Key points for environmental adaptability maintenance of lithium battery packs

Lithium battery packs are relatively sensitive to environmental conditions. Factors such as temperature, humidity, air pressure, dust and electromagnetic interference may all affect their performance, lifespan and safety. To ensure the stable operation of lithium battery packs in complex environments, systematic maintenance should be carried out from the following dimensions

First, temperature adaptability maintenance

Extreme temperature response

High-temperature environment: Long-term operation of lithium battery packs in an environment above 40℃ may accelerate the decomposition of the electrolyte, the thickening of the SEI film, and the deterioration of electrode materials, leading to capacity decline and increased internal resistance. The temperature of the battery pack should be controlled within the range of 15℃ to 35℃ through forced air cooling, liquid cooling or heat pipe cooling technology.

Low-temperature environment: When the temperature is below -20℃, the viscosity of the electrolyte increases and the migration rate of lithium ions decreases, which may lead to a decline in charge and discharge efficiency or even lithium plating. The temperature of the battery pack can be raised above 0℃ through the heating film, heat pump system or preheating function before use.

Temperature gradient control

Avoid uneven temperature distribution inside the battery pack (such as a temperature difference greater than 5℃), which may cause local overcharging or overdischarging. It is necessary to optimize the structural design of the battery pack, add heat-conducting materials or adopt a distributed temperature control system to ensure temperature consistency.

Second, humidity and corrosion protection

Humidity control

The relative humidity of the storage environment should be below 60%, and the humidity of the operating environment should be below 80%. High humidity may cause corrosion of the battery casing, oxidation of the interface and the risk of internal short circuit. The influence of humidity can be reduced by using dehumidifiers, desiccants or sealed packaging.

Anti-corrosion measures

In corrosive environments such as salt spray and chemical gases, anti-corrosion treatment should be carried out on the battery pack casing (such as applying anti-rust paint or using stainless steel), and the sealing of the interfaces should be regularly checked to prevent electrolyte leakage or the intrusion of external corrosive media.

Third, adaptability to air pressure and altitude

High-altitude environment

When the altitude exceeds 3,000 meters, the decrease in air density may lead to a decline in heat dissipation efficiency. At the same time, the internal pressure of the battery pack may be higher than that of the outside, posing a risk of seal failure. The heat dissipation design of the battery pack needs to be optimized, and a pressure balancing valve or breathable membrane should be adopted to maintain the balance of internal and external air pressure.

Low-voltage environment test

During the product development stage, low-pressure simulation tests (such as 0.5 atmospheres) need to be conducted on the battery pack to verify its electrical performance and mechanical structure stability in high-altitude environments.

Fourth, dust and particulate matter protection

Dust-proof design

In environments with a high concentration of dust, sand and other particulate matter, battery packs should be designed with an IP65 or higher protection level. Dust-proof filters, sealing strips or positive pressure protection systems should be adopted to prevent particulate matter from entering the battery pack and causing short circuits or insulation failures.

Regular cleaning

Regularly clean the exposed surface of the battery pack to prevent dust accumulation from affecting heat dissipation or causing electrical faults.

Fifth, Electromagnetic Interference and radiation protection

Electromagnetic shielding

In environments with strong electromagnetic interference (such as near substations and radar stations), electromagnetic shielding treatment should be carried out on battery packs (such as using metal casings or conductive coatings) to prevent electromagnetic interference from causing malfunctions of the BMS (Battery Management System) or communication failures.

Radiation tolerance test

Radiation tolerance tests were conducted on the battery pack to verify the stability of its electrical performance under high-intensity electromagnetic radiation environments.

Sixth, Vibration and shock protection

Shock absorption design

In vibration environments such as vehicles and aviation, shock absorption design for battery packs (such as using rubber pads and spring shock absorbers) is required to prevent the internal structure of the battery from loosening or the welding points from falling off due to vibration.

Impact test

Conduct impact tests on the battery pack (such as half-sine wave impact) to verify its mechanical structural integrity in the event of accidental drops or collisions.

Seventh, Environmental Monitoring and Early Warning

Real-time monitoring

The environmental parameters such as temperature, humidity and air pressure of the battery pack are monitored in real time through BMS, and the threshold alarm function is set. When environmental parameters exceed the safe range, the protection mechanism (such as reducing power operation and cutting off the circuit) is triggered in a timely manner.

Data recording and analysis

Record the operation data of the battery pack under different environmental conditions and optimize the environmental adaptability maintenance strategy through big data analysis.