Car Battery Leaking: Definition, Causes and Solutions

• What is car battery leaking？
• What causes a car battery to leak?
• How to fix a leaking car battery?
• Do electric vehicles have higher airtightness requirements for batteries than fuel vehicles?

What is car battery leaking？

Car battery leakage refers to the escape of the electrolyte solution inside the battery from the battery case.

What causes a car battery to leak?

Car batteries often contain sulfuric acid, which is highly corrosive and can cause damage to various parts of the vehicle. In the process of using the car, what factors usually cause the car battery to leak? Here are some common causes:

1. Aging and wear: Over time, the car battery will age and its case may become weaker. The result may be small cracks or leaks that allow the electrolyte solution to escape.

2. Overcharging: When the charging system in the vehicle fails, or if the battery is continuously subjected to a voltage higher than it can withstand. The battery may become overcharged and overheated, which may also cause the battery to leak.

3. Physical damage: For example accidental impact or mishandling of the battery can crack or damage the case, resulting in battery leakage.

4. Manufacturing Defects: Manufacturing defects can cause the battery to leak, these defects may include casing defects, improper sealing or improper construction.

How to fix a leaking car battery?

Car battery leakage is a relatively serious problem.Here are some steps you can take:

1. Safety precautions: Wear protective gloves and goggles to avoid contact with acid. Make sure you are in a well-ventilated area or open doors and windows for proper air circulation.

2. Disconnect the battery: If it is safe to do so, disconnect the battery from the vehicle.

3. Contain the leak: Place an acid-resistant container or absorbent material around the leaking battery to prevent the acid from spreading to other parts of the vehicle.

4. Seek professional help: Contact a professional mechanic or an automotive service center to assess the situation. They have the knowledge, experience, and proper equipment to safely handle battery leaks. They will be able to determine if the battery can be repaired or needs to be replaced.

In most cases, a leaking car battery will likely require replacement rather than fix. We also do not recommend repairing a leaking car battery because the sulfuric acid in a leaking battery is irritating and corrosive and could cause burns or other health problems if exposed to the leak.

Batteries are sealed units and trying to fix a leak may not be a viable option. It is important to make safety a priority and let a professional handle the situation to minimize any risk.

Remember that handling a leaking car battery can be dangerous, so it's best to rely on trained personnel who can handle the situation properly.

Do electric vehicles have higher airtightness requirements for batteries than fuel vehicles?

Yes, compared with traditional fuel vehicles, electric vehicles generally have higher requirements for the airtightness of batteries. This is because EV batteries are typically packaged in sealed battery packs designed to maintain the integrity of the battery system and protect it from external influences.

The reasons why EV batteries have higher airtightness requirements are as follows:

Safety: Maintaining high airtightness helps ensure the safety of the battery pack. EV batteries contain high-energy cells and electrolytes that must be safely confined to prevent leakage or exposure to external elements.

Thermal Management: Many EV batteries contain a thermal management system that regulates the temperature of the battery pack. Proper airtightness helps prevent the ingress of outside air, which can disrupt the thermal management process and affect battery performance.

Pollution Prevention: Hermeticity helps prevent the ingress of moisture, dust, dirt, or other contaminants that could damage the battery or affect its performance and lifespan.

Efficiency: Maintaining a sealed battery pack helps optimize the efficiency of electric vehicles. Unnecessary air leakage results in energy loss and reduces overall mileage.

To ensure the required airtightness, EV battery packs undergo a rigorous testing and manufacturing process. These processes involve properly sealing battery pack components and performing various quality control tests, including leak testing, to verify the integrity of the seal and identify any potential leaks.

It is important to note that specific hermeticity requirements may vary between EV manufacturers and battery pack designs. Each manufacturer may have its own standards and testing protocols to ensure the highest levels of safety, performance and reliability for its EV batteries.

In order to determine whether the airtightness of the EV battery pack is good, we need to use professional tools to help with detection. The SmartSafe research team has specially developed a device for testing the airtightness of electric vehicle battery packs: iSmartEV ET30.

The iSmartEV ET30 battery pack leak tester (LP) is a state-of-the-art nondestructive testing equipment developed by Smartsafe. This advanced equipment utilizes compressed air as a medium to apply precise pressure to the internal cavity or surface of the battery being tested.

Sensitive sensors are employed to detect pressure variations, enabling the identification of any potential leaks in the battery pack. With its pollution-free operation, rapid testing capabilities, and high accuracy, this cutting-edge device enhances testing efficiency and product quality in the new energy industry.

It has the following product features:

① The incorporation of highly sensitive pressure sensing greatly enhances both the accuracy and stability of the testing process.
② The test progress and data are visually displayed on a 7-inch touch screen, providing a clear and intuitive interface for easy monitoring.
③ The test progress time for each stage is displayed, allowing you to track the duration of each stage throughout the test.
④ Real-time display on the same screen allows simultaneous viewing of the pressure dial and the test curve as the test progresses.
⑤ The system has an automatic memory function that retains the last test parameters. This convenient feature allows for easy modification of parameters during subsequent tests, enhancing efficiency.
⑥ The system enables the pre-setting of various parameters, including workpiece number, volume, pressure, time for each stage, and leakage limit.

In the event of abnormal or failed tests, the tester will provide both audible and visual alarms to ensure safety and prompt attention to the issue.