Since I'm building a 14s6p pack with 21700 cells (Molicel P45B) that can deliver up to 180 A, I'm trying to find the best solution for welding. On my CNC mill I can cut almost any shape and so I made holes and slots into the copper.
Sandwich welding the slots works good with 0.15 mm copper and 0.15 mm nickel, where 100 joule are necessary to get a strong connection.
But now I try building the busbars the other way. First weld the nickel strips to the copper, then turn it around and weld the nickel directly to the cell. Much less energy is needed, 20 joule or less per point. This should work with thicker copper, too. Another advantage is, you can't miss the pole when welding.
Has anyone experience with building this kind of busbars by themself and the currents they can handle? I had contact with a Chinese producer, but manufacturing and shipping is quite expensive, because of my custom layout, so I'd like to build it by myself.
Sandwich welding the slots works good with 0.15 mm copper and 0.15 mm nickel, where 100 joule are necessary to get a strong connection.
But now I try building the busbars the other way. First weld the nickel strips to the copper, then turn it around and weld the nickel directly to the cell. Much less energy is needed, 20 joule or less per point. This should work with thicker copper, too. Another advantage is, you can't miss the pole when welding.
Has anyone experience with building this kind of busbars by themself and the currents they can handle? I had contact with a Chinese producer, but manufacturing and shipping is quite expensive, because of my custom layout, so I'd like to build it by myself.
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