Battery Testing Standards UL 1642 : 2012

While UL 1642 (Edition 5/6) is the primary standard, it is often integrated into a broader compliance ecosystem. Depending on the target market, it is frequently paired with:

• UN 38.3: For international shipping and transport safety.
• IEC 62133-2: The international counterpart for portable applications.
• UL 2054: The mandatory "next step" for finished battery packs.

This standard is not one-size-fits-all; it covers specific lithium-based chemistries including:

• Lithium-Ion Cells: Rechargeable cells used in laptops, EVs, and smartphones.
• Lithium-Metal Cells: Non-rechargeable (primary) high-energy cells.
• Cell Formats: Cylindrical (18650, 21700), Prismatic (pouch), and Coin/Button cells.

Testing is categorized into four "Abuse Pillars" to ensure the cell does not exhibit catastrophic failure:

1. Electrical: Abnormal charging, forced discharge, and external short circuits.
2. Mechanical: Severe crush, impact, shock, and vibration testing.
3. Environmental: Thermal abuse (oven testing at $130^\circ\text{C}$), temperature cycling, and altitude simulation.
4. Flammability: Projectile tests to ensure no debris escapes during a fire event.

For a UL 1642 report to be commercially valid, testing must be conducted by:

• Nationally Recognized Testing Laboratories (NRTL): Such as UL, Intertek (ETL), or CSA.
• ISO/IEC 17025 Accredited Labs: Ensuring the facility meets international technical competency standards for battery testing.

A standard UL 1642 project generally spans 6 to 10 weeks.

• Weeks 1-2: Documentation review and sample intake.
• Weeks 3-8: Active testing (environmental and cycling tests are time-intensive).
• Weeks 9-10: Data validation and final report issuance.

To ensure statistical validity and cover all test parameters, a high volume of samples is required:

• Rechargeable Cells: Typically 40 to 60 individual cells (in various states of charge).
• Non-rechargeable Cells: Approximately 30 cells.

Note: Samples are destroyed during testing and cannot be returned.

The cost varies based on cell chemistry and laboratory choice. Generally, a full UL 1642 evaluation ranges between $6,000 and $12,000 USD. This excludes annual "Follow-Up Service" (FUS) fees required to maintain the UL mark on the product.

To initiate the process, the following technical file is mandatory:

• Cell Specifications: Dimensions, weight, and nominal voltage/capacity.
• Chemistry Profile: Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS).
• Charging Parameters: Maximum charge/discharge current and voltage limits.
• Internal Construction: Cross-sectional drawings of the cell.