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  1. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    A quick update with a few videos showing the steps to assemble and disassemble a pack with the holder. I think the idea of scaling up and down is working. Next, I'd like to simplify and reduce the parts used, especially on the cells contact, and reduce the overall foot print if possible. Feel...
  2. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    I'm glad that my thing doesn't look cheap. This is my previous battery pack and also the reason that led me to making a holder for my applications.
  3. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Hey thanks for the suggestion Drunkskunk, it really secure all the cells in place. If the cells are bricks, it's like cement added onto bricks. It's a versatile module, I think its quite user friendly as well. If the test result is great, yes, I will sell this as a kit.
  4. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Visually it looks complicated, the idea behind is fairly simple. In short, small cells together make a big cell, fused at positive ends (for safety) as depicted in the picture. But simple doesn't mean easy, it's the precision and the use of right materials that make the idea works. I hope I...
  5. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Superb observation :bigthumb: Yes, I can scale this module in parallel as well. I have ordered some copper/brass bracket for parallel connection, need to finalize the length of the bracket. Beside powering my ebike (36V), I would like to try using this pack (in 24V) to power my tools with a DC...
  6. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Just a visual presentation of a 18650 battery polarity.
  7. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Cool suggestion on the cell divider/spacer. I quickly grab a generic 18650 holder/spacer and did a simple test as in the videos below : https://youtu.be/Wac7ImBHmDA Wac7ImBHmDA Slightly rougher test https://youtu.be/BMTe8kdWYKM BMTe8kdWYKM
  8. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    :thumb: I like the suggestion of hitting the aluminium busbar and checking the voltage with an oscilloscope (yet to get one). I did come across whether to have both ends with springs or just one end. As I didn't use the springs as conductor I'll have to fuse both ends (if both ends are springs...
  9. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Yes, a 10S (36V) will need 3 modules, weight 3 lbs. 1 module is 4S 3 module will be 12S for a 10S there will be 2 empty slots available as reserved space for a BMS. Spot on, it looks very old school, very analog indeed. The good thing is I can easily replace most of the parts, like when I...
  10. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Thanks for reminding on the weight issue. This is the weight of one module (32 cells) - 1.082 lbs (pound) or 491 g (gram) Replacing the fiberglass bottom with carbon fiber will bring down the weight by quite some margin but it will bring up the cost. Now I realized that losing weight can be...
  11. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Video : The making of the fiberglass bracket to lock and extend the module into higher voltage https://youtu.be/QjZbZJz3t28 QjZbZJz3t28
  12. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Fuses are the bottle neck so I fuse the positives end only instead of both ends. Copper nuts are costly compare to brass nuts. I try to make the best possible design and keep the cost low at the same time.
  13. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Yes, in theory close-end nut will have more surface contact compare to hollow nut. But at the same time I found that there are many spot weld bumps on recycle 18650 even after cleaning/scraping. When placing a flat surface on the cell contact, the bumps create a gap in between result in less...
  14. Ufobox

    Ufobox's pressure-contact 18650 fused connections

    Hi all, I'm working on my 18650 battery holder project, I red some relevant issues I face and trying to solve being discussed here. Below are some of the features I built into my battery holder : - Cell Level Fuse (just positive ends). Negative ends are all connected. - Stainless Steel Springs...
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