Announcement - Soon to be released easybuild battery box

SniperGaulois

SniperGaulois

10 kW
Joined
Jan 31, 2008
Messages
797
Location
Rhone-Alpes
Hi guys, I need a name for a battery box design, because i'm not great with words and i need a brand name in order to ask for funding to make lots of easy to use boxes destined for 18650's.

I have 3d printed prototypes which are very robust and run at 1500W, and I even did an ebike concept video for one: https://vimeo.com/225647715

I've stress tested it at 25w per cell for 5 minutes and have tested continuity while hitting it hard like a hammer. it has 100% continuity and can handle high currents, my next test will be to strap it to a jackhammer while running it at 25w per cell.

It could be very easy to make alot of these and it would make home electronics projects a lot easier, so i am going to try to commercialize iso standard solderless battery box. Except that i am not briliant with words and i need help for a rythmic and cool name.

beam portal
buffalo bat box
Zappy batty box
megaloadohm box
voyage voltage box
atomvox voltage box
voracious voltage box
zappy creator box ...
pluggy luggage box
wandering watt box


I'd like to afford a metallurgist to design some stamped clip on fuses for it :wink:

Finding new words is so difficult, and as a buddhist in the hymalayas said once, they have so many meanings, it's good to think of every word in a phrase for a while.
 
Some secret design plans:
f9pp2c.jpg

First dummy load test at 900 watts, also did a test a 1400 watts.
2zhodcl.jpg
 
999zip999 said:
Lighting Box.
Click to expand...
I like sparks and arks very much, when i chech my battery box i often spark the leads together just to show people it's powerful. I dont know if i can get funding for a Lightning Box, i have to reassure people about the non cataclysmic tendencies of the hardware.
 
I have taken videos measurements and i can send them out soon, i sent one to doctor bass:). Battery Vault is cool, and also Beam Vault Box perhaps because vaults with beams are fun. For a sales line i had: "make electricity stuff that a woman may switch out herself easily". although i am not crazy enough to dare say that as maybe a woman may hear it on pmt and i would be targeted.
 
OK. So...Buddha say, "where the frocking pictures, grasshopper?"

:lol:
 
zzoing said:
I was intrigued by the quest for solderless battery boxes in the last years, and i've done a mass of research on the topic to figure out the best methods and integration of many electrical parts into a box.

After some time, I stumbled on a design which has the same performance characteristics as a standard spot welded battery box, which takes 10 minutes to build instead of 4 or 10 hours to build, saves you 150 on a spot welder and 10-20 hours of technical reading
Click to expand...

Yes detailed pictures please. You said you stumbled on a design, not invented it so you should not be shy in providing detailed pics so we can all copy the tech and make it for ourselves :lol: This is mostly a DIY site after all and... sharing is caring.
 
Hey thanks for the encouragement! I've had it for about 6 months, I just needed to film more lab-grade experiments on it than the wirey mess that i filmed at home at first.

It's not very easy to make it at home, I had a dozen attemps on a 3d printer to make a good 4p14s version, and you have to mould some stuff, it's full of tricks that i have learnt from alot of research, i want to send out everything as a crack release soon. It has alot of secrets, they are free to renewable startups but not to multinational companies, I intend to publish a video with 3-4 electrical measurements, 3d design animations very soon, actually doctor bass saw a video where it ran on 25 watts for 5-6 min and then I took the lid off and tonked all the batteries on the floor.

Recently I checked continuity with a buzzer at 2khz on a 1p10s to see if a single of the 10 batteries stopped when i hit it... i need to find microsecond continuity tests with a very clear image of the rail to see if there are any tenths of millisecond changes in voltage... I didnt even fasten the batteries properly and the buzzer made a perfect sound in the first 1 minute i thought... Awesome it totally works :)
 
Just be sure to protect yourself and design. Some have learned hard lessons on "borrowed" designs.
 
Thanks Tomjasz, I am tempted to protect some of the ideas. If i can have the company that makes the best ones i will be happy.

I would love to have some people saying what they think about this kind of technology on a video, if i send them a preview of the full version video, if you can film your reaction to the video saying "bla bla this guy is crazy... or this can be good... or this is amazing we have to have this very soon" and send me the video, I will need some points of view from electricians, i can't pay you though because it would be coercion! you can be a on a beta testing list? please message me if you can film review of the project after seeing experiment videos?

Also I have trouble decide a name, what is suitable name for newish technology? have to define a cool word for people with wind and solar energy and make it a hit thing? Afterwards i want to fund a pc game and i will help all ebikes omg what to do. :)
 
I dont have time to read the theared but Im interested in ordering one of your "boxes". What material will they be made out of? Plastic? How much will it be? Shipping to Germany? Custom designs, yes or no?

-Elias
 
Hi Elias, Thanks for the interest, I will film a more hi fidelity video of the voltage continuity measurement and i will have some videos online by next Wednesday. Indeed it has a tabular, tileable design and it's possible to build at home so you can do any kinds of complex and irregular shapes and battery groupings. Thanks!
 
Hi there, Thanks Nelson37 :eek: by lab grade, i mean professional aesthetics and 0.1mm printing and metalwork precision.

