The valve is placed in a sealed chamber where internal pressure is gradually increased using compressed air or inert gases. Testers monitor:

• The pressure at which the valve activates (opening pressure)
• The flow rate of gas release

This ensures the valve triggers within the specified threshold (e.g., 0.5–2 bar for lithium-ion batteries) and releases gas quickly enough to prevent pressure buildup.

Post-release, the valve must reseal (if reusable) to maintain airtightness, tested by vacuum pressure decay methods.

A flame source is applied to the valve's external surface while it's under pressure. The valve must:

• Prevent flames from propagating into the battery chamber
• Quench sparks using mesh screens or porous materials

This is typically verified using a flame arrestor test rig, with no ignition of internal gases allowed during or after the test.

Valves are subjected to extreme conditions:

• Temperature ranges (-40°C to 125°C)
• Thermal cycling tests
• Humidity and vibration exposure

These tests evaluate the valve's pressure sensitivity, material integrity, and resistance to corrosion/mechanical stress in real-world conditions.

Comprehensive leak detection methods:

• Helium mass spectrometry or bubble leak tests for micro-leaks
• Pre-activation airtightness verification
• Post-activation checks for debris ingress (disposable) or resealing (reusable)

Ensures prevention of electrolyte spillage and maintains battery integrity.

Long-term reliability assessment:

• 10,000+ pressure cycles to simulate usage
• Evaluation of moving parts (springs, diaphragms)
• Consistency of activation pressure over time

For electric vehicle batteries, high-cycle testing mimics frequent charging/discharging stress.

Tests must align with industry regulations:

• UL 1973 (battery safety)
• ISO 16750 (automotive)
• IEC 62133

Third-party certifications validate that valves meet explosion-proof requirements, including prevention of external ignition or casing rupture during thermal runaway.