Accurate pressure measurement is crucial during battery charge and discharge cycles, particularly for lithium-ion batteries. Monitoring pressure changes within the battery housing offers valuable insights throughout the entire process—from initial design and prototyping to production, quality control, and battery formation.

Tekscan’s I-Scan pressure measurement system provides engineers with critical data at every stage of battery design and development. This advanced pressure mapping technology enables precise measurement and analysis, helping to turn innovative battery concepts into reality.

Pressure around ports and in flow field before and after pressurization

Why is Evaluating Battery Pressure Crucial?

During normal use, lithium-ion (Li-ion) batteries undergo repeated charge and discharge cycles, leading to thermal cycling. This causes the battery to expand and contract, which over time can result in delamination and degradation.

The liquid electrolyte in Li-ion batteries is especially prone to expansion, which can create localized areas of high and low pressure within the battery stack. If these pressure variations are not addressed in the fixture design, they can lead to premature failures.

By optimizing stack pressure in the assembly process, you can:

• Reduce formation costs
• Minimize capacity fade
• Lower cell variability
• Limit thermal expansion and delamination
• Prevent thermal runaway

How Do You Measure Battery Pressure in Real Time

Engineers recognize the significant impact that fluctuations in battery pressure can have on performance and safety. But how can you accurately measure these changes? Tekscan’s embedded force and pressure sensors, along with advanced software, provide the data you need.

In the accompanying video, you’ll see how the system measures:

• Pressure points across the sensing area
• Average pressure changes across the sensing area
• Pressure variations over time

EV Application for Pressure Mapping

Pressure mapping plays a vital role in ensuring the optimal performance of electric vehicle (EV) batteries. Key applications include:

• Studying battery swell to enhance lifespan and performance
• Optimizing battery formation for efficiency and consistency
• Module-level analysis of stack pressure to validate assembly protocols
• Pack-level insights to identify potential hot zones where failures may occur
• Seamless integration of sensors with battery management systems for real-time monitoring

Pressure Mapping for Electric Vehicle (EV) Design

Beyond optimizing battery stack assembly, pressure mapping is essential for various aspects of EV design, safety testing, and quality assurance.

• Seat and seatbelt design: With the evolving designs of EVs and autonomous vehicles, understanding the pressure dynamics between seat backs and cushions is crucial.
• Tire design: EV tires differ significantly from those for combustion engines due to torque variations and other unique factors.
• Impact testing and chassis design: Testing the impact of debris underneath the vehicle is vital for determining optimal battery placement and protection.
• Door seal measurement: Weak door seal pressure can affect noise control, leaks, and aerodynamic efficiency.

As next-generation EV designs bring new challenges, pressure mapping can assist in everything from optimizing charging port designs to re-engineering key vehicle elements.

Battery Life and Performance – On-Demand Webinar

Tekscan has an on-demand webinar for more info on how pressure mapping helps you improve battery life and performance.  

Engineers worldwide rely on Tekscan’s I-Scan system to gain valuable insights into battery design, whether for automotive applications, consumer electronics, or other innovative products.