After an exhaustive search I cannot determine the best way to protect 18650s against cell chafing (wear through) in a semi-flexible pack.
As a background I'm planning to build (2) separate 36v 10s1p packs comprised of Sanyo NCR18650GAs to extend the range of my electric skateboard. The packs will go underneath the deck and will be exposed to moderate vibration and mild flex (I'm only 140lbs or 63.5kg).
Equipment I already have:
-3/16" or 0.18mm flat tinned copper braid for interconnects between cells (to promote flex)
-60w soldering iron with many tips/flux pen/60/40 ect.
-95mm rubber-like heavy duty heat shrink wrap tube
-iCharger 1010B+
-10 awg wire and bullet connectors
-JST-HX harness
-additional flat-top paper gaskets
First, I'd like to stay away from the top and bottom cell holders that can be found on ebay because I think they will be too stiff and the connection points may just snap.
A few options I thought of with my limited knowledge of pack building:
1. Prime and epoxy individually...by removing the factory shrink wrap, lightly sanding the tubes and using possibly a self-etching primer + paint or just several coats of epoxy primer to make the negative sides impervious to chafing.
2nd option: Buy 0.85mm fiberglass sheet and make dividers in-between each cell, then lightly hot glue at contact point with understanding the the glue will break after pack installation but will create another barrier. Fish paper electric insulation could also be used.
I know it's my first post here but this site seems to be the most respected place for building packs. I'd gladly post pics prior to wrapping for final safety check. Thank you for your help!
As a background I'm planning to build (2) separate 36v 10s1p packs comprised of Sanyo NCR18650GAs to extend the range of my electric skateboard. The packs will go underneath the deck and will be exposed to moderate vibration and mild flex (I'm only 140lbs or 63.5kg).
Equipment I already have:
-3/16" or 0.18mm flat tinned copper braid for interconnects between cells (to promote flex)
-60w soldering iron with many tips/flux pen/60/40 ect.
-95mm rubber-like heavy duty heat shrink wrap tube
-iCharger 1010B+
-10 awg wire and bullet connectors
-JST-HX harness
-additional flat-top paper gaskets
First, I'd like to stay away from the top and bottom cell holders that can be found on ebay because I think they will be too stiff and the connection points may just snap.
A few options I thought of with my limited knowledge of pack building:
1. Prime and epoxy individually...by removing the factory shrink wrap, lightly sanding the tubes and using possibly a self-etching primer + paint or just several coats of epoxy primer to make the negative sides impervious to chafing.
2nd option: Buy 0.85mm fiberglass sheet and make dividers in-between each cell, then lightly hot glue at contact point with understanding the the glue will break after pack installation but will create another barrier. Fish paper electric insulation could also be used.
I know it's my first post here but this site seems to be the most respected place for building packs. I'd gladly post pics prior to wrapping for final safety check. Thank you for your help!