Electrically secure connection of battery tabs

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    Battery Connection
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Discussion Overview

The discussion centers on the methods for securely connecting battery tabs of prismatic LiFePo4 pouch cells in a battery pack, particularly in the context of automotive applications. Participants explore various connection techniques, concerns about moisture, and the implications of different materials and methods used in the assembly process.

Discussion Character

  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • One participant is considering using G10/FR4 for isolators and is concerned about whether pressing the isolators together with M8 threaded rods will provide a secure connection over time in an automotive environment.
  • Another participant suggests separating the contacts from moisture and mentions using Vaseline as a DIY method, while also highlighting the need for thermal monitoring and other safety features in electric car batteries.
  • A different participant argues that battery tabs are typically welded to bus bars or zipper fuses, stating that clamping or crimping methods may introduce unacceptable resistance. They caution against placing any material between the battery tabs, recommending only electrical tape or similar materials.
  • The original poster acknowledges the advice against using materials between the tabs and mentions using alcohol for cleaning before pressing them together, while noting that welding is not a feasible option for their setup.
  • Another participant raises concerns about moisture with non-welded contacts and suggests using specialized cleaning products and anti-corrosion sprays instead of Vaseline.

Areas of Agreement / Disagreement

Participants express differing views on the best methods for securing battery tabs, with some advocating for welding and others exploring alternative methods. There is no consensus on the optimal approach, particularly regarding moisture mitigation and the use of specific materials.

Contextual Notes

Participants mention various cleaning methods and materials, but there is uncertainty regarding their effectiveness and safety in the context of high current applications. The discussion reflects a range of assumptions about the conditions and requirements for battery assembly.

Andy Haard
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Hi
I'm working on a way of connecting prismatic LiFePo4 pouch cells into a battery pack.

I'll probably use G10/FR4 for the isolators, as suggested by MQuack in the Mechanical section of this forum, see this animation (the green parts are the FR4 isolators):http://www.youtube.com/watch?v=mh9fptEnvcM The animation only shows a portion of the complete pack that will be made up of 152 pouch cells, 2p76s
My concern though is if pressing the isolators together using 3 M8 threaded rods will create enough pressure to secure the connections between the battery tabs in the long run in an automotive environment...?
Any taughts on that?
 
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I would think you would want to separate the contacts from any source of moisture such as and ambient air. The DIY way of doing this is to gob Vaseline on the contacts.
If you are trying to make an electric car battery, there are other considerations as well (which you may be aware of): thermal monitoring, fusing and service disconnect.
 
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Battery tabs of pouch cells are normally welded together to bus bars or zipper fuses. Any other method such as clamping or some type of crimp has more resistance than what's allowable for most applications. And BTW, the battery tabs are the hottest part of the battery pack due to higher current densities and ohmic losses.

If welding isn't an option (as its very difficult to get right) you may want to try bar clamps onto a bus instead.

And don't ever ever ever put anything in between the battery tabs such a vaseline or what ever else. Thats just a recipe for disaster. The only thing that would be OK is something like electrical tape or a material that's designed for electrical applications.
 
Thanks Topher, I certainly won't put anything between the tabs, other than alcohol to make sure there absolutely clean before pressing them together.
Welding isn't an option, as you say; it's very difficult to get it right and I like the possibility to be able to replace a bad cell without to much difficulty.
fyi, the load will never be more then 150 amps.
I'm also considering using isolators like this:

The pointy sharp screws will press through the battery tabs.
 
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With this many amps going through non-welded contacts you probably should consider doing something to mitigate moisture. Alcohol often contains water. You may be better off cleaning with something like MicroCare Pro-clean. There are products out there that provide a more professional moisture seal than Vaseline such as 3M Scotch 1600 anti-corrosion spray.
 

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