Alkaline batteries leakage problem.

[BeBuLamar]

In my experience alkaline batteries leak more often now than say 30 years ago. Do you agree? I think there is something that all battery manufacturer changed that cause the batteries more likely to leak. I wonder what? I read that they stopped using mercury in alkaline batteries in 1996 but I saw the problem is only about 5 years. I really do not think the problem is that they go cheap because this problem has hurt their reputaion much more than any money they can save.
I wonder what is the reason?

[Bud]

No it is not the last 5 years problem.

[Gyro]

A forum search reveals 184 thread hits for 'alkaline leak', not including the 15 for 'DuraHell'. Yes, it's an extensively discussed problem. 

[BeBuLamar]

I look here and on the web there is nothing about newer batteries tend to leak more than batteries made many years ago but that is what I observed. Before if I have a leaked battery that's because I either left the battery in a device for years or the device left turned on and drained the battery badly. In recent years I notice barely used, unused batteries leak. So I though manufacturers changed their batteries somehow. But I don't think whatever they changed was just to save money because as you see the many complaint about leakage would hurt them more than whatever saving they get. It seems to me they changed the way batteries are made due to some kind of regulations or something.

[Stray Electron]

  You didn't mention any brand names but Dura-hell batteries aren't called that without reason. There are probably hundreds of post on this forum complaining of those leaking!  That has been leaking for as long as I've been using them (a VERY long time!).   I can't stand the stupid rabbit commercials and I refuse to use brand E.  But I've had very good luck with Rayovacs not leaking. But any more I buy the cheap Chinese batteries and just replace them frequently. Also unless I use something everyday, I take the batteries out and store them separately.

  I don't think that mercury has anything to do with leaking. They haven't used mercury in batteries in the US since the 1970s but batteries leaked long before that and are still leaking today.  Mercury was mostly used in specialized batteries that required a fairly constant voltage over their life cycle.

[Stray Electron]

I look here and on the web there is nothing about newer batteries tend to leak more than batteries made many years ago but that is what I observed. Before if I have a leaked battery that's because I either left the battery in a device for years or the device left turned on and drained the battery badly. In recent years I notice barely used, unused batteries leak. So I though manufacturers changed their batteries somehow. But I don't think whatever they changed was just to save money because as you see the many complaint about leakage would hurt them more than whatever saving they get. It seems to me they changed the way batteries are made due to some kind of regulations or something.

   If you really are seeing more of this problem in the past five years, it's probably because the brand battery that you're using has started using thinner materials (and probably moved their production to China or Mexico).  Also in the last few years, counterfeit copies of name brand batteries have started to appear in many places.

[108CAM]

All those warnings and cautions you get with a battery operated device are there to prevent this very situation from happening.
I periodically check my battery operated items (eg. remotes, toys, torches) for any leakage and replace the batteries when needed.

[IanB]

I think there is something that all battery manufacturer changed that cause the batteries more likely to leak. I wonder what?

I look here and on the web there is nothing about newer batteries tend to leak more than batteries made many years ago but that is what I observed.

I have given a possible/probable explanation for this in most threads on this subject I have posted in.

Basically, a battery is a device to convert chemical energy into electrical energy. Batteries have to perform a miracle, in that the chemical reactions are only supposed to start working when you connect a load to their terminals. If there is no load connected, they are somehow supposed to "turn off" the chemical reaction and become dormant. But this is really difficult. Chemistry wants to happen, and it wants to happen even if you have not connected wires to the battery.

So here's the problem. There is a marketing drive to have "high power", "high performance" batteries, and to do this requires putting much more vigorous and reactive chemicals inside the battery. These much more active chemicals try even harder to react when the battery is on the shelf, making high power batteries more prone to leaking than lower power batteries.

The leaking occurs because the chemical reactions produce gas, which eventually cannot be absorbed and pressurizes the cell, squeezing the insides out through the seals. Alkaline batteries are technically "sealed", but given enough pressure every seal will fail.

The takeaway from this, is that to reduce the risk of leaking you should buy "clock batteries", which are low power batteries designed for long use and long shelf life. These batteries are often much less expensive than the high power varieties, and could often be found in dollar stores. (But less so now than in the past.)

