Hi,
I'm planning on building a custom pack for example 4S4P in a long back to back configuration. For example let's assume 18650 is 50mm long. The total length of the battery would be 50mmx4=200mm long.
Here is my thoughts and dilemma.
Best way to do this is cut a long enough sheet of conductive material to laser weld the material to the batteries on one side positive leads and other set negative than fold that sheet and batteries so it lays flat and now it's back to back, repeat etc. cutting for example a 4"x8" sheet would allow all 8 cells to be welded and folded for one connection point between series of cells.
The dilemma, is having that much of a non resistive path (copper) sheet where the sandwich fold occurs between the battery series an issue or should I cut some material out where the sandwich is occuring to minimize the path of electrical flow? Ohms law doesn't necessarily cover surface area. I have to imagine there is a diminishing point of return. I might be over analyzing this as this is a 4" wide path only.
The battery has to be in this long orientation, no exceptions. Material will be copper and laser welding will be utilized. Max current draw per cell will be 15A. Using springs is not an option between cells.
Would like to get some opinions on the best approach to lay batteries in series using welding approach and pathway for flow.
I'm planning on building a custom pack for example 4S4P in a long back to back configuration. For example let's assume 18650 is 50mm long. The total length of the battery would be 50mmx4=200mm long.
Here is my thoughts and dilemma.
Best way to do this is cut a long enough sheet of conductive material to laser weld the material to the batteries on one side positive leads and other set negative than fold that sheet and batteries so it lays flat and now it's back to back, repeat etc. cutting for example a 4"x8" sheet would allow all 8 cells to be welded and folded for one connection point between series of cells.
The dilemma, is having that much of a non resistive path (copper) sheet where the sandwich fold occurs between the battery series an issue or should I cut some material out where the sandwich is occuring to minimize the path of electrical flow? Ohms law doesn't necessarily cover surface area. I have to imagine there is a diminishing point of return. I might be over analyzing this as this is a 4" wide path only.
The battery has to be in this long orientation, no exceptions. Material will be copper and laser welding will be utilized. Max current draw per cell will be 15A. Using springs is not an option between cells.
Would like to get some opinions on the best approach to lay batteries in series using welding approach and pathway for flow.
