EV Battery Leak Testing

We help you create & define EV Battery component testing requirements.

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    • Test Techniques (scroll for options)
  • Burst (Pressure)
  • Crack (Upstream/Downstream)
  • Differential Pressure Decay
  • Differential Vacuum Decay
  • Laminar Flow
  • Mass Flow Test
  • Occlusion (Blockage)
  • Pressure Decay
  • Sealed Component
  • Vacuum Decay

    • Lithium-ion Battery Testing Equipment and Systems for Automotive Applications

    Global lithium-ion battery-cell production is expected to increase from 280 GWh today to 2,600 GWh in 2030. This aggressive growth prediction puts added pressure on EV battery manufacturers to produce at higher volumes without sacrificing quality or safety. In addition to high production requirements, manufacturers face the challenge of performing quality testing without industry standard guidelines. The lack of EV battery leak testing standards has left many manufacturers struggling to find viable testing solutions.

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    EV Battery Leak Testing Applications

    Battery Covers & Trays

    These can present challenges with flexing due to thermal and environmental changes. Uson’s experience with how a material’s composition responds to variations in temperature or atmospheric conditions can help you navigate these challenges.

    Cooling Modules & Assemblies

    Larger cooling circuits and the number of connections on electrical vehicles can lead to increased cycle times. Our experts can determine the most effective equipment and test method combination to achieve acceptable cycle times without sacrificing quality or safety.

    Battery Packs

    Large volumes make obtaining repeatable results within cycle time difficult. Luckily, Uson’s state-of-the-art technology coupled with over 50 years of experience provides the most reliable and repeatable results in the industry. 

    Electric Drive Unit

    Electric vehicles consist of an electric motor, power module, and transmission.  Each component has individual testing requirements. Uson has worked with the largest automotive manufacturers, and we have the footprint to support the most sophisticated operations.

    We help EV Battery manufacturers overcome industry challenges

    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 and 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.

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    EV Battery Testing Solutions

    Uson is excited to be at the forefront of this emerging industry and applying over 55 years of experience serving automotive manufacturers around the globe. Our leak testing experts are working with both manufacturers and system integrators to develop testing standards for electronic vehicle battery testing processes to support the industry in delivering the highest level of quality and safety to consumers. Contact our Applications team to discuss your upcoming project.

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    Read more about EV Battery applications on our blog.

    Air vs Helium Leak Testing for EV Battery Applications

    Helium leak testing systems are also commonly used in the automotive manufacturing industry. While helium testing is an effective solution in some applications, using helium requires substantial investments in tooling, gas recovery equipment, and the ongoing expense of buying the gas itself. Through application studies and testing, our experts have been successful in identifying opportunities where air leak testing was an effective leak testing option. 

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    AIR LEAK TESTING VS. HELIUM LEAK TESTING

    Ask Our Experts About EV Battery Leak Testing.

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