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Compatibility tests for electrolytes with battery cell materials

 

E-Lyte offers tailored compatibility testing designed specifically for gasket and sealing material manufacturers.

Scientist conducting experiment with liquid

Who benefits from compatibility testing and what results are achieved?

 

 

Since sealing materials in battery cells inevitably come into contact with the electrolyte solution, ensuring chemical compatibility is essential for safety, longevity, and performance.
To qualify a sealing material for use in battery cells, it must undergo thorough testing within a carefully designed, application-specific test scenario. That’s why we begin every project with a collaborative workshop, working closely with our partners to define a targeted, results-driven testing strategy aligned with their materials and application goals.
Partner with E-Lyte to gain the insights you need before your materials go into production.

 

 

 

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Significance of compatibility tests against liquid electrolytes

  • Sealing materials: A critical component in battery systems

     

    In high-performance battery systems, such as those used in electric vehicles and other demanding applications, the compatibility of sealing materials against liquid electrolyte solutions is crucial. These seals ensure that the electrolyte remains securely within the cell while protecting against moisture and external contaminants.

  • Safety and longevity through material resistance

     

    The safety, longevity, and efficiency of battery cells rely heavily on the integrity of these sealing materials. If seals are not chemically resistant, they can degrade or decompose over time. This can lead to electrolyte leakage and trigger chemical reactions with other cell components. Depending on the severity of the reaction, this may reduce performance, or in extreme cases, result in complete cell failure, potentially causing fire. In either case, the battery cannot operate reliably over its expected lifecycle.

  • Performance stability over time

     

    Durability testing ensures consistent performance of the battery cell throughout its service life. Leakage of the liquid electrolyte affects the cell’s functionality by lowering the concentration of the electrolyte solution. As a result, the cell may no longer reach its rated capacity during charging, reducing its ability to store electrical energy effectively.

  • Reducing
    environmental risk

     

    Beyond performance concerns, leaked electrolyte can pose significant environmental hazards. Depending on the chemical composition, harmful substances may be released, leading to contamination and environmental damage. Resistance testing plays a key role in reducing these risks by preventing leakage before it occurs.

  • A key step in battery design and manufacturing

     

    Resistance and durability testing of sealing materials is an essential part of modern battery design and production. It ensures safety, reliability, and environmental responsibility, especially in applications where battery failures can have serious consequences.

Our process for qualifying materials for battery manufacturers

  • 1. Set the right
    goals together

     

    In a focused workshop, both sides exchange insights into the sealing material, the electrolyte composition, and the chemical interactions during operation. This creates a solid foundation, aligns expectations, and ensures effective project planning. By critically evaluating the original objectives and applying our expertise, we define clear project goals and specific parameters for durability testing.

  • 2. Design of a
    custom-fit test study

     

    Once a shared understanding is in place and clear project goals have been defined, the next step is the design of a custom-fit test study. Tailored to the specific properties of the sealing material and the electrolyte system, the study ensures well defined test conditions and meaningful results.

  • 3. Benchmarking
    studies

     

    To give full transparency and context, we also share insights from previously completed compatibility studies. These real-world examples help illustrate what can be expected from the process and final results.

Laboratory equipment and scientific experimentation

Methods and procedures for compatibility tests

To test electrolyte compatibility with various materials, two complementary methods are used. The first involves storing material samples in electrolyte under controlled temperatures, allowing for detailed electrolyte analysis. However, it doesn‘t capture the effects of formation gases or vapors, and decomposition products may impact results. The second method uses prototype pouch cells to expose materials to realistic conditions, including gases and vapors. While more representative, this setup limits electrolyte analysis and may be influenced by physical changes like material swelling.

Method 1

Storage of material samples in electrolyte
under temperature control for a defined period of time.

 

  1. Material test
  2. Electrolyte test
  3. Electrochemical evaluation of electrolyte
    after material contact in pouch cells

Method 2

Storage of material samples in prototype
pouch cells under temperature control.

 

  1. Material test
  2. Electrochemical evaluation of sample material
    in pouch cells

Any questions? Contact us now.

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