell sizes which are not used in IEC 60086-2 have been retained in these tables because of their use in national standards.
Electrochemical system
In the zinc-ammonium chloride and zinc chloride-manganese dioxide systems, the letters R, F, and S are prefixed by an additional letter that indicates the specific electrochemical system, as detailed in Table 1.
Batteries
If a battery contains one cell only, the cell designation is used
If a battery contains more than one cell in series, a numeral denoting the number of cells precedes the cell designation
If cells are connected in parallel, a numeral denoting the number of parallel groups follows the cell designation and is connected to it by a hyphen
If a battery contains more than one section, each section is designated separately, with a slash (/) separating their designation.
Modifiers
To maintain clarity in battery designations, variations of a basic type are distinguished by adding the letters X or Y, which signify different terminal arrangements, and P or S, which denote varying performance characteristics.
Examples
R20 A battery consisting of a single R20-size cell of the zinc-ammonium chloride, zinc chloride-manganese dioxide system
LR20 A battery consisting of a single R20-size cell of the zinc-alkali metal hydroxide- manganese dioxide system
3R12 A battery consisting of three R12-size cells of the zinc-ammonium chloride, zinc chloride-manganese dioxide system, connected in series
4R25X A battery consisting of four R25-size cells of the zinc-ammonium chloride, zinc chloride-manganese dioxide system, connected in series and with spiral spring contacts.
Designation system in use since October 1990
General
This clause applies to all new sizes considered for standardization after October 1990
The designation system for batteries is designed to effectively communicate their characteristics by utilizing a cylindrical envelope's diameter and height This system applies to both round (R) and non-round (P) batteries, ensuring a clear mental representation of each type.
This clause also applies to single-cell batteries and multi-cell batteries with cells in series and/or parallel connection
For example a battery of maximum diameter 11,6 mm and a height of maximum 5,4 mm is designated as R1154 preceded by a code for its electrochemical system, as described in this clause.
Round batteries
C.3.2.1 Round batteries with diameter and height less than 100 mm
The designation for round batteries with a diameter and height less than 100 mm is as shown in Figure C.1
NOTE 1 The number of cells or strings in parallel is not specified
NOTE 2 Modifiers are included to designate for example specific terminal arrangement, load capability and further special characteristics
Figure C.1 – Designation system for round batteries: d 1 < 100 mm; height h 1 < 100 mm C.3.2.1.2 Method for assigning the diameter code
The diameter code is derived from the maximum diameter
The diameter code number is: a) assigned according to Table C.4 in case of a recommended diameter; b) assigned according to Figure C.2 in case of a non-recommended diameter
Code denoting height in 0,01 mm if needed (refer to Figure C.3 and C.3.2.1.3)
Code denoting maximum height in 0,1 mm (refer to C.3.2.1.3)
Code denoting 0,1 mm of maximum diameter (refer to Figure C.2 and C.3.2.1.2)
Code denoting maximum diameter (refer to Table C.4 and C.3.2.1.2)
Number of cells or parallel strings in series
Table C.4 – Diameter code for recommended diameter
Code Recommended maximum diameter Code Recommended maximum diameter
Figure C.2 – Diameter code for non-recommended diameters
C.3.2.1.3 Method for assigning the height code
The height code is the number, denoted by the integer of the maximum height of the battery, expressed in tenths of a millimetre (e.g 3,2 mm maximum height is denoted 32)
The maximum height specifications are defined as follows: a) for flat contact terminals, it includes the overall height with the terminals; b) for all other terminal types, it refers to the maximum overall height without the terminals, measured from shoulder to shoulder.
Decimal part of maximum diameter Code “C”
If the height in hundredths of a millimetre needs to be specified, the hundredth of a millimetre may be denoted by a code according to Figure C.3
NOTE The hundredths of a millimetre code is only used when needed
The LR1154 battery features a round cell or string design, with a maximum diameter of 11.6 mm and a height of 5.4 mm, utilizing a zinc-alkali metal hydroxide-manganese dioxide system.
The EXAMPLE 2 LR27A116 is a battery featuring a round cell or string design, with a maximum diameter of 27 mm and a height of 11.6 mm, utilizing the zinc-alkali metal hydroxide-manganese dioxide system.
The EXAMPLE 3 LR2616J battery features a round cell or string design, with a maximum diameter of 26.2 mm and a height of 1.67 mm This battery utilizes a zinc-alkali metal hydroxide-manganese dioxide system, as detailed in Table C.4 and illustrated in Figure C.3.
