Leak testing for battery tabs is an essential quality control step to ensure the integrity of the tabs’ sealing and prevent potential issues like electrolyte leakage, which could lead to safety hazards and reduced battery performance. The leak testing process for battery tabs is critical to determine the safety of the tab at critical regions that require a strong seal. Here are some of the critical areas that can be inspected for leaks using a penetrating dye:
- The edge of the tab
The metal edge of the tab receives a machined chamfer which is intended to improve the seal with the polymer film. The polymer film should fully seal around the edge of the metal. A penetrating dye can evaluate the successfulness of the edge preparation step and whether it is compatible with the polymer selection and sealing conditions.
- The interior of the film-metal bond
The tab is cut to reveal a cross section of the film-metal-film bond and immersed in penetrating dye; this will reveal any areas that are insufficiently sealed. This detection method will reveal inadequacies of either the sealing method/conditions, or the material and polymer degradation/compatibility.
- The edge of the polymer film
If the dye has penetrated the film from the film boundaries, then this is an indication that the film has not been sealed properly. Further investigation will be required to find the root cause of the problem.
Regular leak testing of battery tabs as part of the manufacturing process helps ensure the quality, safety, and performance of the batteries before they are assembled and distributed to consumers or used in other products. Careful attention is given to areas prone to failure to ensure high quality.
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