IEC 60086-5 specifies safety requirements for primary (non-rechargeable) batteries that use aqueous electrolytes, published by the International Electrotechnical Commission (IEC). While IEC 60086-4 addresses the safety of primary lithium batteries, Part 5 covers the remaining primary battery chemistries — principally zinc-carbon (Leclanché), alkaline manganese dioxide, zinc-air, and silver oxide cells — which use water-based electrolytes and present different safety considerations to lithium systems.
Published by: International Electrotechnical Commission (IEC)
Current edition: IEC 60086-5:2021 (5th edition)
Companion standards: IEC 60086-1 (general requirements), IEC 60086-4 (lithium battery safety)
Scope
IEC 60086-5 applies to all primary batteries with aqueous (water-based) electrolytes intended for portable applications. This includes alkaline manganese (the most common consumer battery chemistry), zinc-carbon, zinc-air (widely used in hearing aids), and silver oxide cells. The standard addresses safety under both intended use and reasonably foreseeable misuse, including conditions that could lead to electrolyte leakage, gas generation, and in extreme cases rupture.
Key Requirements and Testing
The principal hazard with aqueous electrolyte primary batteries is leakage of alkaline or acidic electrolyte, which can damage equipment and cause skin or eye irritation. IEC 60086-5 specifies requirements for cell construction to prevent leakage under normal use and under defined abuse conditions including forced discharge (cell reversal), overcharge, short circuit, and high temperature storage. Tests are designed to verify that cells do not leak, rupture, or vent hazardous gases under these conditions.
The standard also addresses requirements for battery assemblies containing multiple cells, including restrictions on mismatched cells in packs and requirements for preventing cell reversal in multi-cell series strings.
Relevance to Battery Engineering
Although alkaline and zinc-carbon batteries are mature, well-understood technologies, IEC 60086-5 remains relevant for engineers designing battery-powered products that use primary aqueous batteries. Compliance is required for many consumer product markets globally. The standard’s abuse test requirements inform decisions about battery holder design, polarity protection, and PCB protection against leakage damage. For hearing aid and medical device designers, zinc-air battery compliance with IEC 60086-5 is a standard element of regulatory submissions.
References: IEC 60086-5:2021, IEC Webstore
Disclaimer: This is not a definitive guide, just an indication and it is important that you always go back to the source for legislation.
See also: Zinc Air Battery