CLAMPED TABS !!!!!!!!! LIPO or LiFepo4

[RIPPERTON]

For LiPo or LiFePo4, better than soldered, allows for replacement of any blown cells.
You will need to cut the tabs shorter so you can fold them toward the partnering cell.
Dont try to fold the crimped part of the cell pouch, just fold the tab.
You can also use a conductivity paste between the tabs and busbars to ensure good current carrying.
As we found out, the best way to extract heat from the cell is via the tab so the busbars will act as heatsink.
Air cooling works and Im going to try a water cooled chill plate in my Rippy Scoot pack.
Ive always made my own clamp bars and busbars in my cnc router. Screws either side of the tabs will curve the busbar so dont make them too thin. Dont make any clamping parts in nylon or acetal, always aluminium.

 

[SlowCo]

You can also use a conductivity paste between the tabs and busbars to ensure good current carrying.

Good info. What brand/type of conductive paste do you recommend?

 

[spinningmagnets]

I think the best benefit of the conductive paste is to prevent oxidation of the tab surfaces over time.

Thanks for posting these pics!

Obviously, this is working. However, I would recommend adding insulation tape onto the bottom of the clamping bar.

I am happy to see more builders using the bus-plates as a cell-cooling element.

 

[RIPPERTON]

This is a carbon based conductivity paste I got from JayCar (Sydney)

 

[RIPPERTON]

These 2 small clamp bars have the external surface painted to avoid any contact with the crimp area.
The step is like a chamfer that I can machine into the part as its being made. Avoids a sharp edge contacting the crimp area.
The large busbar is fluted for cooling.
The narrow busbar on the left is a terminal. The groups of 3 M4 tapped holes are for the braided aluminium flat cables I used on the race bike.

 

[spinningmagnets]

Nicely done!