Figure C.3 – Height code for denoting the hundredths of a millimetre of height
C.3.2.2 Round batteries with diameter and/or height over or equal to 100 mm
The designation for round batteries with a diameter and/or height ≥ 100 mm is as shown in Figure C.4
Maximum height (tenths of a millimetre)
Decimal part of height mm Code “C”
NOTE 1 The number of cells or strings in parallel is not identified
NOTE 2 Modifiers are included to designate for example specific terminal arrangement, load capability and further special characteristics
Figure C.4 – Designation system for round batteries: d 1 ≥ 100 mm; height h 1 ≥ 100 mm C.3.2.2.2 Method for assigning the diameter code
The diameter code is derived from the maximum diameter
The diameter code number is the integer of the maximum diameter of the battery expressed in millimetres
C.3.2.2.3 Method for assigning the height code
The height code is the number denoting the integer of the maximum height of the battery, expressed in millimetres
The maximum height for flat contact terminals, such as batteries illustrated in IEC 60086-2 (Figures 1, 7, 8, and 9), is defined as the total height including the terminals In contrast, for all other terminal types, the maximum height is measured as the overall height excluding the terminals, specifically from shoulder to shoulder.
The EXAMPLE 5R184/177 is a round battery featuring five parallel cells or strings, utilizing a zinc-ammonium chloride and zinc chloride-manganese dioxide system This battery is designed with a diameter of 184.0 mm and a maximum shoulder-to-shoulder height of 177.0 mm.
Non-round batteries
The designation system for non-round batteries is as follows:
An imaginary cylindrical envelope is drawn, encompassing the surface from which the terminals first emerge from the battery case
Using the maximum dimensions of length (l) and width (w), the diagonal is calculated, which is also the diameter of the imaginary cylinder
Integer of maximum height in millimetres
“/” separating diameter and height code
Integer of maximum diameter in millimetres
Letter denoting electrochemical system (refer to Table 1)
Number of cells or parallel strings in series
For the designation, the integer of the diameter of the cylinder in millimetres and the integer of the maximum height of the battery in millimetres is applied
The maximum height specifications are defined as follows: a) for flat contact terminals, the maximum height includes the overall height with the terminals; b) for all other terminal types, the maximum height is measured as the overall height without including the terminals, specifically from shoulder to shoulder.
NOTE In the event there are two or more terminals emerging from different surfaces, the one with the highest voltage applies
C.3.3.2 Non-round batteries with dimensions < 100 mm
The designation for non-round batteries with dimensions < 100 mm is as shown in Figure C.5
NOTE 1 The number of cells or strings in parallel is not identified
NOTE 2 Modifiers are included to designate for example specific terminal arrangement, load and further special characteristics
NOTE 3 In case the height needs to be discriminated in tenths of a millimetre, the letter code shown in Figure C.7 applies
The EXAMPLE 6LP3146 battery features six cells or strings arranged in parallel, utilizing a zinc-alkali metal hydroxide-manganese dioxide system This battery is designed with a maximum length of 26.5 mm, a maximum width of 17.5 mm, and a maximum height of 46.4 mm The diameter of the surface dimensions (length and width) is determined using specific calculations.
Figure C.5 – Designation system for non-round batteries, dimensions < 100 mm
C.3.3.3 Non-round batteries with dimensions ≥ 100 mm
The designation for non-round batteries with dimensions ≥ 100 mm is as shown in Figure C.6
Integer of the maximum height of the battery expressed in millimetres
Integer of the diameter expressed in millimetres (see NOTE 3) of the cylindrical envelope encompassing the maximum length and width dimensions of the surface from which the terminals first emerge
Code denoting shape (P = non-round)
Letter denoting electrochemical system (refer to Table 1)
Number of cells or parallel strings in series
NOTE 1 The number of cells or strings in parallel is not identified
NOTE 2 Modifiers are included to designate for example specific terminal arrangement, load and further special characteristics
NOTE 3 In case the height needs to be discriminated in tenths of a millimetre, the letter code shown in Figure C.7 applies
The EXAMPLE 6P222/162 is a battery composed of six parallel cells or strings utilizing the zinc-ammonium chloride and zinc chloride-manganese dioxide systems These cells are connected in series, with dimensions not exceeding 192 mm in length and a maximum width specified.
