Which materials are safe to house LiFePO4 battery cells?

phazaar

1 mW
Joined
Aug 10, 2018
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Alright, so I have 8 cells in a housing designed for 10 cells (about 400x300x300mm). The arrangement means there's a 50mm gap between the highest cell and the top of the housing, which makes accessing terminals difficult, and worries me a bit as the top of this needs to be strapped down tight. It would be ideal to fashion two objects the size of the two missing cells to 'fill out' the space, so the cells sit at the top of the housing.

My question is what materials could be used for this? I have excess XPS foam from an insulation project but was wondering if this is a fire hazard. Plenty of wood around, but again, any issues housing LiFePO4 this way?

Beyond that, plastic would be ideal (the housings are plastic themselves), but finding plastic in the right shape is proving really difficult/costly.

Any recommendations greatly appreciated :)
 
ABS plastic is ideal for battery boxing like 6,7,9mm thick
I have built 4 battery boxes with ABS sheets
Aluminium plates on the sides for pouch cell packs.
Two of the boxes for LiFePo
 
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