Alkaline Battery - Leaks

Leaks

Alkaline batteries are prone to leaking potassium hydroxide, a caustic agent that can cause respiratory, eye and skin irritation. This can be reduced by not attempting to recharge disposable alkaline cells, not mixing different battery types in the same device, replacing all of the batteries at the same time, storing in a dry place, and removing batteries for storage of devices.

All batteries gradually self-discharge (whether installed in a device or not) and dead batteries will eventually leak. Extremely high temperatures can also cause batteries to rupture and leak (such as in a car during summer).

The reason for leaks is that as batteries discharge — either through usage or gradual self-discharge — the chemistry of the cells changes and some hydrogen gas is generated. This out-gassing increases pressure in the battery. Eventually, the excess pressure either ruptures the insulating seals at the end of the battery, or the outer metal canister, or both. In addition, as the battery ages, its steel outer canister may gradually corrode or rust, which can further contribute to containment failure.

Once a leak has formed due to corrosion of the outer steel shell, potassium hydroxide absorbs carbon dioxide from the air to form a feathery crystalline structure of potassium carbonate that grows and spreads out from the battery over time, following along metal electrodes to circuit boards where it commences oxidation of copper tracks and other components, leading to permanent circuitry damage.

The leaking crystalline growths can also emerge from seams around battery covers to form a furry coating outside the device, that corrodes any objects in contact with the leaking device.