Detailed testing procedure for UL4200A report of button battery
Date：2025-11-05 10:00:04 Classification
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A UL4200A test report for button batteries is a mandatory requirement for products entering the US market, with particular emphasis on child-proof design. Structural safety testing and misuse testing are the core challenges in the process, requiring advance product design optimization.
I. Complete UL4200A Test Report Process
1. Preliminary Preparation Stage (2 Core Actions)
- Technical Document List
- Product Design Drawings (Battery compartment structure and fastener locations must be indicated)
- Battery Specification Sheet (Button lithium batteries with a diameter ≤32mm require special annotation)
- Instruction Manual (Must include a warning template: "WARNING: Swallowing may lead to serious injury or death. Keep away from children.")
- Sample Requirements
- Quantity: 3 complete sets of samples (including packaging and battery compartment accessories)
- Status: Must be assembled with the final mass-production version of the battery compartment; non-mass-production processes such as 3D printing are not allowed.
2. Testing Institution Selection Criteria (Mandatory Qualifications)
- Must possess: ISO 17025 laboratory accreditation + CPSC accreditation (The list of accredited laboratories can be found on the [CPSC official website] (Dezeway CPC No.: 1552))
- Preferred Selection: Organizations that have completed ≥100 UL4200A tests in the past 2 years (e.g., Dezeway Testing CNAS Registration No.: L8083) can shorten the testing cycle.
II. Core Test Items and Methods (2023 Standard)
1. Structural Safety Test (A Veto Item)
| Test Item | Test Method
| Battery Compartment Anti-Opening Test | Use IEC 61032 probe 11 (50mm diameter, 100mm length) to apply a 5N force to insert.
| Fastener Anti-Loss Test | Simulate a child disassembling screws, using a torque wrench to apply a 0.5N·m force.
2. Abuse Test (4 Torture Tests)
1. Drop Test
- Portable Products: Free fall from a height of 1 meter onto a hardboard, 3 times (1 time each on the X/Y/Z axes)
- Handheld Products: 10 drops from a height of 1 meter (including a 45° angle drop scenario)
2. Impact Test
- 2J impact force (equivalent to a 5kg weight dropped from a height of 40cm) is applied to the battery compartment cover. After 3 impacts, the battery remains firm.
3. Crushing Test
- A 330N force (approximately 33kg weight) is applied to the battery compartment through a 100mm×250mm plane for 10 seconds. The battery should not be squeezed out.
4. Installation Secureness Test
- A 20N outward pulling force is applied to a non-replaceable battery (connected by a hook) for 10 seconds. The battery displacement should be ≤1mm.
III. Report Application and Review Process (5-7 working days)
1. Standard Process
1. Application Submission
- Complete the online application form (must include product model, battery specifications, and intended use).
- Submit the BOM simultaneously (highlighting the battery compartment material and fastener model).
2. Laboratory Testing
- First Stage: Structural Inspection → If unsatisfactory, rectification is required before resubmission.
- Second Stage: Full-Item Testing → Issuance of Original Data Report
3. Report Review and Certification
- Engineers review test data for compliance with standards → Issue an English report (including CPSC standard references)
2. Common Failure Points and Solutions
- ❌ Insufficient battery compartment opening force: Add silicone sealing rings or metal clips to ensure opening force ≥ 15N
- ❌ Loose battery after drop test: Adopt an anti-detachment design (add 0.5mm raised ribs to the inner wall of the battery compartment)
- ❌ Unclear label warnings: Use font size ≥ 10, warning icon size ≥ 10mm × 10mm
Latest Compliance Requirements in 2025
1. Mandatory Label Content (Product + Packaging Dual Labeling)
- Product: Must permanently label the battery model (e.g., CR2032) + "KEEP AWAY FROM CHILDREN"
- Packaging: The main display panel must include an anti-swallowing icon (red background with white skull) + Emergency Contact Number (US Poison Control Center: 1-800-222-1222)
2. Transition Period Notice
- As of March 19, 2024, there is no grace period. US Customs will require 100% verification of UL4200A reports. Products without a report will face a fine of $10,000 per batch.
- Amazon and other platforms require that product detail pages must upload the report number starting in 2025; otherwise, they will be forcibly removed from the platform.
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