Battery combustion tester，IEC 62281:2004

With the widespread adoption of lithium-ion batteries, high-energy-density batteries, and other advanced energy storage devices in consumer electronics, electric vehicles, energy storage systems, aerospace, and related fields, battery safety has become one of the core concerns throughout research and development, manufacturing, and certification processes. The Battery Combustion Tester, as a critical safety testing instrument, is widely used to evaluate battery performance and potential risks under extreme fire exposure conditions, providing a scientific basis for battery design optimization, safety certification, and risk control.

Basic Principle

A Battery Combustion Tester is designed to simulate combustion or explosion behavior that may occur when batteries are exposed to open flames or fire environments. During testing, a flame source is applied beneath a battery or battery pack specimen, which is secured on a high-temperature-resistant wire mesh. The tester allows for continuous observation of whether the battery ignites, explodes, or is completely consumed by fire, while recording the duration and condition of the entire combustion process. This enables evaluation of the battery’s combustion characteristics and fire resistance.

The fundamental principles of combustion testing include:

Placing the battery specimen on a heat-resistant wire mesh with a defined aperture and wire diameter, ensuring that the combustion process occurs under standardized geometric conditions.

Igniting a burner beneath the specimen at a specified distance from the mesh so that the battery is directly exposed to flame.

Observing and recording key events during combustion, such as ignition, burn duration, and whether an explosion occurs.

This testing method can be applied not only to individual battery cells but also to battery packs, helping engineers assess battery behavior and safety performance under extreme abuse conditions.

Importance of Battery Combustion Testing

The significance of battery combustion testing extends far beyond simple observation of burning phenomena. It is an indispensable component of the overall battery safety framework for several reasons:

Prevention of Thermal Runaway Fire Risks

Lithium-ion batteries are prone to thermal runaway when subjected to overheating, short circuits, or overcharging. Combustion testing allows observation of heat release, ignition of surrounding materials, and potential explosion behavior, providing valuable reference data for fire protection and safety design in real-world applications.

Compliance with Safety Standards and Regulations

Many international and national standards, such as UL1642 and GB31241. require batteries to pass combustion or flame exposure tests and define clear acceptance criteria. Conducting combustion tests supports compliance certification and enables battery products to enter target markets.

Enhancement of Product Design and Material Selection

Test results help R&D teams evaluate the influence of materials, battery structures, and electrolyte formulations on combustion behavior, thereby promoting the development of safer materials and more robust battery designs.

Test Procedure

Although specific details and automation levels vary among instruments, most battery combustion testers follow a similar testing process:

Sample Preparation

Place the battery specimen on a flame-resistant, high-temperature wire mesh and verify its initial condition.

Burner Setup

Adjust the burner height to achieve the specified distance from the wire mesh. Standard flame sources, such as Bunsen burners, are commonly used.

Ignition of Flame Source

Ignite the burner and apply the flame to the specimen while monitoring test conditions.

Observation, Timing, and Recording

Continuously observe and time the combustion process until the battery is fully burned, explodes, or the predefined test endpoint is reached.

Data Analysis

Compile data on burn duration, destruction level, and explosion occurrence to support subsequent safety evaluations.

These steps highlight the systematic and scientific nature of combustion testing within the overall safety validation process.

Industry Application Scenarios

Battery combustion testing is widely applied across multiple industries and product categories, including:

Battery Manufacturing and Quality Control

Manufacturers conduct regular combustion tests to verify fire safety performance, ensuring batch consistency and product reliability.

Consumer Electronics and Portable Devices

Due to their compact size and high energy density, batteries used in smartphones, laptops, and other portable devices pose elevated fire risks. Combustion testing helps ensure user safety during normal and abnormal use.

Electric Vehicles and Energy Storage Systems

Large-scale power battery systems installed in vehicles or energy storage facilities can cause severe consequences if a fire occurs. Combustion testing verifies the effectiveness of fire-resistant designs and flame-retardant strategies.

International Certification and Testing Laboratories

Third-party laboratories perform combustion testing to help manufacturers meet regulatory requirements in different global markets and obtain product certifications.

Safety Standards

Common standards governing battery combustion testing include, but are not limited to:

UL1642

An internationally recognized lithium battery safety standard that includes flame exposure tests to evaluate battery reactions under high-temperature external fire conditions. It specifies that batteries must not penetrate the protective wire mesh after testing, thereby preventing fragment ejection.

GB31241 Series

China’s national standards for portable lithium-ion battery safety, defining combustion, explosion, and leakage tests that are mandatory for market access.

SJ/T and IEC Series

Additional industry and international standards, such as SJ/T11170 and IEC60086-4. define combustion behavior assessment methods under various conditions for specific battery types or applications.

Key Equipment Structure

A typical battery combustion tester generally includes the following components:

High-temperature-resistant wire mesh and support platform for holding test specimens during flame exposure

Standardized flame source devices, such as Bunsen burners or gas burners, providing controlled and repeatable fire conditions

Timing systems and observation windows for monitoring and recording combustion behavior

Safety protection features, including protective enclosures and automatic flame shutdown mechanisms

These structural designs ensure that the test process is controlled, safe, and capable of producing comparable and verifiable results.

Safety Precautions

Battery combustion testing involves inherent risks such as open flames, high temperatures, explosions, smoke, and hazardous gas emissions. Strict environmental control and safety measures are therefore essential, including:

Conducting tests in well-ventilated laboratory environments to prevent accumulation of smoke and gases

Using protective enclosures or observation windows to keep personnel at a safe distance from flames

Regular inspection of burners and equipment structures to prevent leaks or structural failures

Ensuring the availability of fire suppression equipment and emergency shutdown systems

These measures help safeguard personnel and facilities during extreme-condition testing.

As a core instrument within the battery safety testing framework, the Battery Combustion Tester evaluates battery combustion behavior under direct flame exposure and extreme environments. It plays a vital role in improving product safety, ensuring compliance with international and national standards, and providing robust safety assurance for end-use applications.

With ongoing advancements in battery technology, combustion testing equipment is also evolving toward higher efficiency, greater intelligence, and increased automation. These developments will further enhance testing accuracy, repeatability, and safety, providing strong technical support for the continuous improvement of global battery safety standards.