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Help me design bus bars for these cells
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All right guys uh the end of the day here, but before i go home i wanted to make a quick video. I kind of want ideas from you guys. Here's what's happening. There are a lot of batteries that show up here at this point, and you know i tend to concentrate on the larger lots and then figure out how to use them figure out how to you know how to yeah what ways of finding new uses for them And stuff right, but then i kind of there's, then what happens? Is that all the little lots of batteries uh? You know single pallet kind of thing, just stays there, you know and then, after a while, i'm like yeah, we have like 10 pounds worth of just small lots right, and so this is where i'm at right now i got ta kind of look at some of Those and then like list them on the website and then figure out what to do with them right and um this one in particular.

Let me show you, this is a very interesting and uh might be something that is a you know. A lot of you guys might find interesting. So here's what i am dealing with right now we have about a pallet of these. These are uh.

Well, these are lipos. This is our. You know what the rc world has traditionally used. Look at these 6.2 or 6200 milliamp hours, 50 c, 3.7, all right 22.9, so almost 23 one hours right.

So these are you know just traditional lipo batteries uh. The challenge is here that we haven't really built anything with lipo batteries and we haven't really. I haven't really explored how to build packs with these right um and, of course, oh i'm always thinking of how to help people do this diy these right, because i don't want to get stuck here. Building batteries for people, so i just don't have the time to do it, but if i can teach you and i can help you build better packs for you, then you know you.

I empowered you to do the thing right. So so, what's the problem with these? The problem is that these are 50 c's and at 6.2 milliamp hours. That means that these will fully charge. They'll do 300 amps, and so, when you're building these, if you short these out, it's a it's a bad news, this tab, if you tap this or you short out and connect this tab to this tab right here, 300 amps right.

So so it's very dangerous to make a mistake with these right um, and so i'm like. How do we sell these? How do we make sure that people don't hurt themselves and don't destroy? You know property or whatever, with these uh, and so what i'm doing right now is. Let me show you here sorry about the mess i have a lot of projects going on. Is i'm trying to design some kind of board right, because a lot of these pouch cells are built this way, i'm not i'm not just crazy.

I'm not like a crazy person, that's got crazy ideas. These are you know we get them here and we see them, and so i'm like thinking, oh okay. Maybe this is how we do it. So this is what i've designed so quick.

So you know so far. It's just quick, i just you know, spent 20 min 10 minutes or something designing this thing, and it's just a little board uh, i'm thinking of using these our xt 980 size holes. We can even solder big cables in here, or maybe an xt90 connector in here and another one in here and then that's like the the positive and then this is the negative. So you use the entire uh connector for uh for one cable right.

So only positive. Only negative, not you know the the one connectors will not it's not going to have positive and negative. At the same time, i've seen other people do these with uh pouch cells before and so that's what i'm doing so here there these are holes. You see them right.

There are holes on the board so that you can stick the tabs through bend them over and then solder them right and so uh. This ones right here have extra exposed traces right here so that um, oh, oh apparently i have to go eat now, um, so anyways um, so that you can bend the tabs. So stick both tabs from the bolt cells. Stick it over bend it over cut it right so that it it's in there and then solder into the board there right and then the same thing all the way.

This one will do 7s, because 7s will make 24 volts. But of course i don't know what you guys uh would need these right. I mean probably rc's. Why do you need 50 c cells? I don't know i can't i can think of a million reasons or a million uh projects that want them, but i i can't think of any specific things that you might need on a product like this, so you can build your own pack now.

First of all, with what uh, what configuration would you want? This is 7s just because that makes 24 volts, but you know in rc's they come in every configuration. They come in three uh, 2s, 3s, 4s, 5s, 6s right and then, of course they go all the way to a super high performance. Uh. You know 8s uh.

I think that's as far as i've ever seen. Of course you don't have to you, can keep going. You know 10s. 12S.

14S. 15S. You know if you want to build some crazy battery for some crazy uh thing right. So let me know in the comments what it is that you would want and this board before we finish it and then send it off to be printed uh, and then you know i'll pick, the top.

You know three or something configurations order that you know finish. Building it and then we can order it, and then we can offer it as uh, whatever something already built and also the batteries you know or the the the boards by themselves and even the you know the gerber file, so that you can just you know, order This board and have a printer yourself, and then you build the packs together right so uh this is it i'm just thinking about that. I'm building this and i thought i wonder what my audience and you guys that are building batteries every day would want this thing to be. So.

Let me know in the comments below we'll see you guys in the next one, oh and by the way, those those batteries uh the cells are already on the uh on the website. So if you guys need them, you can go pick them up there. All right. Small batch, so they're, probably not gon na last a long time.

Hopefully we can make this before those things sell out, but i don't think so. They haven't been moving that quick. So it's okay, ah see you guys in the next video.

13 thoughts on “Help me Design a pack using 50C LIPO cells”
  1. Avataaar/Circle Created with python_avatars Alias says:

    The problem with these is connecting the tabs… solder doesn't seem to stick… I'm trying to replace 2 bad cells on my pack… looks like they were spot welded before and I've got amazon bringing me a spot welder today but this morning I'm watching videos about the a123 pouch cell and one tab is copper one is aluminum neg and pos. And apparently spot welding those together doesn't work??? Guess I'll find out today…. might have to find a way to simply clamp them together or I'm thinking of using wire to sort of sow the tabs together??? Any advice??? After note… ended up getting some small binder clips got a whole pack of em for .97 cents… clipped them on and pulled off the metal tabs…

  2. Avataaar/Circle Created with python_avatars Kyu T Lee says:

    The connections on those do not seem to be what I have seen. Ugh!!
    Why are you deleting info comments with links that I am sharing to try and help?
    Guess you really do not want ANY IDEAS!!!

