Battery Performance Testing | Summary of Environmental Performance Test Items for Lithium-Ion Batteries
In the R&D, mass production, and pre-delivery stages of lithium-ion batteries, environmental performance testing is a critical link connecting laboratory validation with real-world use and transportation scenarios. Through conditions such as high-altitude (low-pressure) simulation, high-temperature and high-humidity storage, and temperature cycling, cells and batteries are systematically evaluated for sealing integrity, capacity retention, and safety thresholds under low pressure, humid heat, and alternating hot–cold environments. These tests help expose potential issues such as leakage, swelling, and interfacial bonding failure in advance.
During transportation, fluctuations in cargo hold temperature and humidity, along with continuous vibrations, can stress the battery. Extreme climates—such as high-temperature sun exposure or freezing cold—may further trigger swelling or electrolyte leakage. This makes environmental testing results directly tied to the operational safety of end devices, especially in critical applications like new energy vehicles and energy storage power stations.
Only through rigorous simulation testing can lithium-ion batteries be ensured to perform reliably in complex environments. This not only secures stable functionality but also provides trustworthy performance data to the entire supply chain, laying a solid foundation for safe operation and reliable delivery.
1、Overview of Environmental Performance Test Items
| No. | Test Item | Test Purpose | Acceptance Criteria |
|---|---|---|---|
|
1 |
High-altitude simulation test |
Verify battery safety in low-pressure environments |
No leakage / no smoke / no fire / no explosion; post-test OCV ≥ 90% of initial |
|
2 |
High-temperature & high-humidity storage test |
Verify capacity retention of the battery under high temperature and humidity |
No deformation / no leakage / no explosion / no fire |
|
3 |
Temperature cycling test |
Verify stability of battery performance under large temperature variations with alternating hot–cold conditions |
No fire / no explosion / no gas leakage / no liquid leakage |
2、Detailed Explanations of Environmental Performance Test Items
2.1 High-Altitude Simulation Test (Low Pressure)
Test Purpose:
Simulate the conditions experienced by a cell or battery when transported at high altitude and low pressure.
Test Steps:
① Charge fully at 0.5C (use 1.0C for high-rate batteries), then rest for 10 min;
② At 20 ± 5 °C, store the cell or battery in a vacuum chamber with an atmospheric pressure of 11.6 kPa (simulating an altitude of 15,240 m) or lower, for at least 6 h.
Acceptance Criteria:
a) The cell or battery shall show no leakage, no smoke, no fire, and no explosion;
b) The post-test open-circuit voltage shall not be lower than 90% of the initial open-circuit voltage.
Figure 1. Lithium-ion battery undergoing a low-pressure simulation test
2.2 High-Temperature and High-Humidity Storage Test
Test Purpose:
Simulate the condition of a cell or battery when placed in a high-temperature and high-humidity environment.
Test Steps:
At 40 °C & 90% RH
① Discharge at 0.5C and record capacity A;
② Charge at 0.5C to full, then store at 40 °C & 90% RH for 48 h;
③ Remove the sample, rest at room temperature for 2 h, then discharge at 1.0C and record capacity B.
At 60 °C & 90% RH
① Discharge at 0.5C and record capacity A;
② Charge at 0.5C to full, then store at 60 °C & 90% RH for 24 h;
③ Remove the sample, rest at room temperature for 2 h, then discharge at 1.0C and record capacity B.
Acceptance Criteria:
At 40 °C & 90% RH:
① No visible deformation / no leakage / no explosion / no fire;
② B/A ≥ 70%.At 60 °C & 90% RH:
① No visible deformation / no leakage / no explosion / no fire;
② B/A ≥ 85%.
Note: Different customers or applications (such as wearables, automotive, energy storage) may specify varying requirements for test duration, RH%, or capacity threshold. Always follow the contract or technical drawing before execution.
Figure 2. Battery undergoing a high-temperature and high-humidity storage test
2.3 Temperature Cycling Test (Hot–Cold Alternation)
Test Purpose:
Evaluate the performance of a cell or battery under repeated temperature cycling conditions.
Test Steps:
① Charge to full at 0.5C (use 1.0C for high-rate batteries), then rest for 10 min;
② Place the sample in a chamber at 75 ± 2 °C and hold for 6 h;
③ Lower the chamber temperature to −40 ± 2 °C and hold for 6 h, with the transition time not exceeding 30 min;
④ Repeat steps ①–③ for a total of 10 cycles.
Acceptance Criteria:
The battery shall not catch fire, not explode, and shall have no gas leakage and no liquid leakage.
Figure 3. Temperature cycling process schematic
Figure 4. Battery undergoing a temperature cycling test
3、Referenced Standards and Applicable Specifications
The above environmental performance tests are carried out with reference to the following industry standards:
UL1642
UL2054
IEC62133
GB/T 18287
UN38.3
Certain customer-specific standards
4、Summary and Recommendations
The above three environmental performance tests together establish a reliability verification system for lithium-ion batteries’ adaptability to environmental conditions from different perspectives. The high-altitude simulation test focuses on the challenge of low-pressure environments to battery sealing; the high-temperature and high-humidity storage test targets performance stability under hot and humid conditions; and the temperature cycling test emphasizes verifying tolerance to drastic alternations between hot and cold. Together, they comprehensively cover the typical harsh scenarios that may be encountered during transportation and under extreme climates.
The testing procedures all follow the logic of “environment simulation – performance monitoring – data traceability.” By precisely controlling temperature, humidity, and pressure, along with real-time parameter acquisition, they fully reproduce the state changes of the battery under specific environmental conditions. Clear acceptance criteria—such as no leakage, no swelling, no abnormal appearance, and capacity decay not exceeding the specified threshold—provide a quantitative basis for interpreting results.
Overall, the three tests complement one another: they ensure safe and reliable operation of batteries in complex environments, while also supplying dependable data support for battery design optimization and the expansion of application scenarios.