A short answer is that: I intend to subject the box to 10,000 hours of bike attached to a jackhammer(an ATV rollcage ISO test for mtbf) sitting outdoors in the rain to establish MTBF and cause, and to give show you the tests. multiple times. i want a seriously high value battery, not a fast made one. for the moment i have only subjected it to 10 times the lateral force of a bike going downstairs, across the least strong vectors of the battery, as an electrical test. the test of the strengh of the plastic is not so important while i dont have access to a resin printer, trust me it will be very strong. its inherently cheap box but i have to r n d it alot. that's why it makes so much sense to make many of it.

I wanted to do as you say and realized i had the choice of risking the ABS filament prototype before doing the following:

integration of 14bms wires tidily with professional aesthetics
0.1mm precision ibm lab grade resin prototype for extended tests (i.e. similar to production versions)
choice of starting the project for only ebikes or also testing in a quad rollcage and for guitar amps and do a fun good project.
 
Really looking forward for this battery box, whatever name it will have. :mrgreen:

I have many projects going to get in production and I am really interested in ordering one of these if they get released.
 
Thanks, that's very nice i need some help to make me move faster for it.

Regarding price, The price for myself would be 25-50 cents per battery of materials and production costs if i can make a lot of them, prior to shipping and without including a bms.

Eventually it will be more of a group buy philosophy than a "dude who wants money" company, although it will be a company.

I have some strange projects about trying some year 2k style post office boxes in third world villages, as post office boxes have become digital, i want to implant some mini bollards in villages with an integrated wiki and sms/mms as learning and communications stations for eco architecture and organic farming(especially afghanistan :) ), to make far away societies more structured and less demographic if i can make some money. in fact it's only so that indian arid agriculture knowledge can end up going to afghanistan and to send seeds of cool plants around the world, something of that sort.

The idea is to get the batteries into rickshaws because i have been in Delhi traffic, it's heavy. Ideally it will weigh about 7g per battery, an 18650 is 45g, definitely under 12g, after that there is another outer armature for waterproofing if necessary.
 
Do you have something like a date where you want to publish the box? Like "in two month" or some thing?
 
Punx0r said:
This thread seems to completely lack any details about the proposed product?
Click to expand...

Yes sorry Punx0r here are some videos, please note that future contacts will be round, i just made them square because copper isn't easy for me to machine.

...I had some videos here for a while with the test at high power and impact, and some views of the box, but i was only asking for help with a name, it's best if i make a proper presentation video with all graphs and materials to quantify and qualify as clearly as i can.

here is a test where the batteries finished at 40'C, I probably ran them over 26w, and my box only has 1.6mm wires in it. i need 2.3. The box is going to be rated at about 20W peak and 12W continuous.
 
I dont know about you guys but asking a name for a product that is still in draft on the first post is a bit silly.
You have mentioned somewhere plastic molding. Will you have it produces by tens of thousands? Even stamping dies cost a lot not to mention a mold for injected parts.
Sorry, but at this stage it sounds unrealistic to me. I hope i am wrong.
 
hehe, sorry everything is a bit sketchy here, i have no free time. i have to redub the videos and make the triangle battery animation not similar to a tsunami wave.

As regards the practicality of doing this project in large volumes:


  • you save money when you buy the cells
    you save money when you recycle them afterwards
    it's less wasteful
    it's cheaper to ship
    it's faster to make
    you can adjust the groups so that they are balanced
    you can take out any low batteries if you find them
    so the performance should be technically better across a range of uses
    if you need some batteries for another project of for trekking lightly, you can take any serial lines of cells out
    it takes out half of the difficulty out of your green energy project so that you have more time and money to spend upgrading all the other elements of your project.

can you make a list of the disadvantages, that would outweigh the benefits?

It's one of the simplest projects to mass produce. I must clearly illustrate the simple physics of the invention and to get it on the right startup website and so forth. It's a good tool for hobbyists who use electricity, and people with camping cars and boats and bikes and electric guitars, no?
 
Thanks Agniusm. I did 7-8 small 3d printed drafts and a couple of ebike ones.

The trick:
2rxw946.jpg


The "invention" is the use viscoelastic polymers within the box which is the only way in which a battery can be held cozily enough that it is safe enough to avoid internal arcing. I am curious, has anyone used viscoelastic polymers in an evehicle solderless box ever?

I suggested it on the forum last year and I am certain that it is the only practical solution to making a reliable and safe easily built box.

It is because i am studying the problem from that perspective that I am hopeful to mass produce the working design into a variety of formats asap for everyone's benefit.

I am interested if you can tell of your findings regarding oxidization inside the box when it is subjected to shaking and knocking? a little bit of internal arcing can be a good thing because it can ionize some of the natural oxides of the surfaces of the metal, and therefore maintain a good contact.

However, arcing at the kinds of currents that we use in our batteries, is not so great, perhaps it would oxidize and corrode the battery caps if any kind of rigid box was used in a daily scenario.
 
I had to call the Vimeo channel Lightning box. It sounds a bit dangerous to attract funding and also there are various lightning boxes that exist perhaps commerically. viscoelectric perhaps? "cozy forest bat box" is my fave for today. If someone gives me some cool words that i use in the marketing attempt, i will deffo give him a battery box if the marketing works. I like the word Arduino and i want 3-6 syllables which is recogsineyesable.

I could have patented the use of viscoelastic polymers as a kind of spring inside the battery, except that i chose to publicly encourage the idea on this forum without thoroughly checking that it does in fact work amazingly well. Obviously no one else was going to take the advice to make a squishable battery box on the thread so I have printed and tested one. It's best that renewable technologies be free.
 
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