Testing that Reaches the World

Overcharge testing is vital, particularly for Lithium-Ion batteries, for ensuring the safe use in consumer electronics, electric vehicles, eMobility, industrial, military and other applications. By identifying potential failure modes and risks, manufacturers can create safer, more reliable battery systems that meet industry standards and protect end-users. 

The benefits of overcharge testing for batteries is enhanced safety which allows battery developers to identify and mitigate risks associated with overcharging before they reach the market.  Customers can use insights gained from testing to enhance battery design, extending lifecycle and performance and ensure their products meet safety standards meeting regulatory requirements and industry standards, such as UN 38.3 and IEC 62133 as well as market acceptance. 

Battery Overcharge Testing begins with a fully charged battery to its recommended maximum voltage.  The battery is then subjected to charging at a specified rate beyond its maximum voltage limit for a predetermined duration.  Throughout the process the Clark test engineering team with be monitoring various parameters including temperature, voltage, and physical changes.  Post-testing, the battery is analyzed for signs of failure, including swelling, leakage, or damage to internal components. 

This testing simulates conditions where a battery is charged beyond its maximum voltage, helping to evaluate the battery’s response and identify potential safety risks.  Understanding how a battery behaves when overcharged can provide insights into its performance limits and failure mechanisms. 

As the battery is subjected to charging beyond its maximum voltage under controlled conditions, our test team monitors and assesses its response.  Throughout the testing process, we closely monitor critical parameters, including temperature, voltage, and physical changes. 

Post-testing, we analyze the collected data to identify any signs of failure by visual inspection and electrical testing to evaluate the overall performance of the battery under overcharge conditions.  Our customer then receive a comprehensive report detailing our findings, including design validation and safety performance.