Whether you’re designing batteries for electric vehicles, industrial systems, or consumer electronics, your goals remain the same: maximize performance, extend lifespan, and ensure safety.

Pressure and Temperature Mapping in real-time.

Achieving those goals requires understanding how pressure and temperature behave throughout the battery lifecycle—from early design to full-scale production. Tekscan’s I-Scan pressure mapping system, also available with temperature sensing capabilities, gives engineers real-time, high-resolution data to improve battery reliability, performance, and manufacturability.

Why Monitor Pressure & Temperature in Battery Systems?

During charge and discharge, internal battery components expand and contract due to thermal and electrochemical changes. This cycling can lead to:

• Mechanical delamination
• Gas formation
• Deformed surfaces
• Capacity fade
• Thermal runaway

Localized pressure and temperature variations—if undetected and not accounted for in the battery fixture design—can compromise performance, shorten lifespan, or lead to failure. Real-time pressure mapping allows engineers to:

• Maintain uniform stack pressure
• Reduce variability during formation
• Identify defects early
• Improve safety and durability

Measuring Battery Pressure in Real Time

I-Scan provide a dynamic view of surface pressure across battery housings, fixtures, and internal components. Unlike pressure-sensitive film, the system delivers repeatable, actionable data in real time.

• Identify high and low pressure zones
• Monitor pressure uniformity
• Track changes over time
• Capture pressure behavior during thermal events

EV Battery Applications for Pressure Mapping

Tekscan solutions support pressure and temperature sensing throughout the development and production of lithium-ion batteries across form factors and industries.

Prismatic Cells

Pressure mapping applications for EV Batteries.

• Monitor swelling to extend cycle life
• Optimize pressure during formation

Module

• Validate consistent stack pressure
• Identify anomalies in assembly

Pack

• Detect pressure and temperature hot spots
• Feed sensor data into battery management system for smart safety control

Lifecycle Testing

Flexible Tekscan Model 7800 matrix sensor wraps around battery components.

The Model 7800 is designed specifically for battery testing. This flexible, thin sensor wraps around the cell and between layers to provide a 360◦ view of battery pressure. The long 90° tab keeps electronics safely outside the housing. It enables long-term, high-resolution data collection across full lifecycle testing protocols.

The sensor supports applications including:

• Multi-month charge/discharge testing
• Correlating pressure and temperature with capacity and impedance
• Detecting deformation, gas formation, and delamination
• Comparing new chemistries or structural designs

Flexible Tekscan Model 7800 and T800 matrix pressure and temperature sensors.

For comprehensive insights, combine pressure and temperature mapping during stress testing. The 7800 pressure sensor and T800 temperature sensor are designed to work together for simultaneous correlated temperature and pressure data.

Stack Pressure Validation

Sensors can be installed between cells or modules during assembly to ensure that the correct initial stack pressure is applied in the fixture.

Quality Control for Manufacturing

• Improve yields during formation process
• Verify specified stack pressure in cell fabrication
• Identify cell manufacturing defects

Battery Management System

• Sensors embedded in assembly to measure pressures during operation
• Safety control to limit battery output if spike pressures detected

Battery Design Pressure Measurement Applications 

Whether you are working on liquid electrolyte lithium-ion batteries, Li-ion chemical alternatives like silicone anode, the newest solid-state compositions, or testing the components of the future, our pressure mapping system analysis helps you test, diagnose, and innovate your battery design in the following ways:

• How Pressure Mapping Insights Improve Battery Performance and Safety - Charging and discharging causes changes in temperature, electrochemistry, or volume expansion. Measuring changes in pressure can tell you how the mechanics of the internal components are affected.
• Improving Lithium-Ion Battery Life and Performance - Find the sweet spot for battery stack pressure in your housing to optimize performance and durability.
• Pressure Testing to Reduce Thermal Runaway Risks - We know how defects can cause dangerous thermal runaway in Lithium-Ion batteries. Testing expansion is critical.
• Measuring Relative Force Feedback from Swelling Within Lithium-Ion Battery Housing  -  Tekscan's ultra-thin embedded sensors can create alerts for pressure changes before they reach hazardous levels.
• Battery Formation - Ensuring uniform pressure during the battery formation process can reduce formation time, and improve efficiency. 
• Battery Monitoring - Embedded system pressure monitoring during the manufacturing stage to identify non-uniformities, uneven surfaces or defects for Quality Assurance. 

Engineers all over the word are using I-Scan to gain insights into their battery design for automotive, consumer electronics, and more.
How can we help you?

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