Lab Companion Liquid-Cooled Temperature & Humidity Test Chamber for EV Battery Packs | Anti-Condensation Patent Design

Driven by the rapid advancement of new energy vehicles and energy storage industries, battery pack performance—including energy density, fast-charging capability, and thermal management reliability—has become a core benchmark for market competitiveness. As the dominant thermal management solution for modern battery packs, liquid cooling systems deliver efficient and uniform heat dissipation. Their tightness, cyclic stability, and environmental adaptability under extreme temperature and humidity conditions directly determine the safety and service life of EV and energy storage battery packs.

Based in China’s Yangtze River Delta, a core industrial cluster for new energy batteries, vehicle manufacturing, and supporting components, Lab Companion develops dedicated liquid-cooled temperature and humidity test chambers for battery pack validation. Equipped with a patented anti-condensation system, our equipment eliminates condensation defects that commonly occur in conventional environmental chambers during low-temperature and high-humidity cycling. It provides stable, accurate, and condensation-free test conditions for R&D verification and mass production reliability testing of battery pack liquid cooling systems.

1. Core Technical Challenges of Battery Pack Liquid Cooling System Testing

1.1 High Environmental Sensitivity of Liquid Cooling Systems

A complete battery liquid cooling system consists of cooling plates, pipelines, water pumps, throttle valves, and cooling fluid media. These components are highly sensitive to alternating temperature and humidity conditions. Under high-temperature and high-humidity environments, the cooling fluid may suffer performance degradation, such as increased conductivity and viscosity deviation. During rapid temperature drop cycles, pipeline connectors and sealing gaskets are prone to micro-deformation due to thermal expansion and contraction, leading to potential micro-leakage risks.

Therefore, standardized temperature and humidity cycling tests are essential to simulate extreme climate conditions worldwide, including high-temperature humid regions and low-temperature dry regions, as well as actual vehicle operating conditions such as fast-charging heat generation and cold-start scenarios, to fully verify the long-term reliability of liquid cooling systems.

1.2 Hidden Risks Caused by Condensation in Conventional Test Chambers

Traditional temperature and humidity chambers inevitably generate condensation on the inner walls and sample surfaces during dynamic temperature and humidity cycling, which causes severe interference and potential hazards for battery liquid cooling system testing:

• Condensation dripping on high-voltage connectors reduces insulation resistance, leading to leakage and short-circuit risks;

• Moisture penetration into pipeline insulation layers damages thermal insulation structure and degrades heat preservation performance;

• Condensation on cooling plate surfaces distorts heat exchange efficiency test data, resulting in inaccurate and unrepresentative test results.

Lab Companion’s patented anti-condensation technology solves this industry pain point systematically through optimized airflow organization, precise humidity control, and upgraded chamber structural design.

2. Lab Companion Patented Anti-Condensation Technology

2.1 Dual Dehumidification & Dry Air Purging System

The chamber adopts a dual-stage dehumidification solution combining mechanical compression dehumidification and molecular sieve rotary dehumidification to adapt to full-range temperature and humidity switching. During the transition from high-temperature humid conditions to low-temperature conditions (e.g., 20℃/95%RH to -40℃), the system automatically activates dry air purging. Preprocessed dry air with a dew point ≤ -40℃ is injected into the chamber to rapidly replace humid internal air, fundamentally preventing vapor saturation and condensation during temperature drop processes.

2.2 Full-Cavity Wall Anti-Condensation Heating Technology

High-precision low-power heating tapes are arranged on high-risk condensation areas, including chamber inner walls, door frames, and observation windows, and linked with the main control system in real time. The system continuously monitors internal temperature, dew point temperature, and humidity. When the wall temperature approaches the dew point threshold, micro constant-temperature heating is automatically triggered with a precise temperature difference control within 2℃. This ensures that the inner wall temperature is always higher than the air dew point, physically eliminating structural condensation.

2.3 Optimized Airflow Structure to Avoid Local Sample Condensation

Different from the direct-blow structure of traditional chambers, Lab Companion adopts a side-wall porous uniform airflow design with adjustable guide baffles, forming a uniform surrounding airflow field. The surface wind speed of battery samples is stably controlled between 0.5 m/s and 1.5 m/s, preventing local overcooling and condensation caused by direct high-speed cold air impact. The dual horizontal and vertical composite air supply mode adapts to battery packs of various sizes and structures.

2.3 Patent Certification & Third-Party Verification

Lab Companion’s anti-condensation technology has obtained national utility model patents and passed authoritative verification by the National Institute of Metrology, China. Under the full working range of -40℃ to 85℃ and 10%~98%RH, continuous 500-hour unattended operation proves that no visible condensation appears on the chamber’s visible area and key sample surfaces, delivering stable and reliable anti-condensation performance.

3. Professional Liquid Cooling Test Configuration & High-Precision Control System

3.1 Integrated Liquid Cooling Circulation Interface for Vehicle-Condition Simulation

The chamber is equipped with standard G1/2 internal thread liquid inlet and outlet interfaces, which can be directly connected to external cooling circulation devices. Closed-loop liquid cooling tests can be realized without chamber modification, highly restoring the actual vehicle thermal management loop. The pipeline adopts corrosion-resistant stainless steel material, with sealing parts supporting a wide temperature range of -60℃ to 200℃, compatible with mainstream ethylene glycol-based cooling fluids. Built-in high-precision flow meters and pressure sensors record real-time flow rate and pressure fluctuation data to ensure full test traceability.

