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ELECTRIC VEHICLES (EVs) AND AUTOMOTIVE ELECTRONICS

Leak testing of EV components, batteries, and inverters

Technical guide to leak testing for critical components in electric vehicles, including inverters, lithium batteries, e-axles, and fuel cell systems. Find information on leak rates, testing methods using air or helium, and recommended equipment for each industrial application.

SPECIALIZED TECHNICAL GUIDE

Selection of leak tests for EV components

Automotive electrical and electronic systems require more stringent leak-tightness standards than traditional components. This guide allows you to quickly identify the appropriate test method (air or helium), the acceptable leak rate, and the ideal equipment based on the type of component, ranging from electronic housings to batteries and hydrogen systems.

Component / Application Reference leak (Criteria) Recommended Method Recommended Equipment
Inverter leak test
Technical Description Converts DC power to AC power in electric vehicles. Its airtight seal is critical for protecting electronic components from moisture and contamination.
0.5 mL/min Air / Helium LS-R902EV / LDS3000
Inverter housing leak test
Technical Description Enclosure that protects the inverter from dust, moisture, and external elements.
0.3 mL/min Air / Helium LS-R902EV / LDS3000
Converter leak test
Technical Description A device that regulates and converts voltage levels in automotive electrical systems.
0.3 mL/min Air LS-R902EV
Converter housing leak test
Technical Description It protects the converter's internal circuits, preventing contamination and electrical failures.
0.4 mL/min Air / Helium LS-R902EV / LDS3000
Converter housing​ Micro-leak test
Technical Description High-precision application for detecting microleaks in sealed electronic systems.
2.5×10-5 Pa・m³/s Helium LDS3000
Separator leak test
Technical Description A component that separates fluids or gases in electrical or thermal systems.
1 mL/min Air / Helium LS-R902 / LDS3000AQ
Base plate leak test
Technical Description A structural plate that supports electronic or mechanical components and requires proper sealing.
1.5×10-2 Pa・m³/s Air / Helium LS-R902EV / LDS3000
Lithium battery leak test
Technical Description EV batteries require a completely airtight seal to prevent moisture from entering and to avoid safety risks.
1.0×10-5 Pa・m³/s Helium LDS3000
Lithium battery lid leak test
Technical Description It protects the battery from external contaminants and ensures the system remains sealed.
0.5 mL/min Air LS-R902EV
E-axle (water channel) leak test
Technical Description Cooling channels that require testing to prevent refrigerant leaks.
5 mL/min Air LS-R902EV
E-axle (complete unit) leak test
Technical Description An integrated system that combines the motor, transmission, and electronics in electric vehicles.
1 mL/min Air / Helium LS-R902EV / LDS3000AQ
EV Battery leak test (Assembly)
Technical Description Complete battery assembly requiring leak testing during production.
30 mL/min Air LS-R902EV
EV motor (assembly) leak test
Technical Description Complete electric motor that requires sealing for thermal and electrical protection.
12 mL/min Air LS-R902EV
EV motor housing leak test
Technical Description A housing that protects the motor from external environmental conditions.
34 mL/min Air LS-R902EV
EV Engine (water channel) leak test
Technical Description Engine cooling channels that must be kept free of leaks.
5 mL/min Air LS-R902EV
Fuel cell battery cover leak test
Technical Description Leak test for fuel cell battery cover
6.0×10-4 Pa・m³/s Helium LDS3000
Fuell cell components leak test
Technical Description Components that use hydrogen and require maximum airtightness for safety reasons.
5.0×10-2 Pa・m³/s Helium LDS3000AQ

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