How Lithium Batteries Achieve Waterproofing? | Gushine IP68 Waterproof Battery Solutions
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Gushine Electronics

Abstract:
 This article analyzes the hazards of water intrusion in lithium batteries and details Gushine's three proprietary industrial waterproofing technologies—ultrasonic wire welding, dual-potting processes, and seal-gasket hybrid encapsulation. Designed for deep-sea equipment, outdoor energy storage, and harsh environments, our IP67/IP68 certified solutions ensure reliable performance under extreme conditions.

I. Three Critical Hazards of Water Ingress in Lithium Batteries

1.1 Electrical Short-Circuit Risks

Water penetration induces micro-shorts between electrodes. Lab tests show a 38% drop in internal impedance and a 5x increase in self-discharge rates for water-exposed batteries, severely compromising operational stability.


1.2 Metal Corrosion Effects

Humidity accelerates corrosion of current collectors, with aluminum foil corrosion rates reaching 0.15mm/year. Unprotected batteries in 90% humidity environments suffer 60% cycle life degradation.


1.3 Electrolyte Reaction Hazards

Water reacts with LiPF₆ electrolyte to generate HF acid (reaction: LiPF₆ + H₂O → LiF + PF₅ + HF), causing cell swelling (>15% expansion) and thermal runaway risks (T ≥ 150°C).


II. Gushine's Industrial-Grade Waterproof Battery Technologies

2.1 Precision Ultrasonic Wire Welding

  • Applications: Compact devices (radios, PDAs, security gear)

  • Parameters: 20kHz vibration welding, seam strength ≥15N/mm²

  • IP Rating: IP67 (1m depth, 30 mins)

  • Advantages: 0.3mm weld width optimizes sealing and space efficiency


2.2 Dual-Potting Waterproof Process

  • Applications: Underwater robots, deep-sea detectors, tropical equipment

  • Process:

    1. Primary potting: Vacuum-assisted epoxy resin filling (voids <0.05%)

    2. Secondary potting: Pressure-compensated silicone injection

  • Validation: Passes 72hr 50m depth (5bar) simulation


2.3 Seal-Gasket + Adhesive Hybrid Technology

  • Applications: Power batteries, outdoor ESS

  • Components:
    √ Fluorosilicone gasket (compression set <10%)
    √ Dual-layer UV-cured adhesive (bonding strength ≥8MPa)

  • IP Rating: IP68 certified (-40°C to 85°C operation)


III. Gushine Waterproof Battery Validation System

3.1 Air Tightness Testing

  • Helium mass spectrometry (sensitivity: 1×10⁻⁷ mbar·L/s)


3.2 Environmental Simulations

  • Salt spray (5% NaCl, 96hr)

  • Thermal shock (-40°C ↔ 85°C, 50 cycles)

  • High-pressure waterjet (15MPa, 30s)


3.3 Certifications

  • UL1642 / UL2054 / IEC62133 compliance


IV. Industry Applications

  • Marine Exploration: 48V 3000mAh battery for ROVs (72hr @100m depth)

  • Industrial Inspection: IP69K-rated batteries for 80°C steam cleaning

  • Military-Grade ESS: MIL-STD-810G compliant systems


Waterproof Battery Selection Guide

  • IP54: Dust-protected, splash-resistant (smart home appliances, indoor security cameras, fitness equipment, retail POS systems)
  • IP55: Dust-protected, low-pressure water jets (agricultural sensors, wearhouse logistics)
  • IP65: Dust-tight, low-pressure water jets (consumer drones, garden lights, electric scooters)
  • IP66: Dust-tight, high-pressure water jets (industrial inspection drones, therman cameras, marine deck lighting)
  • IP67: Temporary immersion (1m/30min) (consumer electronics, action cameras, medical handheld diagnostics, industrial two way radios
  • IP68: Continuous immersion (depth/time defined) (underwater robots, underwater inspection device)


Gushine offers full-custom solutions from cell selection (LFP/NMC/polymer) to structural design. Our engineering team simulates operational conditions (depth, temperature, vibration) for optimal reliability.

Need a waterproof battery for extreme environments? Contact our engineer team today for a customized solution!
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2023.03.04
How Lithium Batteries Achieve Waterproofing? | Gushine IP68 Waterproof Battery Solutions
This article analyzes the hazards of water intrusion in lithium batteries and details Gushine's three proprietary industrial waterproofing technologies—ultrasonic wire welding, dual-potting processes, and seal-gasket hybrid encapsulation. Designed for deep-sea equipment, outdoor energy storage, and harsh environments, our IP67/IP68 certified solutions ensure reliable performance under extreme conditions.
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