113 mm, and a maximum height of 162 mm
Figure C.6 – Designation system for non-round batteries, dimensions ≥ 100 mm
Integer of the maximum height of the battery expressed in millimetres (see NOTE 3)
Symbol separating the length/width and height codes
Integer of the diameter expressed in millimetres (see NOTE 3) of the cylindrical envelope encompassing the maximum length and width dimensions of the surface from which the terminals first emerge
Code denoting shape (P = non-round)
Number of cells or parallel strings in series
NOTE The tenths of a millimetre code is only used when needed
Figure C.7 – Height code for discrimination per tenth of a millimetre
Ambiguity
In the rare case that multiple batteries share identical diameters and heights within the encompassing cylinder, the additional battery will be labeled with the same designation followed by “–1.”
Maximum height in millimetres (integer)
Decimal part of height mm Code
Table C.5 – Physical designation and dimensions of round cells and batteries based on Clause C.2
Physical designation Maximum battery dimensions
NOTE The complete dimensions of these batteries are given in IEC 60086-2 and IEC 60086-3
Table C.6 – Physical designation and dimensions of non-round batteries based on Clause C.2
NOTE 1 The actual used designation of these batteries is 2R5 and R-P2 since these batteries were already recognized under these numbers before they were standardized
NOTE 2 The complete dimensions of these batteries are given in IEC 60086-2
Standard discharge voltage U s – Definition and method of determination
Definition
The standard discharge voltage \( U_s \) is characteristic of a specific electrochemical system and remains constant regardless of the battery's size or internal design This unique voltage is solely determined by the charge-transfer reaction The definition of the standard discharge voltage \( U_s \) is provided in Equation (D.1).
U s is the standard discharge voltage;
C s is the standard discharge capacity; t s is the standard discharge time;
R s is the standard discharge resistor.
Determination
General considerations: the C/R-plot
The discharge voltage \( U_d \) is determined using a C/R-plot, where \( C \) represents the discharge capacity of a battery and \( R \) denotes the discharge resistance Figure D.1 illustrates a schematic plot of discharge capacity \( C \) against discharge resistor \( R_d \) in a normalized format, specifically plotting \( C(R_d)/C_p \) as a function of \( R_d \) At low values of \( R_d \), the discharge characteristics are observed to be different.
C(R d )-values are obtained and vice versa On the gradual increase of R d , discharge capacity
C(R d ) also increases until finally a plateau is established and C(R d ) becomes constant 5 :
The equation \$C_p = \text{constant}\$ (D.2) indicates that \$\frac{C(R_d)}{C_p} = 1\$, as shown by the horizontal line in Figure D.1 This illustrates that the capacity \$C = f(R_d)\$ is influenced by the cut-off voltage \$U_c\$; a higher \$U_c\$ results in a larger fraction \$\Delta C\$ that cannot be utilized during discharge.
NOTE Under plateau conditions, capacity C is independent of R d
The discharge voltage U d is determined by Equation (D.3) d d d d R t
4 Subscript d differentiates this resistance from R s ; see Equation (D.1)
For extended discharge periods, the capacity (\$C_p\$) of a battery may decline due to internal self-discharge This effect is particularly significant in batteries with a high self-discharge rate, such as those losing 10% or more of their charge each month.
The quotient C d /t d of Equation (D.3) represents the average current i(avg) when discharging the battery through discharge resistor R d for a given cut-off voltage U c = constant This relation may be written as:
For R d = R s (standard discharge resistor) Equation (D.3) changes to the Equation (D.1), and consequently Equation (D.4) changes to:
The determination of i(avg) and t s is accomplished according to the method described in D.2.3 and illustrated by Figure D.2.
Determination of the standard discharge resistor R s
To achieve 100% capacity realization, the optimal discharge resistor \( R_d \) is essential for determining \( U_s \) The discharge process can take a considerable amount of time; however, a good approximation for \( U_s \) can be obtained using Equation (D.6) to minimize this duration.
A capacity realization of 98% is deemed accurate for determining the standard discharge voltage \( U_s \), achieved by discharging the battery through the standard discharge resistor \( R_s \) The factor of 0.98 or higher is not critical, as \( U_s \) remains nearly constant for \( R_s \leq R_d \), making the precise attainment of 98% capacity realization less significant under these conditions.
Determination of the standard discharge capacity C s and standard
For illustration refer to Figure D.2, which represents a schematic discharge curve of a battery Figure D.2 addresses areas A1 below and A2 above the discharge curve Under
The average discharge current, denoted as \$i_{avg}\$, is derived from the condition \$A1 = A2\$ (D.7) However, this condition does not specifically correspond to the mid-point of discharge, as illustrated in Figure D.2 The discharge time, \$t_d\$, is identified at the cross-over point where \$U(R,t) = U_c\$ Additionally, the discharge capacity can be calculated using Equation (D.8).
