UN38.3

T.1 Altitude Simulation

· Store cells and batteries for at least 6 hours at 20 ± 5°C and an atmospheric pressure not exceeding 11.6 kPa.

· The open-circuit voltage after testing must be at least 90% of the value before testing. This requirement does not apply to fully discharged batteries and cells.

Samples (batteries) must show no leakage, venting, disassembly, rupture or fire.

T.2 Thermal Test

· Battery storage conditions are as follows:

· One temperature cycle: 72 ± 2°C for 6 hours, then −40 ± 2°C for 6 hours.

· Maximum interval between temperature changes: 30 minutes.

· Repeat for 10 cycles.

· After cycling, store batteries at 20 ± 5°C for 24 hours.

· The open-circuit voltage after testing must be at least 90% of the value before testing. This requirement does not apply to fully discharged batteries and cells.

Samples (batteries) must show no leakage, venting, disassembly, rupture or fire.

T.3 Vibration Test

· Securely mount cells and batteries on the vibration table.

· Apply sinusoidal vibration with a logarithmic sweep from 7 Hz to 200 Hz and back to 7 Hz over a 15-minute cycle.

· Begin at 7 Hz with a peak acceleration of 1 gn until reaching 18 Hz. Then maintain an amplitude of 0.8 mm (1.6 mm total excursion) while increasing frequency until peak acceleration reaches 8 gn, at approximately 50 Hz. Maintain 8 gn until the frequency reaches 200 Hz.

· One vibration direction must be perpendicular to the sample's polarity axis. Test each cell in three mutually perpendicular directions for 12 cycles per direction, lasting 3 hours each and 9 hours in total.

· The open-circuit voltage after testing must be at least 90% of the value before testing. This requirement does not apply to fully discharged batteries and cells.

Samples (batteries) must show no leakage, venting, disassembly, rupture or fire.

T.4 Shock Test

· Secure each cell or battery sample on a rigid support covering all mounting surfaces.

· Subject each cell or battery to half-sine shocks with a peak acceleration of 150 gn and a pulse duration of 6 milliseconds. Large cells and batteries are subjected to half-sine shocks of 50 gn and 11 milliseconds.

· Apply three shocks in the positive direction and three in the negative direction along each of three mutually perpendicular mounting axes, for 18 shocks in total.

· The open-circuit voltage after testing must be at least 90% of the value before testing. This requirement does not apply to fully discharged batteries and cells.

Samples (batteries) must show no leakage, venting, disassembly, rupture or fire.

T.5 External Short Circuit Test

· Stabilize the test environment at 57 ± 4°C until the cell or battery's external temperature reaches 57 ± 4°C.

· Short-circuit the positive and negative terminals through a total external resistance below 0.1 Ω. Maintain the short circuit for at least 1 hour after the external temperature returns to 57 ± 4°C.

· Observe the cell or battery for a further 6 hours before reaching a conclusion.

· During testing and for 6 hours afterward, the cell or battery sample must:

- Have an external temperature not exceeding 170°C.

- Show no disassembly, rupture or fire.

T.6 Impact Test

Impact (for cylindrical cells at least 18 mm in diameter)

· Place the test cell or polymer cell on a flat, smooth surface.

· Place a 15.8 mm diameter bar across the center of the cell, then drop a 9.1 kg mass onto the sample from a height of 61 ± 2.5 cm.

· The sample's longitudinal axis must be parallel to the flat surface and perpendicular to the longitudinal axis of the 15.8 ± 0.1 mm diameter curved surface placed across its center. Each sample is subjected to one impact only.

· The maximum cell or battery surface temperature must not exceed 170°C.

Cells and polymer cells must show no disassembly or fire within 6 hours after the test.

T.6 Crush Test

Crush (for prismatic, pouch, coin/button and cylindrical cells below 18 mm in diameter)

· Crush the cell or component cell between two flat surfaces. Increase the force gradually, with a speed of approximately 1.5 cm/s at the first point of contact. Continue until one of the following occurs:

- The applied force reaches 13 kN ± 0.78 kN.

- The cell voltage drops by at least 100 mV.

- The cell deforms by 50% or more of its original thickness.

· Apply force to the widest face of prismatic or pouch cells, to the flat surfaces of coin/button cells, and perpendicular to the longitudinal axis of cylindrical cells.

· The maximum cell or battery surface temperature must not exceed 170°C.

Cells and polymer cells must show no disassembly or fire within 6 hours after the test.

T.7 Overcharge Test

· Charge the sample at twice the manufacturer's recommended maximum continuous charging current.

· The minimum test voltage is:

· If the recommended charging voltage does not exceed 18 V, use the lower of twice the manufacturer's specified maximum charging voltage or 22 V.

· If the recommended charging voltage exceeds 18 V, use at least 1.2 times the manufacturer's specified maximum charging voltage.

· Conduct the test for 24 hours at an ambient temperature of 20 ± 5°C.

Test samples must show no disassembly or fire during testing or for 7 days afterward.

T.8 Forced Discharge Test

· At an ambient temperature of 20 ± 5°C, force-discharge each cell by connecting it to a 12 V DC power supply at an initial current equal to the manufacturer's specified maximum discharge current.

· Obtain the specified current using a series load of appropriate resistance and power rating. Forced discharge duration in hours equals the rated capacity divided by the initial current in amperes.

Test samples must show no disassembly or fire during testing or for 7 days afterward.

1.2 m Drop Test (Packaged)

At 20 ± 5°C, drop the packaged lithium battery from a height of 1,200 mm, measured from its lowest point, onto an 18–20 mm thick hardwood board placed on a concrete floor.

The sample must not catch fire or explode during or after testing.

Test Acceptance Criteria

(1) No disassembly or fire during tests T.1 to T.6.

(2) During tests T.1, T.2 and T.5, any effluent must not be toxic, flammable or corrosive.

a. No venting or leakage is visible.

b. No venting or leakage causes mass loss exceeding the limits in Table 38.3.4.7.1.

(3) During tests T.3 and T.6, any effluent must not be toxic or corrosive.

a. No venting or leakage is visible.

b. No venting or leakage causes mass loss exceeding the limits in Table 38.3.4.7.1.

(4) Perform one 1.2 m drop in each of the six positive and negative X, Y and Z directions, with no leakage, disassembly, fire, explosion or damage.