Battery Pack Tracer Gas Leak Testing for IP67/IP68 Sealing
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Solution Overview
Problem
Traditional gas detection methods for battery packs, particularly those using helium as a tracer gas, face challenges in precision due to environmental and pressure-related issues, failing to meet the stringent IP67 and IP68 waterproofing standards and potentially damaging battery cells during vacuum testing.
Innovation Solution
A battery pack leakage detection system and method utilizing a tracer gas cumulative test, which includes a test container, gas filling subsystem, gas stirring subsystem, and test analysis subsystem, allowing for tracer gas filling and analysis under atmospheric pressure to assess sealing performance without deforming the battery pack, using helium or hydrogen as tracer gases and mass spectrometry for precise leakage rate calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vacuum helium test method is used to detect leakage, then measurement precision is improved, but battery cells are damaged due to pressure difference expansion
Solution Approach 1:
Instead of placing the battery pack in a vacuum environment (traditional method), the patent inverts the approach by placing the battery pack in a normal pressure environment and creating a vacuum inside the test chamber. The battery pack is filled with tracer gas before testing, and the mass spectrometer detects tracer gas that leaks from the battery into the vacuum chamber, thereby detecting leaks without subjecting the battery to damaging external vacuum conditions
Solution Approach 2:
The patent introduces tracer gas (such as helium) as an intermediary substance. The tracer gas is filled into the battery pack before testing, and its leakage into the test chamber serves as the detection target. This intermediary approach allows indirect detection of sealing performance without requiring the battery to withstand extreme pressure differences, thus protecting the battery cells while maintaining high measurement precision
2Measurement precision
If traditional gas detection method is used, then operation simplicity is maintained, but detection precision is insufficient for IP67 and IP68 standards
Solution Approach 1:
The patent replaces traditional mechanical pressure testing methods with a mass spectrometry-based detection system. Instead of relying on pressure changes or bubble formation methods, the system uses a mass spectrometer to detect and quantify tracer gas molecules in the test chamber, providing significantly higher detection precision suitable for IP67 and IP68 waterproof standards
Solution Approach 2:
The patent changes the detection parameter from macroscopic pressure or visual inspection to microscopic molecular detection. By using mass spectrometry to detect the presence and concentration of tracer gas molecules, the system achieves much higher sensitivity and precision, capable of detecting extremely small leakage rates that traditional methods cannot identify
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively tests battery pack sealing performance under atmospheric pressure, ensuring compliance with IP67 and IP68 standards while avoiding damage to battery cells, providing a more precise and reliable detection of leakage rates.
Implementation Method 1
a mass spectrum test analysis subsystem configured for sampling the mixed gas in the test cavity and analyzing the sampled gas to obtain the content of the leaked tracer gas in the test cavity
Data Source
AI summary
A battery pack leakage detection system and detection method are provided. The system includes a test container, a gas filling subsystem, a gas stirring subsystem and a test analysis subsystem. The method can test the sealing performance of the battery pack under the atmospheric pressure, so that the battery pack can meet the corresponding sealing grade requirements of IP67 and IP68. The method not only solves the problem that the traditional gas detection method cannot meet the test requirements of IP67 and IP68 due to insufficient measurement precision, but also solves the problem that the traditional vacuum helium detection method will damage the battery cells in the battery pack.