Battery packs are the heart of electric vehicles, but what goes into making a safe and reliable one? This article explores the various requirements that battery packs need to meet.

Performance and Consistency:

  • Charging: Battery packs need to charge within a specific time at different temperatures and charge levels (e.g., 0-80% vs. full charge).
  • Internal Resistance: This resistance should stay within limits across varying temperatures and charge levels. It should also have a slow growth rate over time to ensure long battery life.
  • Consistency: Cells within the pack should have similar capacity, voltage, and self-discharge rates. A good Battery Management System (BMS) helps maintain this consistency.

Battery Life:

  • Design Life: Packs are designed to last a certain number of years or kilometers in operation and while parked.
  • Cycle Life: This refers to the number of charge/discharge cycles a battery can handle before its capacity significantly reduces.
  • Calendar Life: Batteries degrade even when not in use. Requirements specify how well they should store at room temperature and high temperatures.

Thermal Management:

  • Cooling System: The battery pack needs a cooling system to maintain optimal temperature during charging and discharging. This includes flow rate, water inlet temperature, and cooling performance targets.
  • Heating and Insulation: Battery packs may also require heating systems for operation in cold climates and insulation for all-weather performance.
Battery Pack


  • Mechanical Safety: The pack needs to be sealed against dust and water (IP ratings), and withstand vibrations, impacts, and crashes. It should also meet relevant safety standards.
  • Electrical Safety: The pack should have features like high-voltage interlock, proper insulation, and protection against short circuits, overcurrent, overcharge, and over-discharge.
  • Thermal Safety: The pack should have measures to detect and prevent thermal runaway, including alarms and protection against external fire and extreme temperatures.

Additional Requirements:

  • Electromagnetic Compatibility (EMC): The pack should not generate excessive electromagnetic interference.
  • Flame Retardancy: Non-metallic materials in the pack need to be flame retardant.
  • Restricted Substances: Certain materials are prohibited or restricted for environmental and safety reasons.

Certification and Components:

  • The pack and its components need to be certified according to relevant national and international standards.
  • Specific requirements exist for high-voltage interlock circuits, wiring harnesses, grounding, insulation, and pre-charging circuits.

By meeting these rigorous requirements, battery pack manufacturers ensure the safety, performance, and longevity of electric vehicle batteries.


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