INDUSTRIES & APPLICATIONS

Electric Vehicles Industry – Moisture

The Role of Moisture Analysis in the EV Industry

Moisture control is one of the most critical factors in the EV industry, particularly in lithium-ion battery manufacturing. Even trace amounts of moisture can compromise battery safety, reduce performance, and shorten lifespan, making moisture analysis essential at every stage of battery production. AMETEK Brookfield’s Computrac analyzers provide precise control over moisture levels in key battery materials—such as electrodes, electrolytes, and separators—ensuring safe and reliable battery operation, enhanced manufacturing processes, and environmental resilience.

Safety and Prevention of Thermal Runaway: Excess moisture in lithium-ion batteries can lead to gas formation and swelling, which increases the risk of thermal runaway—a dangerous condition where the battery overheats and can catch fire. Brookfield’s Computrac analyzers help manufacturers monitor moisture so they can maintain strict control over moisture levels during production, ensuring that batteries are free from water contamination. This helps reduce the risk of battery failure, improving safety for consumers.

Preventing Gas Formation and Cell Swelling: Moisture contamination can cause side reactions that produce gases within the battery cell, leading to swelling, leakage, or even rupture. Brookfield’s Computrac analyzers provide the precision measurement needed to prevent these issues, ensuring the structural integrity and reliability of the battery.

Improving Battery Reliability and Longevity: Controlling moisture content in EV batteries also enhances their long-term performance and reliability. Moisture can react with lithium-based materials to form harmful compounds, such as lithium hydroxide or lithium carbonate, which degrades battery capacity and reduces its cycle life. By ensuring that moisture levels are kept at safe levels during production, Brookfield’s Computrac analyzers help extend the operational lifespan of batteries, allowing EVs to maintain performance over many years of use.

Enhanced Cycle Life: With proper moisture control, lithium-ion batteries can retain their capacity and cycle life over extended use, providing longer driving ranges and reducing the need for battery replacements, which enhances the overall reliability of the EV.

Moisture in Solid-State Batteries: As the EV industry explores next-generation battery technologies such as solid-state batteries, moisture control remains critical. Solid-state electrolytes are highly sensitive to moisture, and contamination can degrade their ionic conductivity, compromising battery performance. By using Brookfield’s Computrac analyzers customers ensure that solid-state battery materials are processed in controlled environments to prevent moisture-related degradation.

Ensuring High Energy Density and Safety: By maintaining strict moisture control, Brookfield’s analyzers help improve the energy density, safety, and longevity of solid-state batteries, which are seen as a future replacement for conventional lithium-ion technology due to their higher energy efficiency and lower fire risk.

Enhancing the Manufacturing Process with Quality Control and Cost Efficiency

Improving Manufacturing Quality and Reducing Defects: Moisture analysis plays a critical role in ensuring quality control throughout the EV manufacturing process. Maintaining optimal moisture levels in battery components, adhesives, and thermal management materials helps reduce defects, improve product uniformity, and increase overall production efficiency.

Reducing Production Waste: By helping customers prevent moisture-related defects, Brookfield’s Computrac helps manufacturers minimize waste caused by out-of-spec components, reducing the need for rework or scrap materials. This leads to greater production efficiency and cost savings, ensuring that more units meet the required specifications on the first pass.
Ensuring Adhesive and Sealant Reliability: Moisture content also affects the performance of adhesives and sealants used in the assembly of EV battery packs and enclosures. Excess moisture can weaken bonds and cause corrosion, while improper curing due to moisture imbalances can affect long-term durability. Brookfield’s Computrac analyzers help ensure the adhesives and sealants maintain optimal performance, enhancing structural integrity and long-term reliability.

Sealing and Protecting EV Components: Proper moisture control in adhesives and sealants ensures that EV batteries and power electronics are effectively sealed, protecting them from environmental factors such as humidity and water exposure, which is critical for both safety and performance.

Ensuring Environmental Resilience with Climate Adaptability and Longevity

Supporting Environmental Resilience and Climate Adaptability: Moisture analysis is essential for ensuring that EV components—particularly batteries—are resilient to environmental conditions such as humidity, temperature fluctuations, and exposure to moisture. Brookfield’s Computrac analyzers help manufacturers design EV batteries and materials that are climate-adaptive, enabling them to withstand challenging environmental conditions while maintaining safety and performance.

Adapting to Climate Extremes: Electric vehicles are exposed to a wide range of environmental conditions, from freezing cold to extreme heat and humidity. By monitoring and controlling moisture content during production, Brookfield’s analyzers help ensure that batteries and other components perform reliably in diverse climates, reducing the risk of degradation or failure due to moisture-related issues.
Longevity and Durability of EV Components: Ensuring proper moisture control during manufacturing contributes to the longevity of electric vehicle batteries and components. Brookfield’s Computrac analyzers help manufacturers produce batteries that are not only efficient but also durable enough to withstand years of use, even in challenging environmental conditions. This reduces the need for premature replacements, minimizing the environmental impact of battery disposal and resource consumption.

Extended Battery Life and Reduced Environmental Impact: By enhancing the durability and performance of batteries through moisture control, EV manufacturers can extend the life of their products, reducing the environmental footprint associated with the production and disposal of batteries. This contributes to the sustainability of the electric vehicle industry, supporting a greener future.