Air tightness tester: How to perform the air tightness test of the cold plate of the new energy battery pack? PLUS Automation

A battery pack liquid cooling plate is a heat-dissipation device for battery packs: it carries away surplus heat so that the pack does not overheat and age. Liquid cooling plates are widely used in electric and hybrid vehicles and are usually built from thin fin plates (aluminium or copper alloy) that are nested or welded together, with internal channels that guide the coolant to remove heat. Most of these plates undergo strict quality control including air tightness testing to guarantee cooling performance and durability.

Battery pack cooling plate air tightness testing normally uses the following methods:

1. Bubble method: immerse the plate in a water tank, apply pressure and watch for bubbles. Bubbles indicate a leak.

2. Pressure change method: place the plate in a sealed chamber and monitor the pressure with a sensor or gauge. Stable pressure means good sealing; a pressure drop means a leak.

3. Vacuum method: place the plate in a vacuum chamber, evacuate it and watch for pressure change or gas seepage, which indicates a leak.

4. Tracer gas method: inject a tracer gas into the plate and use a gas detector to locate leaks.

These methods can be used alone or together for a complete assessment of the plateu2019s sealing performance. Take care to work safely and accurately, avoid damaging or contaminating the plate, choose the method that suits the situation and act on the results.

Cooling plate air tightness testing verifies sealing performance to keep the battery pack safe and reliable. The test procedure is as follows:

1. Prepare the equipment: a pressure test set-up including pressure sensors, gauges and a pressure pump.

2. Prepare the test liquid: water or another non-corrosive liquid.

3. Prepare the plate: connect the cooling plate to the pack and make sure the joints are tight.

4. Seal the test set-up: place the plate in a sealed test chamber and confirm the chamber is leak-tight.

5. Apply pressure: use the pump to fill the chamber with the test liquid and raise the pressure gradually to the specified test pressure.

6. Observe the pressure: monitor the chamber pressure with a sensor or gauge. Stable pressure means good sealing; a drop means a leak.

7. Analyse the result: judge from the pressure change whether the plate passes. If it leaks, investigate and repair it.

Note that cooling plate air tightness testing must be carried out in a professional laboratory or service centre to ensure safety and accuracy, and the pack and plate must be protected from damage or contamination.