  3. Avataaar/Circle Created with python_avatars Alex says:

    These are what a lot of EV's use. Common designs include metal "L shaped" places between the packs which dissipate heat to the underlying metal container.

  4. Avataaar/Circle Created with python_avatars vic garbutt says:

    These would not be useful for a power wall. they current capacity far exceeds a power wall needs. It would be a waste of lithium. So, it is for hi current applications.

    E-scooters, heating elements, Pumps, Compressors, welders, Drones, spot welders., Boat motor, Winches, stop me if im outa my mind please.

    4P 3S would be a great 12 volt 24.4 Amp HR. battery. Almost any use, except maybe a motorcycle battery, would be FAR under the current capacity of these cells. A 12 volt winch on a boat would be a super end use. A boat motor, or any drone in the larger sizes.

    An 80 volt E-bike battery could have a 24.8 amp/hour pack for around 850$ (plus tax , delivery, duties, etc.). That's pretty sweet, at around 84 cells. There is ZERO issue in terms of current needs. So, current handling is the highest priority, and max 2 cells per board.

    so maybe a few boards might be designed. One for 2P, 3P, and 4P. The thing is, MOST uses wont need 100 amps, but we still need to parallel 4 up to get a 70 KM range on an 80 volt scooter. I would never need 400 amps, but would need the amp-hours for range. So for a scooter, a maximum conceivable current might be 50 amps. At 50 amps that would pull less than 15 amps per cell, making a cool running safe battery pack. So,…. for a e-scooter 80 volt scooter pack, each "S" is 4 cells in parallel. So perhaps each board can hold 2 cells, which can be stacked in parallel, and the board can be joined by XT90's to the next stack of 2 boards. Perhaps there might be 6 standoff buss's, ( 2 more with no connection on the boards at all., or the 5th and 6th standoffs might be used somehow to series the next 2 boards in) the boards probably should be able to handle 50 amps. the copper might be 4.2 mils copper on both sides with through hole rivets to utilize both sides of the copper. Traces should be HUGE to conduct current. Perhaps a PCB with 4 mil copper on each end, and convert the cells from positive and neg on one end, to it being positive on one end and neg on the other end. They could be blades of 1 or 2p. Ever use edge connectors to transfer hi current utilizing all pins?

    OR……. each board could series 2 cells on each board.

    OR a 3D printed "blade" holders for the cells could stand the cells up (as it were) and the PC board(s) would collect the current. By rotating the cell 90 degrees each time to series them.

    OR… positive on one side of the board and negative on the other? one end to solder the tabs and the other end to tap the cell? then use edge connectors? and make a board to hold the edge connectors to slot in the boards?

    a 2 inch wide board with slots in the center, as well as a break in the copper so there is 2 buses running the length, so when the tabs are brought through the back, one folds left and one fold right? perhaps 3d printed insulator/guides attaches to the board to insulate and keep both tabs from shorting on a buss.

  5. Avataaar/Circle Created with python_avatars David Puissegur says:

    I forgot to add that the RC plane batteries do not need an internal protection module. But they will need an external Balance lead for charging. The charging unit takes care of balancing the internal battery packs.

  6. Avataaar/Circle Created with python_avatars Frank Martinez says:

    Solar panels collect power during day which energy sent to grid. The energy is dropped when it’s to much. Solution power walls hold that energy and use as needed. Great idea.

  7. Avataaar/Circle Created with python_avatars Brandon Bennett says:

    This might be exactly what I am looking for. I’m trying to make an electric longboard With a high top speed and a lot of range. But My goal within the project is for it to look like an original longboard. Are these still available? Is it possible to attach a BMS to these cells and charge them safely? I would like to see what a 12 S4P configuration of these cellsWould it look like compared to 18 650s of the same specs.

  8. Avataaar/Circle Created with python_avatars David Bailey says:

    I think adapting those to your old Amazon box build you did a few years back. Maybe you could finally succeed at creating a portable electric gas can for electric cars. So many possibilities.

  9. Avataaar/Circle Created with python_avatars Kevin x says:

    It depends on the voltage, I would be interested in using those as a 12 volt car battery backup booster.

    If you have it set up for 12 volt, however you set it up, series and parallel, there will be many different uses for it, including building it up into a portable solar battery system.

  10. Avataaar/Circle Created with python_avatars Aaron Aaron says:

    I want a LiFePO4 starter battery, but don't know of any BMSs configured for a common 600-900 CCA. I think there is a big market for repurposing small Ah cells for this purpose. Can you imagine, never having to buy another lead acid CCA batter ever again for an ICE vehicle?

  11. Avataaar/Circle Created with python_avatars Schmich says:

    Don't these need way more care than Li-ion? (a real question, not claiming) As I've heard of people only charging these whilst being watched over or doing it in burn-proof case.

  12. Avataaar/Circle Created with python_avatars Sid Jones - Random Stuff says:

    I would look at your smaller batteries with possible everyday applications. For example, tons of people own a Wyze cam, that requires power. If you could create a rechargeable battery system for a Wyze cam that doesn't need to be charged but once a month, I would buy it. I am sure there are other products people use every day that would be similar. Thanks for all you do. 👍😁

  13. Avataaar/Circle Created with python_avatars Byte Logic Systems, Inc says:

    Stackable to 20s and modular enough to mount them parallel as well. Maybe with a couple heavy gauge connector pads for mains and some attachments to run fan off of on board circuit. I'll tell you right now I'm grabbing some for electric motorcycle.

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