New Leak Detection Methodology to Protect against Microscopic Leaks and Water Ingress in Battery Cells, Battery Packs and ADAS Sensors

Ingress protection standards published by the International Electrotechnical Commission (IEC) classify and rate the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact and water and may be insufficient. The IP 67 or European EN 60529 test duration is 30 minutes during which time “water ingress in a harmful quantity will not be possible". What is a “harmful quantity” is not stated, nor is the test designed to predict future leak tightness for battery packs for electric and hybrid vehicles, sensors for ADAS (Advanced Driver Assistance Systems), fuel cell stacks, cooling circuits and other automotive electronics where long-term exposure to moisture can cause significant issues. This paper will provide empirical results to show leak sizes that allow either water ingress or egress at typical operating pressures and translate these results into test gas leakage rates.