The standard capacity C s is obtained for R d = R s , changing Equation (D.8) to Equation (D.9)
C s = i(avg) × t s (D.9) a method which permits the experimental determination of the standard discharge capacity C s and the standard discharge time t s , needed for determination of the standard discharge voltage U s (see Equation (D.1))
Figure D.2 – Standard discharge voltage (schematic)
Experimental conditions to be observed and test results
To experimentally determine the C/R-plot, it is advisable to collect 10 individual discharge results, each representing the average of nine batteries, ensuring that the data is evenly distributed across the expected range The initial discharge value should be taken at approximately 0.5 C, as shown in Figure D.1, while the final experimental value should be around \( R_d \approx 2 \times R_s \) The collected data can then be graphically represented in a C/R-plot, following the guidelines in Figure D.1.
Discharge mode : R = constant Cut-off voltage : U c = constant
D is char ge cur rent
U value is to be determined leading to approximately 98 % C p The standard discharge voltage
A system achieving 98% capacity realization should not differ by more than -50 mV from the 100% capacity realization value Any variations within this mV range are attributed solely to the charge-transfer reaction of the system being analyzed.
When determining C s and t s according to D.2.3, the following cut-off voltages are to be employed in accordance with IEC 60086-2:
The experimentally determined standard discharge voltages U s (SDV) shown in Table D.1 are only given to permit the interested expert to check its reproducibility
Table D.1 – Standard discharge voltage by system
The determination of the U s values for systems A, B, G, and P is currently being analyzed Notably, system P presents a unique scenario, as its U s value is influenced by the specific catalyst used for oxygen reduction Additionally, since system P operates as an open system exposed to air, factors such as environmental humidity play a significant role in its performance.
CO 2 after the activation of the system, is of additional influence For system P, U s values of up to 1,37 V may be observed
Preparation of standard methods of measuring performance (SMMP) of consumer goods
NOTE This annex has been derived from ISO/IEC Guide 36:1982, Preparation of standard methods of measuring performance (SMMP) of consumer goods (withdrawn 1998).
General
To provide valuable information to consumers regarding the performance of consumer goods, it is essential to utilize reproducible standard methods for measuring performance These test methods should yield results that clearly correlate with a product's practical use, serving as a reliable foundation for informing consumers about the product's performance characteristics.
As far as possible, specified tests should take into account limitations in test equipment, money and time.
Performance characteristics
The first step in the preparation of a SMMP is to establish as complete a list as possible of the characteristics that are relevant in the sense discussed in Clause E.1
NOTE Once such a list has been drawn up, consideration can be given to selecting those attributes of a product that are most important to consumers making purchase decisions.
Criteria for the development of test methods
Each performance characteristic must have a corresponding test method that accurately reflects consumer experiences with the product It is crucial that these methods are objective, yielding meaningful and reproducible results Additionally, the test methods should be designed for maximum consumer benefit, considering the balance between product value and testing costs In cases where accelerated testing or indirect methods are employed, the technical committee must offer guidance for the proper interpretation of results in the context of normal product use.
Calculation method for the specified value of minimum average duration
To determine the minimum average duration, follow these steps: First, gather a minimum of 10 weeks' worth of randomly selected duration data Next, compute the average duration values from eight samples taken from each population.
To ensure accurate calculations, it is essential to eliminate any values that fall outside of 3 standard deviations (σ) from the population Next, compute the average (x) of the remaining above-average values for each population, along with the corresponding standard deviation (σ x) Additionally, establish the minimum average duration value that each country must provide.
B: x × 0,85 Calculate both A and B; define the larger value of the above two as its minimum average duration
Code of practice for packaging, shipment, storage, use and disposal of primary batteries
General
The greatest satisfaction to the user of primary batteries results from a combination of good practices during manufacture, distribution and use
The purpose of this code is to describe these good practices in general terms It takes the form of advice to battery manufacturers, distributors and users.
Packaging
Proper packaging is essential to prevent mechanical damage during transport, handling, and stacking The selection of materials and pack design must effectively inhibit unintentional electrical conduction, terminal corrosion, and moisture ingress.
