INFICON, a provider of leak detection solutions, is underscoring the importance of comprehensive testing for electric vehicle (EV) battery cells, modules, and packs at The Battery Show South, held at the Georgia World Congress Center in Atlanta, April 16-17, 2025. INFICON’s automotive market sales manager, Thomas Parker, highlighted the need for leak testing at multiple stages of the battery assembly process, from individual cells to completed battery packs.
“Each battery cell, before and after being assembled into a module, should undergo leak testing,” Parker said. “Testing is necessary at various stages, and once a battery pack is complete, the internal battery cooling circuits must also be tested for leaks, as leaking cooling circuits could impact battery performance and safety.”
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Currently, North American EV battery manufacturers do not test 100% of individual cells for electrolyte leakage, which could result in undetected defects, increased risks of battery fires, higher warranty costs, and potential reputational damage. “It is essential to conduct more thorough testing of individual cells before they are assembled into packs,” Parker continued. “Each metal-ion cell used in EV propulsion must be leak-free to prevent moisture or liquid degradation over time.”
The SAE testing standard J3277 has been introduced to address battery pack integrity, including methods for testing water and coolant ingress. This testing typically involves pressurizing battery packs with test gas and using robotic inspection with a “sniffer” probe to detect leaks. While this process ensures that battery packs are leak-free at the time of inspection, it does not guarantee the long-term safety of individual cells or modules. Technological advancements now allow for near-molecular level leak testing of individual cells and modules, which can be done at production line speeds.
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Additionally, SAE is working on a new standard, J-3337, focused on electrolyte leakage at the cell level for both Lithium-ion (Li-Ion) and Sodium-ion (Na-Ion) batteries. This standard will use non-destructive testing methods, such as vacuum chambers and spectrophotometers, to detect any volatiles associated with the electrolyte. “The integrity of the cell housing is crucial for battery longevity, as interactions between the electrolyte and water vapor can cause degradation,” Parker noted.
INFICON remains committed to supporting the advancement of EV battery safety and advocating for comprehensive testing standards to enhance the integrity and safety of battery packs, ultimately contributing to the longevity of electric vehicles.