New weldless battery system crowdfunfing project

Batteries, Chargers, and Battery Management Systems.
john61ct   100 kW

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Re: New weldless battery system crowdfunfing project

Post by john61ct » May 31 2019 9:29am

Yes obviously it **can** be done, just a question of time, effort and funds available.

Good such systems are inevitable as the market matures.


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liveforphysics   100 GW

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Re: New weldless battery system crowdfunfing project

Post by liveforphysics » May 31 2019 5:50pm

Polycarbonates + humidity + voltage stress = crazing (surface cracks), then crumbling.

Sometimes even good base plastic materials (polypropylene, Polyethylene can use a filler/dye that absorbs humidity and corrodes apart under voltage stress.

Test to validate whatever material you're going to use.
Each carcinogen vapor exposure includes a dice roll for cancer.

Each mutagen vapor exposure includes a dice roll for reproductive genetic defects in your children.

Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

Every post is a free gift to the collective of minds composing the living bleeding edge of LEV development on our spaceship.

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Matador   10 kW

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Re: New weldless battery system crowdfunfing project

Post by Matador » Jun 03 2019 11:27pm

The springs I used a springsteel (tried the biggest spring gauge I could test). They litterally cooked at 4 amps per springs....
But springsteel has very high resistance... And will glow red hot and loose their recoil.

Berillium copper, well 38% IACS is certainly very impressive. I see hopes in this!
Does it spring back without deforming (even if it heats up ?).

You'd need something like that. Copper contact surface with knobbling would be good too:
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Reference for curious people: https://endless-sphere.com/forums/viewt ... 5#p1277444


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Matador   10 kW

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Re: New weldless battery system crowdfunfing project

Post by Matador » Jun 03 2019 11:35pm

And I mean knobbling on the surface like on this picture:
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agniusm   10 MW

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Re: New weldless battery system crowdfunfing project

Post by agniusm » Jun 06 2019 6:26am

flippy wrote:
Mar 06 2019 3:13pm
vruzend is a flawed concept with no regard for safety. that is simply the end of the story.

anything less then spotwelding is a compromise in safety and reliabliity.
I agree that vruzend is bad design and 2 majotlr flaws i outlined to them which they dismissed.
Saying that anything less than spotwelding is compromise in safety is a load of BS.
Spotwelding is least you can do. I have dismantled X2 batteries, the segway, and they are professiinally welded, glued but failed with corosion to spotwelds.
I have sold thousands of my solderless modules and in 2 years heard notging but good. In those 2 years i have seen many failed spotwelded packs.
Just saying, if some designs might look as disaster, others just might be better ;)

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flippy   100 kW

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Re: New weldless battery system crowdfunfing project

Post by flippy » Jun 06 2019 8:09am

your packs are not friction fit wich is a plus compared to vruzend, but is also suseptible to corrosion, even worse then welding.

and many people that fix or build batteries onyl see the busted ones, otherwise they would not go to a battery supplier.
Lithium beats liquid dinosaurs.

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agniusm   10 MW

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Re: New weldless battery system crowdfunfing project

Post by agniusm » Jun 06 2019 11:59am

flippy wrote:
Jun 06 2019 8:09am
your packs are not friction fit wich is a plus compared to vruzend, but is also suseptible to corrosion, even worse then welding.

and many people that fix or build batteries onyl see the busted ones, otherwise they would not go to a battery supplier.
Yes, not friction, compression. Regarding corrosion. I have left one module outside exposed to elements for a year including winter with temps of sub0 and snow. Only thing corroded was bolts i have left in it which were those high tensile, black ones.
I had nissan leaf pack which has tin plated copper bus bars from 2013 car and they looked brand new. Sure it probably was hermetically sealed but all electrical connections in power transformers, if not aluminium, tin plated copper. Also look at the tube ring lugs, same, tin plated copper, holding pretty good everywhere.
For the power packs i dont see spotwelding as an option. If you look at conductivity of nickel, it is 1/5 of copper. I have 0.6mm copper busses when most weld 0.15mm nickel. When you start layering nickel, it starts becoming a mess and reliability goes down. You are sceptical cause you have not tried it. Its too simple to go wrong :)

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BlueSwordM   100 mW

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Re: New weldless battery system crowdfunfing project

Post by BlueSwordM » Jun 13 2019 9:38pm

Wait, why would AG's design be prone to corrosion?

I mean, nickel-zinc/tin plated copper has excellent resistance to corrosion.
As he mentioned, only the steel bolts have been corroded, and that could be fixed with a zinc, then nickel, plating.

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agniusm   10 MW

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Re: New weldless battery system crowdfunfing project

Post by agniusm » Jun 14 2019 4:50am

BlueSwordM wrote:
Jun 13 2019 9:38pm
Wait, why would AG's design be prone to corrosion?

I mean, nickel-zinc/tin plated copper has excellent resistance to corrosion.
As he mentioned, only the steel bolts have been corroded, and that could be fixed with a zinc, then nickel, plating.
Thanks, exactly. Actually i address that with high quality stainless steel bolts from Japan and plastic screws and nuts from Germany. There is no issues regarding corrosion of what i sold and selling whatsoever. There is no current transferred trough fixings which would be bad idea so stainless works good

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BlueSwordM   100 mW

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Re: New weldless battery system crowdfunfing project

Post by BlueSwordM » Jun 14 2019 10:00am

Or if you are fancy, Titanium parts for the bolts and screws :)

Absolute overkill. :)

I'd like to add that I'm working on my 3rd Gen battery spring design.

Since I couldn't change the material to BeCu C17500 45% IACS because of its poor mechanical properties, or use the prototype material BeCu C17550 60% IACS as it would be wayyyy too expensive, I decided to look at multi layer electroplating. :D

I'll write more about it later.

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