Transport and handling
To ensure safety and integrity, it is essential to minimize shock and vibration during transport This includes avoiding practices such as throwing boxes from trucks, slamming them into place, or stacking them excessively high, which can overload the battery containers beneath Additionally, adequate protection from adverse weather conditions must be provided.
Storage and stock rotation
The storage area should be clean, cool, dry, ventilated and weatherproof
For optimal storage, maintain a temperature range of +10 °C to +25 °C, ensuring it does not exceed +30 °C Avoid prolonged exposure to extreme humidity levels, above 95% RH or below 40% RH, as they can harm both batteries and their packaging It is essential to keep batteries away from radiators, boilers, and direct sunlight to preserve their integrity.
Storing batteries at lower temperatures, such as in cold rooms between –10 °C to +10 °C or in deep-freeze conditions below –10 °C, can enhance their storage life, provided that special precautions are observed It is essential to keep the batteries in protective packaging, like sealed plastic bags, to prevent condensation while they acclimate to ambient temperature However, it is important to avoid accelerated warming, as it can be harmful to the batteries.
Batteries which have been cold-stored should be put into use as soon as possible after return to ambient temperature
Batteries may be stored, fitted in equipment or packages if determined suitable by the battery manufacturer
The height to which batteries may be stacked is clearly dependent on the strength of the pack
As a general guide, this height should not exceed 1,5 m for cardboard packs or 3 m for wooden cases
For optimal storage during extended transit, it is crucial to keep batteries away from ship engines and avoid leaving them in unventilated metal containers during the summer months.
Batteries will be quickly dispatched after production, following a first in, first out (FIFO) stock rotation system to distribution centers and end users To facilitate this process, storage areas and displays must be well-designed, and packaging should be clearly labeled.
Displays at sales points
When batteries are unpacked, care should be taken to avoid physical damage and electrical contact For example, they should not be jumbled together
Batteries intended for sale should not be displayed for long periods in windows exposed to direct sunlight
Battery manufacturers must supply detailed information to help retailers choose the appropriate battery for each user's specific application, particularly when providing the initial batteries for newly acquired equipment.
Test meters do not provide reliable comparison of the service to be expected from good batteries of different grades and manufacture They do, however, detect serious failures.
Selection, use and disposal
Purchase
When selecting a battery, it is essential to choose the appropriate size and grade for your specific needs Numerous manufacturers offer multiple grades of batteries within the same size category You can find information regarding the most suitable grade for your application at the point of sale and on the equipment itself.
If the specific size and grade of a battery from a certain brand is unavailable, the IEC designation for the electrochemical system and size allows for an alternative selection This designation must be clearly marked on the battery label, which should also display the voltage, the manufacturer's or supplier's name or trademark, the manufacturing date (which may be coded), the expiration of the guarantee period, and the polarity (+ and -) Some of this information may also be found on the packaging.
Installation
Before inserting batteries into the equipment's battery compartment, ensure that both the contacts of the equipment and the batteries are clean and correctly positioned If needed, clean the contacts with a damp cloth and allow them to dry before proceeding with the insertion.
Correctly inserting batteries according to polarity (+ and -) is crucial for optimal equipment performance Always adhere to the manufacturer's instructions and use the recommended battery types Neglecting these guidelines can lead to equipment malfunctions and potential damage to both the device and the batteries.
Use
It is not good practice to use or leave equipment exposed to extreme conditions, for example radiators, or cars parked in the sun, etc
It is advantageous to remove batteries immediately from equipment which has ceased to function satisfactorily, or when not in use for a long period (e.g cameras, photoflash, etc.)
Be sure to switch off the equipment after use
Store batteries in a cool, dry place and out of direct sunlight.
Replacement
To ensure optimal performance and safety, always replace all batteries in a set simultaneously Avoid mixing new batteries with partially used ones, as well as combining different electrochemical systems, grades, or brands Neglecting these guidelines can lead to some batteries being overused, increasing the risk of leakage.
Disposal
Primary batteries may be disposed of via the communal refuse arrangements, provided no contrary local legal requirements exist Refer to IEC 60086-4 and IEC 60086-5 for further details
IEC 60050-482, International Electrotechnical Vocabulary – Part 482: Primary and secondary cells and batteries
IEC 62281, Safety of primary and secondary lithium cells and batteries during transport
ISO/IEC Guide 36:1982, Preparation of standard methods of measuring performance (SMMP) of consumer goods (withdrawn 1998)
ISO 2859, Sampling Procedures for Inspection by Attributes Package
ISO 21747, Statistical methods – Process performance and capability statistics for measured quality characteristics