Testing Requirements for Newly Manufactured Lithium Batteries

Newly produced lithium batteries must undergo a series of stringent tests to ensure their performance, safety, and reliability. Below is a detailed summary of these tests:                                                                                                  

I. Physical Characteristics Testing                                                                                                          

1. Dimension and Weight Testing: Measure the battery’s dimensions and weight to ensure compliance with design specifications.
2. Appearance Inspection: Check the battery’s casing, terminals, labels, etc., for any defects or damage.
3. Casing Strength Testing: Test the strength and durability of the battery casing by applying pressure or squeezing.                                                                                                                                                                          

II. Electrical Performance Testing                                                                                                         

1. Capacity Testing: Use specific charging and discharging equipment to measure the amount of energy released by the battery during charge and discharge cycles, verifying that it meets the nominal capacity.
2. Internal Resistance Testing: Utilize specialized internal resistance testers to measure the battery’s internal resistance under various conditions (e.g., charging, discharging, resting). Internal resistance affects power output, charging efficiency, and self-discharge rates.
3. Voltage Testing: Measure both open circuit voltage and working voltage. Open circuit voltage refers to the battery’s terminal voltage when not connected to a load, while working voltage is the actual output voltage under load. Testing voltage changes under different conditions helps assess performance stability and compatibility with devices.
4. Rate Performance Testing: Evaluate the battery’s performance at different charge and discharge rates, such as 0.5C, 1C, and 2C, to understand its behavior under fast charging and discharging and its suitability for high-power applications.
5. Self-Discharge Testing: Measure the rate at which the battery discharges naturally while at rest; lower self-discharge rates indicate better storage performance.
6. Discharge Characteristics Testing: Include measurement of the discharge curve and discharge efficiency of the battery.                                                                                                                                                  

III. Safety Testing

(These tests must be conducted at specialized testing facilities equipped with professional testing equipment and trained personnel to ensure accuracy and reliability, and to provide detailed test reports and certifications.)                                                                                                                                                                             

1. Overcharge Testing: Simulate battery performance during overcharging to check for protective mechanisms, such as triggering an overcharge protection circuit, and observe whether the battery heats up, swells, or poses risks of fire or explosion.
2. Overdischarge Testing: Assess the safety of the battery during excessive discharge, which can cause irreversible damage and reduce lifespan.
3. Short Circuit Testing: Intentionally short-circuit the battery terminals to observe the effectiveness of short circuit protection, and monitor temperature changes and potential smoke or fire events.
4. Puncture Testing: Use a sharp object (e.g., a steel needle) to puncture the battery, simulating scenarios where the battery may be breached, to check for violent chemical reactions, fire, or explosions.
5. Crush Testing: Place the battery in a crushing apparatus and apply a certain level of pressure to test its safety and stability under external forces.
6. Impact Testing: Apply sudden impact forces to the battery to verify safety and stability under mechanical shock.
7. Thermal Stability Testing: Subject the battery to various temperature environments (e.g., high and low temperatures) to observe performance variations and check for potential thermal runaway problems.                 

IV. Environmental Adaptability Testing                                                                                                    

1. Temperature Cycling Testing: Subject the battery to multiple cycles of varying temperatures, from low to high and back to low, to evaluate performance stability and reliability under thermal fluctuations.
2. Humidity Testing: Batteries intended for use in humid environments, such as outdoor devices, must undergo humidity testing to assess performance and reliability in high moisture conditions.
3. Vibration Testing: Simulate vibrations the battery may encounter during transport and use to evaluate structural integrity and connection reliability.
4. Low Pressure Testing: Replicate conditions of use at high altitudes or low-pressure environments to check for leakage or bulging.                                                                                                                                            

V. Additional Testing

1. Electromagnetic Compatibility (EMC) Testing: Assess the battery’s susceptibility to and immunity from electromagnetic interference in its operating environment.
2. Environmental Compliance Testing: Analyze heavy metal content and hazardous substances in the battery to ensure compliance with environmental regulations.
3. Cycle Life Testing: Perform multiple charge and discharge cycles to monitor capacity degradation over time to evaluate battery lifespan.                                                                                                                                    

In summary, newly manufactured lithium batteries must undergo a comprehensive and rigorous testing process to ensure their performance, safety, and reliability. These tests cover various aspects, including physical characteristics, electrical performance, safety, environmental adaptability, and additional criteria, providing robust assurance for battery quality control and subsequent applications.