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Battery Acupuncture Test
The Battery Acupuncture Test (also known as the nail penetration test) is a destructive safety test used to assess the behaviour of rechargeable batteries—particularly lithium-ion cells and packs—when subjected to internal short-circuit conditions caused by mechanical damage such as penetration by a nail, needle, or sharp object. This test simulates real-world abuse conditions such as vehicular crashes, crushing, or punctures that may lead to thermal runaway, fire, explosion, or leakage.
Detailed Technical Specifications
| Needle Material | Hardened Steel |
| Needle Diameter | Typically 2 mm to 5 mm (varies by standard, e.g., 3 mm in GB/T 31485) |
| Penetration Speed | 10–40 mm/s (GB/T 31485 specifies ~25 mm/s) |
| Needle Angle | 90° (perpendicular to the largest flat surface of the battery) |
| Penetration Depth | Through center of battery or until fully penetrated |
| Test Environment | Ambient (~20–25°C), sometimes at elevated temperatures (e.g., 50°C) |
| Monitoring Period | Minimum of 1 hour post-penetration (may vary by standard) |
| State of Charge (SOC) | Typically tested at 100% SOC (fully charged) |
| Number of Samples | 3–5 cells/packs per configuration (varies by standard and test plan) |
During and after penetration, batteries are monitored for:
- Rapid temperature rise
- Vent release
- Smoke emission
- Fire / open flame
- Explosion (rupture with force)
- Electrolyte leakage
Standards Followed:
- UN 38.3
- IEC 62133-2
- UL 1642
- UL 2054
Application Areas
- Electric Vehicles (EVs) – Ensures traction battery safety in crash scenarios (e.g., GB/T 31485)
- Consumer Electronics – Smartphones, laptops (IEC 62133, UL 2054)
- Energy Storage Systems (ESS)
- Aerospace and Defence Systems
- Relevant International Standards
The acupuncture test or similar mechanical abuse tests are included in several international safety standards. These standards help ensure consistency in test methodology and define pass/fail criteria:
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