3.2 Three-Parameter Independent Closed-Loop Control

The intelligent multi-loop control system supports independent closed-loop regulation of three core parameters to simulate complex vehicle operating conditions:

• Independent temperature and humidity control of chamber internal air;

• Multi-point temperature monitoring inside battery packs (supporting thermocouple lead access);

• Independent programmable temperature control of cooling fluid inlet and outlet.

It supports synchronous operation of rapid chamber temperature change and constant/following cooling fluid temperature change, accurately reproducing actual vehicle thermal management behaviors such as fast charging heat generation and low-temperature cold start.

3.3 Custom Large Capacity & Comprehensive Safety Protection

To adapt to the large size and heavy weight of power battery packs, Lab Companion provides standard chamber volumes from 1m³ to 10m³ and supports fully non-standard customization. The chamber bottom is reinforced with load-bearing structure and equipped with auxiliary lifting platforms to simplify sample access and improve test efficiency.

The safety configuration fully complies with international battery test specifications. Standard configurations include explosion-proof pressure relief ports and smoke alarm systems; optional automatic nitrogen fire extinguishing devices effectively cope with extreme scenarios such as battery thermal runaway, fully meeting UL and IEC international safety standards to protect personnel and equipment safety.

4. Typical Application Scenarios

4.1 Liquid Cooling Plate Temperature & Humidity Cycling Durability Test

A Chinese new energy core component enterprise verified the tightness and corrosion resistance of battery liquid cooling plates under alternating extreme conditions. The test cycle was set to 12 hours, including 6 hours of high temperature and high humidity (85℃/95%RH) and 6 hours of low-temperature drying (-40℃), with a total of 200 cycles.

Throughout the test, the chamber maintained stable temperature and humidity output. The anti-condensation system was automatically activated during condition switching, leaving no condensation on sample surfaces. Helium leak detection after the test showed no leakage rate change, and no impurities or precipitation appeared in the cooling fluid, fully verifying the durability and stability of the liquid cooling plate.

4.2 Low-Temperature Cold Start Test of Complete Battery Pack Liquid Cooling System

A Chinese vehicle OEM conducted low-temperature start verification for battery pack liquid cooling systems under extreme winter conditions. The test required 8-hour static storage at -30℃ with synchronous low-temperature cooling fluid, followed by rapid temperature rise to detect stalling, abnormal noise, or startup failure of pipelines and water pumps.

Benefiting from independent fluid temperature programming capability, the chamber supports a uniform heating rate of 5℃/min, accurately simulating real low-temperature startup conditions. Zero condensation interference ensures authentic and reliable test results, effectively shortening OEM R&D and verification cycles.

4.3 High-Altitude Low-Pressure & Humidity Coupling Test

For export vehicle project requirements, Lab Companion provides an optional low-pressure module to simulate high-altitude environments up to 4000m (62kPa equivalent air pressure). It achieves accurate humidity control under air pressure ≥20kPa, covering complex coupling test conditions of low pressure, wide temperature variation, and high humidity, meeting global standard verification requirements for exported vehicles.

5. Localized R&D & After-Sales Service in China

Lab Companion maintains an R&D and service center in Shanghai, China, delivering efficient and professional full-cycle technical support and after-sales services for global and domestic customers:

• 2-hour remote response: Professional engineers deliver fast remote diagnosis, parameter commissioning and online fault troubleshooting via video & remote desktop;
• Spare parts & consumables inventory: Full-range spare parts and standard consumables are stocked at our Shanghai warehouse for prompt worldwide shipping upon request;
• Semi-annual remote preventive maintenance: Free remote equipment calibration guidance, system inspection and sealing component maintenance consultation;
• Customized online training: Remote operation training plus full set of SOP documents, supporting customized test procedure compilation via online technical coaching.

• Semi-annual regular inspection: Free on-site equipment calibration, system cleaning, and sealing component inspection to ensure long-term stable operation;

• Professional technical training: On-site operation training and complete SOP documents are provided, supporting customized test procedure formulation.

6. Core Technical Advantages

• Patented Anti-Condensation System: Multi-system linkage control eliminates condensation on chambers and samples under all working conditions, avoiding safety hazards and test data distortion;

• Integrated Liquid Cooling Test Design: Plug-and-play liquid cooling interface realizes vehicle-level loop simulation without external modification;

• Ultra-Wide Environmental Simulation Range: Temperature range: -70℃ to 180℃, humidity range: 10%~98%RH, optional low-pressure module for full-scenario test coverage;

• Full Data Traceability: Real-time recording of temperature, humidity, air pressure, cooling fluid flow, temperature, and pressure data, compliant with IATF 16949 and ISO 17025 certification requirements;

• Multi-Dimensional Safety Redundancy: Complete explosion-proof, early-warning, and fire-extinguishing configurations adapt to high-power battery pack rigorous test scenarios.

Conclusion

Thermal management performance determines the cruising range, safety, and service life of new energy battery packs, serving as a key link in product R&D and quality verification. Lab Companion focuses on the actual test demands of the new energy industry. With patented anti-condensation technology as the core advantage, our integrated liquid-cooled temperature and humidity test chamber realizes collaborative and precise control of environmental simulation and liquid cooling loop operation.

Widely applicable to reliability testing of liquid cooling plates, cooling pipelines, and complete battery pack systems, our equipment delivers condensation-free, high-stability, and high-precision test conditions, helping global customers optimize R&D cycles and improve product market competitiveness. Lab Companion will continue to focus on environmental test technology innovation for the new energy industry, empowering the high-quality development of global green transportation and energy storage industries.