Leak testing electric vehicle battery packs is often more challenging than any tests performed at the component or subassembly level, due to the myriad of factors at play. In this blog post, Chuck Hagyard discusses these challenges and how to overcome them for an effective leak test.
What are the challenges of battery pack leak testing?
Below are two of the key challenges you are likely to encounter with battery pack leak testing and strategies to overcome them. Any kind of test that builds pressure (with air) inside the pack can cause the volume to expand like a balloon, which will increase the measured leak rate.
How difficult is a leak test for electric vehicle battery packs?
Leak testing electric vehicle battery packs is often more challenging than any tests performed at the component or subassembly level, due to the myriad of factors at play. In this blog post, Chuck Hagyard discusses these challenges and how to overcome them for an effective leak test.
Is a leaking battery a problem?
A leaking battery is more than just an inconvenience for the vehicle owner. Lithium-ion, the most common form of rechargeable battery for EVs, can burst into flame or even explode. Leak testing these large and structurally complex packs poses unique challenges.
Testing battery packs for leaks is a critical safety step for automakers. Due to material instability, any test that uses air to build pressure inside the pack can cause the volume to expand like a balloon, increasing the measured leak rate.
What happens if an EV battery leaks?
A leaking battery is more than just an inconvenience. The most common type of EV battery, lithium ion, can burst into flame or even explode if there is a leak. All the components of an EV battery are vulnerable to leaks – the cells, the modules, the cooling components and the packs that make up the final assembly.
Can a rechargeable battery explode?
Lithium-ion, the most common form of rechargeable battery for EVs, can burst into flame or even explode. Leak testing these large and structurally complex packs poses unique challenges. While air-leak testing is well established, battery pack testing best practices are still evolving.