Leak testing helps prevent safety hazards, ensures optimal battery performance, and maintains the integrity of EV battery systems.
Billions of lithium-ion battery cells are manufactured every year for use in electric, hybrid-electric, autonomous vehicles, medical devices, and a variety of consumer electronics products. Most quality issues occur during battery-cell production, battery-module assembly, or battery-pack assembly.
These include:
● Leaks allowing humidity or water into the cell
● Leaks allowing electrolytes out of the cell
● Modules and housing integrity
Historically, pressure and visual test methods have been used for soft-pouch, cylindrical and prismatic cells. However, these methods can be slow, unreliable, and may miss small lithium-ion leaks that, if left undetected, can create big quality and safety problems. Uson by PAC has a variety of leak testers and test methods for reliable, non-destructive testing of battery cells, housing, and assemblies.
View EV Battery Brochure
View EV Battery Brochure
Leak-free battery packs contribute to the long-term reliability of EVs. Even small amounts of humidity or moisture in a battery module can cause the system to short circuit, reduce service life, and degrade performance. Uson’s leak testers deliver the assurance of quality, so bad parts don’t leave the factory.
Larger cooling circuits and the number of connections on electrical vehicles can lead to increased cycle times during manufacturing. Efficient leak testing methods help to identify leaks promptly, without compromising quality or safety. With Uson’s leak testers, manufacturers can achieve acceptable cycle times while maintaining production efficiency.
Battery covers and trays can flex during thermal and environmental changes. Uson, with our vast experience in understanding how a material’s composition responds to variations in temperature or atmospheric conditions, can help you navigate these challenges.
EV cars consist of an electric motor, power module, and transmission, and each has individual testing requirements. Leaks in these systems can reduce heat dissipation, and compromise battery performance and safety. Uson has a proven record of providing leak testing solutions for powertrain applications, and we have the footprint to support the largest and most sophisticated operations.
Reduce the chance of fires, explosions, or chemical reactions that pose danger to drivers, passengers, and the environment.
Capture vast amounts of data for a clear view into how the manufacturing process is performing.
Develop leak rate definitions for EV batter component testing applications.
