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Overcharging test

a) Initialization charging of battery module;
b) The battery module is charged in a constant current manner until the voltage of any battery cell reaches 1.5 times the termination voltage of the battery cell charging or for a period of time
Stop charging at 1 hour, and the charging current should be the smaller of 1Crcn and the maximum continuous charging current of the product;
c) Observe for 1 hour;
d) Observe for any signs of expansion, leakage, smoking, fire, or explosion.

 

Overcharging test is an important testing method for evaluating the safety and stability of battery modules under overcharging conditions. By simulating the reaction of battery modules under overcharging conditions, detect whether the battery will experience dangerous situations such as expansion, leakage, smoking, fire, explosion, etc. The following is the detailed content of the overcharge test:

 

1. Test purpose

Evaluate the safety and stability of battery modules under overcharging conditions.

Ensure that the battery module does not experience dangerous situations such as expansion, leakage, smoking, fire, explosion, etc. under overcharging conditions.

Verify whether the battery module complies with relevant safety standards and requirements.

 

2. Testing principle

By charging the battery module in a constant current manner until the voltage of any battery cell reaches 1.5 times the termination voltage of battery cell charging or for 1 hour, the appearance, structural integrity, and safety of the battery are tested.

 

3. Testing methods

(1) Test preparation

Initialize and charge the battery module.

Prepare constant current charging equipment and voltage measurement equipment.

(2) Overcharge test

Charge the battery module with a constant current, taking the smaller of 1C<sub>rcn</sub>and the maximum continuous charging current of the product.

Stop charging when the voltage of any battery cell reaches 1.5 times the termination voltage of battery cell charging or when the time reaches 1 hour.

(3) Observation after testing

Observe for 1 hour and record whether the battery module has any phenomena such as expansion, leakage, smoking, fire, explosion, etc.

 

4. Testing standards

International standards:

IEC 62133 (Safety requirements for portable sealed secondary batteries).

UN 38.3 (Safety testing for transportation of lithium batteries).

Industry standards:

GB 31241 (Safety Requirements for Lithium ion Batteries for Portable Electronic Products, China).

UL 1642 (Lithium Battery Safety Standard, USA).

 

5. Testing equipment

Constant current charging device: used for charging at a specified charging current.

Voltage measurement equipment: used to measure the voltage of battery cells.

Infrared thermal imaging device: used to monitor the temperature changes of battery modules during overcharge testing.

 

6. Data analysis and evaluation

Appearance inspection: Record whether the battery module has any expansion, leakage, or other phenomena.

Safety assessment: Observe whether the battery module has any dangerous situations such as smoking, fire, explosion, etc.

Electrical performance: Measure the voltage and internal resistance of the battery module to evaluate whether its electrical performance is normal.

 

7. Common problems and solutions

Battery expansion: It may be due to excessive internal pressure or material failure, and battery design and production processes need to be optimized.

Leakage: It may be due to insufficient battery sealing, and the sealing design of the battery needs to be improved.

Fire or explosion: It may be due to internal short circuit or material failure of the battery, and the battery design and production process need to be optimized.

 

8. Application scenarios

Testing of battery modules for consumer electronics products such as smartphones, laptops, and tablets.

Electric tools: such as battery module testing for electric drills and chainsaws.

Electric vehicles: such as testing of power battery modules for electric vehicles.

Energy storage system: such as testing of solar energy storage battery modules.

 

9. Test report

Test conditions: including charging current, charging time, termination conditions, etc.

Test results: including appearance inspection results, safety assessment, electrical performance, etc.

Conclusion and Suggestions: Evaluate whether the sample meets the relevant standards and propose improvement suggestions.

Through overcharge testing, the safety and stability of battery modules can be comprehensively evaluated under overcharge conditions, ensuring that they can meet safety requirements in practical use and providing scientific basis for the design and optimization of battery modules.

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