LiPo Pack Compression and Other Assembly Questions...

Frank

100 W
Joined
Dec 10, 2007
Messages
287
Location
Maine/Nova Scotia
I'm getting stuff together to construct my first LiPo pack for a bicycle. It'll be a 12S6P pack made up of 6S bricks paralleled together then joined for 18Ah total capacity. What is the recommended way to hold the cells together? Is compression required or recommended? I have some hard plastic I was going to use to provide some puncture resistance, does this seem acceptable? Suggestions, comments, etc. welcomed. :)

thanks,
Frank
 
Fiberglass filament tape, and hard plastic on the edges and corners. I put a layer of gorilla tape around the whole assembled Pack(s) for external protection.
 
I think Lipo cells also need compression, I did have a few bare new cells sitting on the bench withouth compresion at 3,85v and after a few weeks they were all swollen up.

As for A123 cells, I have seen some DIY packs that were leaking on the edges and that seems to happen because of the bare cells touching eachother without a layer of tape in between.

I have repaired lipo packs before with a layer of tape between them and they also failed after a while, I know think that is because the cells touch each other.

Maybe someone can confirm this ?
 
'reworked a few bricks and other than filament tape over clear packing wrap I haven't done much in the way of compression. I do have a few spare/test Turnigy 20C cells 2 years old scavenged from bricks that have nothing wrapped around them and they still perform well. IMO puffing has more to do with impurities and SOC rather than compression.

Compression may help if they suffer from impurity problems but good cells don't seem to care based on what I've experienced.

Some form of puncture/abrasion protection is a good idea. I use thin Masonite or sometimes floor covering materials to give 'em a thicker skin. Always wrap 1st with clear plastic shipping wrap before applying any tape to make it easier to disassemble should they require rework/surgery.
 
Compression much beyond what you get from the shrink wrap may not be needed. My gut feeling is a pack that really puffs right away belongs in the trash, and compressing it is not as good a solution as replacing it so you have a nice set of packs that all are free of defects.

But, it's quite possible that compressing the pack now would help with preventing the slight puffing that is typical as an RC lipo pack ages. It took a year of fairly hard use for mine to start doing that. At some point though, if enough gas is being made inside that cell, it's going to either swell, or pop the pouch. I think I read somewhere, that compressing the cell might help lower the IR of the cell for high amp applications like a drag race. I doubt it's really required to do it for a bike. My own opinion is a pack that really wants to swell more than the others is to be weeded out of the string.

I totally support the idea of adding more protection that you get from just the stock shrink wrap. On my dirt bike for example, I have a very tight fitting aluminum box that does keep the packs compressed to some extent. But in this case, removing the packs to charge, I need some tape on the packs to prevent chafing the shrink wrap on the box. In particular, thourougly tape up the bottoms of packs that have naked pouch exposed on the bottom.

The other way I use my lipo is on a variety of bikes that just have a bag or a toolbox mounted. In that case, I take old coroplast political signs and cut them into very tight fitting boxes to protect the pack. Again, I suppose I do get some compression, but the real aim is to give the packs a chance if I crash the bike, and protect against any movement that may happen inside the bag as I ride.
 
Tight compression is not necessary, but a firm pack build is. Cells charged over time just sitting on a shelf will eventually swell due to the lithium barrier build up in any voids in the cell between plates. (the lithium does not transfer, it stops in any void) A normal, firm pack confinement will help eliminate the voids.

Cells are shipped half charged, they will sit in that state best, never fully charge and let them set....

The MAJOR cause of barrier build up and swelling is overcharging. Followed by,to a lesser extent, low cell voltage from over drawing the cell.

Charge to 85% of the cell's capacity and never draw down past 3.0volts per cell (standing), your pack will last years.

miz
 
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