If the cathode and anode come in contact with each other, a very active chemical reaction would occur. A barrier must be between the two.
A paper separator soaked with an electrolyte that promotes ionic or electrolytic conductivity is used as this barrier
The anode portion is a gel made up of zinc powder and several other materials. The anode is then inserted into the steel can against the paper separator.
To insure a long shelf life, the battery must be sealed.
The seal is made of a brass nail (which acts as the current collector), a plastic gasket, a steel washer and metal endcap.
The four items are preassembled and inserted into the middle of our steel can up against the indentation (which was formed earlier)
A top plate is welded to the other end of the can to provide the positive polarity safety feature.
The batteries are then stored, given another voltage test and a decorative,insulating outer label is applied.
black (for electrical conductivity and moisture absorption), and zinc chloride electrolyte (which assists the chemical reaction).