IEC 60086-4
IEC 60086-4 Standard Overview
IEC 60086-4 is a standard established by the International Electrotechnical Commission (IEC), officially titled “Primary batteries – Part 4: Safety requirements for lithium batteries.” This standard outlines the safety testing and requirements for primary lithium batteries to ensure their safe operation during both intended use and foreseeable misuse scenarios. It is applicable to both standardized and non-standardized primary lithium batteries and covers aspects such as battery design, quality planning, sampling, testing, and safety warnings.
The IEC 60086-4:2019 edition was published on April 25, 2019, replacing the previous 2014 edition. This updated version includes several technical revisions, such as:
Modifications to explosion criteria.
Addition of parameters for over-discharge testing of specific battery types.
Introduction of sub-clauses for testing validity.
Revision of symbols in figures.
Addition of requirements for child-resistant packaging of coin batteries.
Recommendation for the safety warning “KEEP OUT OF REACH OF CHILDREN.”
Additionally, this version incorporates the content of the errata from October 2019 and April 2020, as well as the interpretation sheet from May 2020.
This standard is essential for lithium battery manufacturers, users, and regulatory bodies involved in ensuring the safety and reliability of battery products.
Specific Testing Requirements of IEC 60086-4
The IEC 60086-4 standard specifies detailed safety testing and requirements for primary lithium batteries. Here are some key testing requirements outlined in the standard:
Altitude Simulation Test: Evaluates the battery’s performance under simulated high-altitude conditions.
Thermal Cycling Test: Subjects the battery to cycles of high and low temperatures to assess its stability under extreme temperature variations.
Vibration Test: Simulates vibrations that the battery may experience during transportation or use to ensure its structural integrity.
Shock Test: Tests the battery’s tolerance to mechanical shocks.
External Short-Circuit Test: Examines the battery’s safety performance under external short-circuit conditions.
Impact Test: Assesses the battery’s tolerance to impacts.
Crush Test: Simulates extreme conditions where the battery is subjected to crushing forces.
Forced Discharge Test: Evaluates the battery’s reaction under forced discharge conditions.
Abnormal Charging Test: Assesses the battery’s safety performance under incorrect charging conditions.
Free Fall Test: Tests the battery’s safety after free-falling from a certain height.
Thermal Abuse Test: Evaluates the battery’s safety performance under overheating conditions.
Overdischarge Test: Examines the battery’s performance under overdischarge conditions.
These tests are designed to ensure the safety of lithium batteries throughout their lifecycle, from design and production to distribution, use, and disposal. The IEC 60086-4:2019 version also includes technical changes such as revisions to explosion criteria, the addition of overdischarge test parameters, the introduction of a subclause on testing validity, and the revision and addition of safety markings. These requirements help enhance the safety and reliability of battery products.
Other international standards for lithium battery testing
In addition to the IEC 60086-4 standard, international standards or industry standards for lithium battery testing also include:
UL 1642: This is a safety standard for lithium batteries established by Underwriter Laboratories Inc., covering safety requirements for lithium batteries, including battery construction, testing methods, and classification.
UL 2580: This is a safety requirement for electric vehicle power batteries, including testing methods and safety performance requirements for batteries.
UL 9540A: This is a safety requirement for energy storage systems, including testing methods and safety performance requirements for energy storage batteries.
UL 1973: This is a safety standard for batteries used in stationary and mobile auxiliary power supply applications.
ISO 12405: This is a series of test specifications for lithium-ion traction battery packs and systems for electric road vehicles, including high-power and high-energy battery systems for different applications.
IEC 62660: This is a series of standards for the performance testing, reliability, and abuse testing, as well as safety requirements for secondary lithium batteries used in electric road vehicles.
IEC 62619: This is a safety requirement for secondary lithium cells and batteries containing alkaline or other non-acid electrolytes used in industrial applications.
IEC 63056: This is a safety requirement for secondary lithium cells and batteries containing alkaline or other non-acid electrolytes used in electrical energy storage systems.
SAE J2929 Standard Overview
SAE J2929 is a safety standard for electric and hybrid vehicle propulsion battery systems that utilize lithium-based rechargeable batteries. This standard was established by the Society of Automotive Engineers (SAE) to ensure the safety and reliability of these battery systems in automotive applications.
Scope of SAE J2929
SAE J2929 comprehensively covers safety testing for both individual battery cells and entire battery systems. The standard includes a wide range of tests designed to evaluate the battery’s performance and safety under various extreme conditions. These tests are crucial for ensuring that the battery systems remain safe during both intended use and potential misuse scenarios.
Specific Testing Categories
Mechanical Tests:
Drop Test: Assesses the battery’s integrity when subjected to impact forces from a fall.
Vibration Test: Evaluates the battery’s durability under prolonged vibration, simulating conditions during transportation or vehicle operation.
Impact Test: Tests the battery’s ability to withstand sudden impacts.
Crush Test: Simulates the effects of compression forces on the battery.
Puncture Test: Evaluates the battery’s response to penetration, ensuring it remains safe even when pierced.
Electrical Tests:
External Short-Circuit Test: Examines the battery’s safety performance when an external short circuit occurs.
Overcharge Test: Assesses the battery’s behavior under overcharging conditions to prevent thermal runaway and other hazards.
Over-Discharge Test: Evaluates the battery’s performance when subjected to over-discharge conditions.
Environmental Tests:
Temperature Shock Test: Evaluates the battery’s performance under rapid temperature changes.
Humidity Cycle Test: Assesses the battery’s durability in high-humidity environments.
Immersion Test: Tests the battery’s safety when submerged in water.
Salt Spray Test: Evaluates the battery’s corrosion resistance in salty environments.
Thermal Runaway Propagation Test:
This test evaluates the battery system’s ability to prevent the spread of thermal runaway from one cell to another, ensuring that a failure in one cell does not lead to a catastrophic failure of the entire battery pack.
Importance of SAE J2929
These rigorous tests are designed to simulate real-world conditions that electric and hybrid vehicle batteries may encounter, ensuring that they remain safe and reliable throughout their operational life. By adhering to SAE J2929, manufacturers can provide consumers with confidence in the safety and performance of their battery systems, ultimately contributing to the broader adoption of electric and hybrid vehicles.
These standards cover safety testing from individual battery cells to battery systems, including mechanical tests (such as drop, vibration, impact, crush, and puncture), electrical tests (such as external short circuit, overcharge, and over-discharge), environmental tests (such as temperature shock, humidity cycle, immersion, and salt spray), and thermal runaway propagation tests. These tests are designed to assess the battery’s response under extreme conditions, ensuring its safety performance during intended use and possible misuse.