Philaphlous
1 kW
- Joined
- Mar 28, 2017
- Messages
- 431
Like the title says. I'm starting the design process of my 3rd ebike battery. To go into a little history:
[*] The first ebike battery was a super weird shaped battery that hugged the frame tube on my bike. I created individual cell balancing leads and I hot glued every cell together. I used solder wick wire as my cell connector and that has done me well.
[*] My 2nd battery consisted of mostly new cells between panasonic ncr18650 and LG S3 18650 cells.i still have some older laptop cells in the mix and I'm wanting to finally kick those to the curb. I also have a few cheap Chinese cells I've verified have at least 2000mah capacity. The cells are made into a right angle triangle pack and hot glued together.
[*] Finally to the new battery. I'm hoping to replace almost all if not all of the Chinese cells and any other older cell with the Panasonic cells. I can get them for just under $2 a cell right now and that seems to be a decent price. This time around I'm going to be using cell spacers. The 20mm puzzle piece ones that I can create my own design. This will be a 13s 8p 104 cell pack. Bms of course and I'll be using the same solder wick wire for my soldered cell connections. I'll be doubling up the safety by shrink wrapping the cells a 2nd time along with the cardboard tabs at the positive terminals.
2 questions so far.
1) What glue should I use for the cells in the spacers? I'm definitely gluing each spacer together once I have the final design, however do I need to glue each cell into the spacers or no?
2) so I'm going to use solder wick wire for the connections. This is great since it's braided copper and it's 3.5mm wide. I am going to encase the battery in either a plastic or aluminum triangle case. Which material should I use? I feel like the polypropylene will flex better but not hold up as well. And it's non conductive. My other option is aluminum sheet. That will hold up better, look better, but pose a short potential thst I will mitigate and require more tooling. Which should I go with? And more $$$.
I have a design planned out for the cells and their connections. I'll share that later.
I'll also mention that at a later time I'm planning on doubling the battery as a backup battery / power wall. It'll only be around 1kw but it should be enough to run enough devices if there's an outage.
[*] The first ebike battery was a super weird shaped battery that hugged the frame tube on my bike. I created individual cell balancing leads and I hot glued every cell together. I used solder wick wire as my cell connector and that has done me well.
[*] My 2nd battery consisted of mostly new cells between panasonic ncr18650 and LG S3 18650 cells.i still have some older laptop cells in the mix and I'm wanting to finally kick those to the curb. I also have a few cheap Chinese cells I've verified have at least 2000mah capacity. The cells are made into a right angle triangle pack and hot glued together.
[*] Finally to the new battery. I'm hoping to replace almost all if not all of the Chinese cells and any other older cell with the Panasonic cells. I can get them for just under $2 a cell right now and that seems to be a decent price. This time around I'm going to be using cell spacers. The 20mm puzzle piece ones that I can create my own design. This will be a 13s 8p 104 cell pack. Bms of course and I'll be using the same solder wick wire for my soldered cell connections. I'll be doubling up the safety by shrink wrapping the cells a 2nd time along with the cardboard tabs at the positive terminals.
2 questions so far.
1) What glue should I use for the cells in the spacers? I'm definitely gluing each spacer together once I have the final design, however do I need to glue each cell into the spacers or no?
2) so I'm going to use solder wick wire for the connections. This is great since it's braided copper and it's 3.5mm wide. I am going to encase the battery in either a plastic or aluminum triangle case. Which material should I use? I feel like the polypropylene will flex better but not hold up as well. And it's non conductive. My other option is aluminum sheet. That will hold up better, look better, but pose a short potential thst I will mitigate and require more tooling. Which should I go with? And more $$$.
I have a design planned out for the cells and their connections. I'll share that later.
I'll also mention that at a later time I'm planning on doubling the battery as a backup battery / power wall. It'll only be around 1kw but it should be enough to run enough devices if there's an outage.