1. GB 31241-2022 "Safety Technical Specification for Lithium-ion Batteries and Battery Packs for Portable Electronic Products" [Mandatory National Standard | 3C Certification Basis]

   Applicable to: mobile phones, laptops, power banks, Bluetooth earphones, power tools, handheld barcode scanning devices, small portable digital cells & battery packs

    

Battery cell safety testing projects

• External short circuit at room temperature
  SOC: fully charged; External resistance≤ 0.05Ω; continuously observed for 1 hour; Determination: Non-fire, non-explosive, non-liquid leakage
• High-temperature external short circuit
  After standing in a 55°C constant temperature chamber for 4 hours, a short circuit occurs; other conditions are the same as above
• Overcharging
  Charging at 3 times the standard charging current; Three-way system charging up to 4.6V; Lasts up to 7 hours; No explosion or fire
• Forced discharge (reverse charging)
  External power supply reverse forced discharge; Simulates the risk of the battery cell being charged in the reverse direction
• Low pressure (simulates air transport low pressure)
  11.6kPa，6h； Simulates high-altitude transport, with no cracks or leakage
• Temperature cycling
  -40°C~85°C, high and low temperatures for 4 hours each, 10 cycles
• Vibration test
  7Hz~200Hz sine sweep, three-axis vibration
• Acceleration impact
  Peak 150g, 6ms semi-sine wave, impact in six directions
• Free fall
  1.2m high, hard cement surface, six faces fall in sequence
• Squeeze test
  Steel flat extrusion with pressure until the shell deforms or reaches the load corresponding to the cell's weight; No fire or explosion allowed.
• Heavy objects impact
  A 9.1kg steel rod from a height of 61cm is struck vertically against the large surface of the cell
• Thermal abuse (oven baking)
  Heat at 5°C/min to 130°C and hold for 30 minutes

Overvoltage charging protection, overcurrent charging protection, undervoltage discharge protection, overload protection, short-circuit protection, reverse charging, flame retardant testing, washing testing; Verify the reliable operation of BMS protection logic.

Key changes in the old and new versions: GB31241-2022 added requirements for thermal runaway propagation and strengthened pouch lithium polymer testing requirements, which are mandatory 3C testing standards for mobile power banks.

2. GB 38031-2025 "Safety Requirements for Power Batteries Used in Electric Vehicles" [Mandatory National Standard | New Car Announcement Access, Replaces 2020 Edition, Effective 2026-07-01]

Applicable to: power cells, modules, battery packs, and battery systems for new energy passenger vehicles / commercial vehicles.

(1) Cell Cell Testing Items

• Overcharge test
• Overdischarge test
• External short circuit test
• Squeeze test
• Acupuncture test (core mandatory item: no fire or explosion after needling).
• Heavy objects impact
• Heat abuse
• External short circuit after fast charging cycle (added in 2025 version)
  Process: 20% to ↔80% fast charging cycles 300 times → Stand-to-the-loop → External short circuit; Verify the safety baseline after long-term fast charging ages.
   

(2) Battery Pack/System PACK-Level Testing (16 items in total)

• Vibration test (random vibration + fixed frequency vibration, simulating full vehicle road bumps, fixed according to the vehicle's installation method)
• Mechanical impact
• Bottom Impact (Major New Addition)
  Simulating vehicle support and hard objects hitting the battery underside on the road

  ✅ Determination: No electrolyte leakage, no casing cracks, no fire or explosion; After testing, the insulation resistance ≥ 100Ω/V
• Exterior fire burns
• Soak in seawater (soak in 3.5% NaCl solution for 2 hours)
• Temperature cycling
• Humidity-heat circulation
• Water immersion test
• Insulation performance testing
• Overcharge protection
• Overdischarge protection
• External short circuit
• Thermal diffusion test (core vehicle safety)
  Triggering thermal runaway for one of the cells; The new standard requires that the battery system must not catch fire or explode, and a warning signal must be sent to the entire vehicle in advance; high-temperature flue gas must not enter the passenger cabin.
• Drop test
• Squeeze test
• BMS Function Verification (Equalization, High-Voltage Interlock, Contactor Protection)

3. GB 44240-2024 "Safety Requirements for Lithium-ion Batteries and Battery Packs Used in Electrochemical Energy Storage Power Stations" [Mandatory National Standard | Effective August 1, 2025]

Applications: residential energy storage, commercial and industrial energy storage, grid-side energy storage, base station backup power cells, modules, battery clusters. Core focus: suppression of thermal runaway spread, long-term static safety, and cluster-level interlock protection.

Main test items: Cells: overcharge, over-discharge, external short circuit, extrusion, thermal abuse, needle punch; Module/PACK: temperature cycling, vibration, shock, water immersion, damp heat, module thermal diffusion tests, cluster-level thermal spread assessment; Differences from power batteries: energy storage batteries focus on long-term float charging, calendar aging, and risks of uneven multi-series and parallel connections; Needle punch requirements can be waived according to the system's protection plan.

• GB/T 31486-2024 "Electrical Performance Requirements and Test Methods for Power Batteries Used in Electric Vehicles"
  Test contents: appearance, dimensions and weight, room temperature capacity, charge and discharge rate 0.2C/0.5C/1C/2C, -20°C low-temperature discharge, 55°C high-temperature discharge, charge retention capability (self-discharge), capacity recovery, DC internal resistance, energy efficiency, constant power discharge.
  Standard test procedure example (room temperature rated capacity): 25°C constant temperature standing→ standard charging → standing for 1h→1C constant current discharge to cutoff voltage; Repeat 5 times to obtain a stable volume.
   
• GB/T 31484-2015 "Cycle Life Requirements and Test Methods for Power Batteries Used in Electric Vehicles"
  Two major tests: (1) Standard cycle life: charge and discharge cycles at room temperature and fixed SOC windows; Industry universal threshold: 1000 cycles ≥80% initial capacity; (2) Cycle life: simulates vehicle dynamic power load (NEDC/CLTC operating power curve), closer to real vehicle use.
   
• GB/T 31467-2023 "Test Methods for Electrical Performance of Lithium-ion Power Battery Packs and Systems for Electric Vehicles"
  PACK completes the machine's leveled energy, peak power, charge/discharge efficiency, high and low temperature energy output, and operating condition simulation.