[David Hess]

In my experience alkaline batteries leak more often now than say 30 years ago. Do you agree? I think there is something that all battery manufacturer changed that cause the batteries more likely to leak. I wonder what? I read that they stopped using mercury in alkaline batteries in 1996 but I saw the problem is only about 5 years.

The removal of mercury in newer cells seems to coincide with the time period where leaking became a lot more likely.  If there is a better explanation, I have not heard it yet.

[Doctorandus_P]

I have not had problems with leaking batteries. As I understand the problem mostly manifests itself some years after the batteries are already empty.

Also, a possible way to mitigate problems is to wrap the batteries in some absorbent paper. This will not prevent them from leaking, but it is likely to soak up the electrolyte and keep the damage more localized when it happens.

[BillyO]

As I understand the problem mostly manifests itself some years after the batteries are already empty.

This is not the only case.  They can start to leak even when they are producing a sufficient amount of power to keep the device working.  This is what makes them so insidious.  Unless you open you devices every few days, you can still have a $500 DMM destroyed by these.

My approach has been to replace batteries long before I absolutely need to.   It's expensive, so I now resort to using 1.5V litiums in devices that need AA or AAA cells.  It's actually working out about the same cost, but at least I have peace of mind.

Here is an example of where things can get you unexpectedly.  A few years ago I lost a very good (read expensive) LED flashlight.  One day it was working fine, next day it was irreparably dead.  It was probably leaking for quite some time, but the boost converter in the LED driver was making up for the the reduced voltage of the cells.  Kudos to them for making a unit that got the most out of my batteries.    To make matters worse, the batteries had swollen to the point they could not be removed.  Even if I could have replaced an eaten connection of some sort, this thing was just done.  Thanks DuraHell.

[IanB]

I have not had problems with leaking batteries. As I understand the problem mostly manifests itself some years after the batteries are already empty.

No, not at all. There are plenty of instances of batteries leaking while new in their packaging.

Leaking of alkaline batteries is mainly a matter of how many years have passed since manufacture. If used or discarded within a year of purchase you will probably not see a leak.

[BeBuLamar]

I have not had problems with leaking batteries. As I understand the problem mostly manifests itself some years after the batteries are already empty.

No, not at all. There are plenty of instances of batteries leaking while new in their packaging.

Leaking of alkaline batteries is mainly a matter of how many years have passed since manufacture. If used or discarded within a year of purchase you will probably not see a leak.

I have batteries leaked in their packaging purchased less than a year.

[BeBuLamar]

As I understand the problem mostly manifests itself some years after the batteries are already empty.

This is not the only case.  They can start to leak even when they are producing a sufficient amount of power to keep the device working.  This is what makes them so insidious.  Unless you open you devices every few days, you can still have a $500 DMM destroyed by these.

My approach has been to replace batteries long before I absolutely need to.   It's expensive, so I now resort to using 1.5V litiums in devices that need AA or AAA cells.  It's actually working out about the same cost, but at least I have peace of mind.

Here is an example of where things can get you unexpectedly.  A few years ago I lost a very good (read expensive) LED flashlight.  One day it was working fine, next day it was irreparably dead.  It was probably leaking for quite some time, but the boost converter in the LED driver was making up for the the reduced voltage of the cells.  Kudos to them for making a unit that got the most out of my batteries.    To make matters worse, the batteries had swollen to the point they could not be removed.  Even if I could have replaced an eaten connection of some sort, this thing was just done.  Thanks DuraHell.

I replaced my batteries very early and I still have the leakage problem. I also have leaked battery that stuck inside my flashlight. I can't pull it out even when I drill, tap a threaded hole and screw in a hook. But Rayovac paid for my flashlight which was $50.

[BillyO]

I replaced my batteries very early and I still have the leakage problem.

I don't doubt that.

I also have leaked battery that stuck inside my flashlight. I can't pull it out even when I drill, tap a threaded hole and screw in a hook. But Rayovac paid for my flashlight which was $50.

Amazing!  I'll try for that teh next time it happens.