Materials That Must NEVER Make Contact
Graphite anode ↔ LiMn₂O₄ cathode
Steel mesh current collectors (touching each other)
Wet electrodes ↔ Metal casing (before proper assembly)
PPE Required
Safety Glasses
Nitrile Gloves
Lab Coat
Closed-Toe Shoes
Step-by-Step Safety Checkpoints
Steps 1–2:
Anode placed correctly (mesh down, graphite up)
Step 3:
Few drops of electrolyte added
Step 4:
Separator completely covers anode (no gaps or folds)
Step 5:
Cathode placed (active material down)
Step 6:
Separator VISIBLE around ALL edges (most important check)
Step 7:
Spring placed (wider side down)
Step 8:
Final electrolyte added
Step 9:
Cathode cap placed
Step 10:
Hands clear of crimping area (before operator depresses handle)
After placing the spacer, look down from above. You should see the white glass fibre separator as a complete ring around the spacer. If you see brown or black electrode material touching the spacer edge, STOP and reassemble.
ACTION: Never proceed to crimping if you cannot clearly see the white separator in a complete circle.
Hazardous Materials
| Chemical | Key Hazards |
|---|---|
| Lithium electrolyte | Flammable liquid, irritant to eyes and skin, contact dermatitis |
| Lithium metal | Reacts vigorously with water, spontaneous ignition risk, store under inert oil |
| LiMn₂O₄ (cathode material) | Dust irritant, may cause respiratory sensitisation if inhaled |
| Graphite (anode material) | Dust irritant, inhalation hazard in powdered form |
| Glass fibre (separator) | Eye and skin irritation, inhalation hazard if abraded or damaged |
Emergency Procedures
🔥 If Battery Gets Hot or Smells Strange
Remove assembly immediately. Place on heat-resistant surface away from people. Do not touch until cool. Notify supervisor. Do not attempt to use or charge.
🌊 If Electrolyte Spills
Notify supervisor immediately. Wipe with absorbent material and dry thoroughly. Clean area with acetone or ethanol. Wash hands with soap and water. Do not allow electrolyte to dry on skin.
👁️ Eye or Skin Contact
Rinse immediately with water for at least 5 minutes. Remove contaminated clothing. For eye contact, rinse with water for 15 minutes. Seek medical attention. Show this safety data sheet to medical personnel.
🤝 Crimping Injury
Stop immediately. Release pressure on crimper handle. Assess injury severity. Apply ice wrapped in cloth if swelling present. Seek first aid or medical attention for laceration or significant bruising.