The importance of environmental testing for battery safety testing

In the context of the rapid development of modern technology, batteries, as an important part of energy storage and supply, are widely used in electric vehicles, renewable energy systems, mobile devices and other fields, with the growing demand for high-performance, lightweight batteries, the need for rigorous testing of batteries to ensure their safety and reliability is also growing.

Potential dangers of battery safety testing

The battery may be damaged during testing, such as being dented or perforated, causing harmful liquids to leak. In addition, exceeding the battery's functional temperature range or overcharging can also cause the battery to overheat, increasing the risk. The European Council for Automotive Research and Development (EUCAR) has further classified these risks in order to provide an important safety standard reference for battery testing.
Each EUCAR danger level corresponds to a number, ranging from 0 to 7, where 0 means the lowest risk and 7 means the highest risk. As the level increases, controlling risk becomes more challenging. Once the required hazard level is determined, the test chamber introduces a series of safety features. Whether testing existing energy storage solutions or evaluating innovative new chemicals and technologies for the future, consulting with a trusted environmental test chamber manufacturer is the first step to ensure your risk level is met and to ensure the safety of people and products at all stages of battery testing.

Environmental test chamber

An indispensable tool for conducting comprehensive battery testing and research, environmental test chambers enable manufacturers to assess the performance and safety of batteries in a real-world environment before they are put on the market by simulating the conditions they may face throughout their lifetime. These test chambers are equipped with the necessary safety features to help mitigate some of the most serious risks involved in battery testing. In a battery test device, you may see the following common safety options

Rupture disk

The bursting disc plays a key role as a pressure release mechanism. It is deliberately designed as a weak point to break under specific pressures, releasing pressure and avoiding damaging Windows or forcing open doors. This mechanism is crucial during battery testing, as the pressure can vary. The bursting discs are installed in the chimney, their size and number depending on the specific design of each test chamber, to ensure that the chimney is connected to the on-site exhaust system. Once the bursting disc breaks, it needs to be replaced. To further ensure that the bursting disc can effectively release violent exhaust gas, the test chamber liner is reinforced to withstand overpressure in excess of the bursting disc rating.

Explosion-proof sheathed heater

Explosion-proof sheathed heaters are used to manage the temperature in the environmental test chamber. They provide controlled heating to ensure a stable temperature in the test environment. Since all electrical connections are made outside the workspace, no sparks are caused.

Gas monitoring

Gas monitoring uses sensors to detect and quantify the concentration of potentially dangerous gases released during battery testing. This safety feature helps maintain a safe test environment by providing timely warnings and taking necessary interventions when gas levels exceed safety thresholds.

Rain sprinkler system

Rain shower system is a fire extinguishing device that can be activated in the case of fire emergency. These systems employ additives such as blowing agents or gelling agents to help extinguish fires when they occur.

Sprinkler system

The sprinkler system is equipped with a nozzle to spray cooling water onto each battery. This safety feature is becoming more and more widely used as it helps prevent thermal runaway phenomena and extinguish fires.

Fresh air purification

This safety feature involves the constant introduction of fresh air into the test space to reduce the concentration of dangerous gases or fumes, ensuring that the working space remains below the lower explosive limit. The heating and cooling system must be appropriately sized, as this option may introduce additional air flow and fresh air needs to be adjusted according to the test process.

Fire detection by gas monitoring

Combined with fire detection and gas monitoring, potential fire risks can be detected early. This function triggers an alarm or activates a fire suppression system when rising gas levels could indicate a fire risk.
As battery technology continues to evolve and new applications emerge, test methods and safety standards also need to continue to improve. By integrating comprehensive safety features into the environmental test chamber, manufacturers can stay ahead of the curve and ensure compliance with regulatory requirements. Whether it's a gas monitoring or fire detection system, each safety component plays a vital role in protecting people and preventing potential hazards.

Understanding these safety initiatives and equipping your environmental test chamber with packaging that meets your product's EUCAR hazard rating are important steps to ensuring the safety of people and products. When dealing with the complexity of battery testing, close cooperation between manufacturers and industry partners is essential. Together, we can pave the way for safer and more efficient battery solutions to support the development of future technologies.