This white paper, prepared by Sphere Energy and Flexoo, explores the critical role of pressure monitoring systems in enhancing the performance, safety, and longevity of battery cells, particularly for electric vehicles (EVs) and stationary energy storage systems. It outlines how internal pressure variations—caused by material expansion, temperature changes, or cycling behavior—can compromise battery efficiency and safety. The document highlights the importance of real-time pressure mapping to identify non-uniform stress distribution, which can lead to dendrite formation, gas generation, and mechanical degradation.

By combining advanced sensor technology from Flexoo with Sphere Energy’s specialized testing platforms, the white paper presents a robust methodology for pressure characterization across pouch and prismatic cells. Practical insights from testing a commercial 73Ah cell demonstrate the real-world benefits of these systems in detecting swelling, tracking pressure evolution, and selecting optimal compression pads. Ultimately, the work showcases how pressure-sensitive testing and design can accelerate battery development and ensure safer, higher-performance battery systems.

Get the full picture — download our white paper now.