INFICON stresses enhanced EV battery safety

Leak detection systems provider INFICON has highlighted the urgent need for comprehensive testing of all EV battery cells, modules and packs.

North American EV battery manufacturers currently do not test 100% of individual cells assembled into battery packs for electrolyte leakage, leading to missed defects and possible battery fires, higher warranty costs and potential reputational damage.

The introduction of SAE testing standard J3277 establishes a method for ensuring battery pack integrity, including methods for water ingress and coolant ingress testing. This testing ensures that battery packs are leak-free at the time of inspection, but it does not guarantee the long-term safety of individual cells or modules within the pack.

“Every battery cell, prior to assembly into a module and again after module fabrication, should be leak tested,” said Thomas Parker, automotive market sales manager at INFICON. “Cells and modules require testing at multiple stages. Once a battery pack is completed, internal battery cooling circuits also become part of the leakage requirements. Leaking cooling circuits may rapidly degrade battery performance and safety.”

“There is a critical need for more thorough testing of individual cells before they are assembled into packs,” Parker added. “Each metal-ion cell now preferred for EV propulsion must be leak-free to prevent liquid or atmospheric moisture from causing dangerous degradation over time.”

“The lifetime of a battery strongly depends on the tightness of the cell housing, because of the harmful effects caused by the interaction between the electrolyte and water vapor,” Parker said. “Rapid detection of leaks in the production of battery cells is absolutely essential to achieving necessary service life and safety requirements.”

Source: INFICON