Find Leaks Before They Stop Production

In modern battery manufacturing, maintaining tightness throughout all production steps is a growing challenge. During assembly and welding, even cells that have passed initial leak testing can develop new micro-defects. These very small electrolyte leaks may remain undetected by conventional methods, yet they can affect performance, safety, and service life. 

As production scales up and designs become more compact, the need for precise and fast leak localization has increased across the industry. While end-of-line leak detection systems can identify defective modules or packs, finding the exact source of the leak has often required additional effort and time. 

To close this gap, INFICON developed the BES4000 Electrolyte Sniffer Leak Detector, a solution designed specifically for pinpointing electrolyte leaks in assembled battery modules and packs. 

The system is based on Electrolyte Sniffing, a non-destructive method that detects vapors of electrolyte solvents such as DMC or EMC escaping from leaking cells. With a smallest detectable leak rate of 0.5 g/a (1 ppm) and a response time below one second, BES4000 enables precise pinpointing directly on the production line.

This targeted approach supports fast rework instead of scrapping, reduces material loss, and shortens production cycles. 

BES4000 works seamlessly with the INFICON ELT Vmax Electrolyte Leak Detector. While ELT Vmax identifies if cells fail leak testing, BES4000 pinpoints the exact location of the leak. Together, both systems form a consistent workflow from detection to localization and provide valuable insight into process stability and long-term quality trends.