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  • Writer's pictureSemco Infratech

Ensuring Battery Performance Through Advanced Air Tightness Testing

Ensuring Battery Performance Through Advanced Air Tightness Testing

In the high-stakes world of energy storage, a tiny leak can have disastrous consequences. That's why ensuring the utmost air tightness of your batteries is crucial for peak performance, extended lifespan, and most importantly, safety. 

This article delves into the secrets of battery air tightness, exploring various testing methods and unveiling the impact they have on your energy storage system's overall health and reliability. 

Get ready to discover how proper sealing can unlock the full potential of your batteries and keep your energy flowing smoothly.

Consequences of leakage of battery pack

  1. The cracking of the sealing glue of the upper cover and the bottom groove causes poor sealing, which is easy to cause external liquid to penetrate and pollute the working environment of the battery.

  2. The leakage of the safety valve due to the sealing problem may cause damage to other parts.

  3. Inadecised sealing leads to acid leakage at the terminal, which affects the battery and vehicle wires and causes the circuit to burn out.

  4. If it is not sealed, it will lead to the loss of power capacity and the decline of battery life and safety.


Consequences of leakage of battery pack

The part to be tested


The combination of the upper and lower boxes, high-voltage electrical connectors, water-cooled pipes, and heat dissipation ports (waterproof and breathable holes).


Difficulties in detection


A. The battery pack has a large area, and small internal space, and the shell itself is thin and can withstand less pressure.

B. The battery pack is equipped with a high-voltage connector port and a heat dissipation port. How to effectively block it when detecting it?


Battery pack detection requirements


For the airtight performance of the battery pack. There are two indicators that can evaluate the air tightness of the battery pack, namely: pressure drop value and leakage rate. The pressure drop value is the change value of the internal pressure of the battery pack from the beginning of the test to the end of the test. The leakage rate is the rate of leakage.


According to the internal pressure of the battery pack and the size of the external atmospheric pressure during detection, it is divided into positive pressure tests and negative pressure tests.


Difficulties in Detection

The air tightness test mainly uses dry compressed air as the medium to inflate (or negative pressure) the measured object and determine whether the inflatable body is leaking.


The leaking gas cannot be measured directly but starts from the effect of the leakage of the gas. That is to say when the measured object and the compressed air source are cut off, if the gas leaks, the internal pressure of the measured object will inevitably change. What we need to measure is this pressure change. By calculating the internal pressure change of the object to complete the air tightness test OK or NG judgment of the tested product on the production line.


We conclude that energy storage batteries require stringent air tightness due to potential safety hazards and performance degradation caused by leaks. Two main areas are tested for air tightness: the battery pack itself and the liquid-cooled pipes (if applicable). The testing process involves inflating (positive pressure) or deflating (negative pressure) the battery pack with compressed air and measuring the pressure change over time. If the pressure drops significantly, it indicates a leak.


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