All EV battery packs that I have seen, have bolted connections between battery modules. True, inside the modules the cells are welded to connecting copper foil or bus bars and that copper is typically plated with something (except in some Leaf batteries) but all module to module connections are bolted, no matter if it is Nissan Leaf or Tesla or GM or Hyundai or Kia...
On Fri, May 2, 2025 at 9:27 AM Lee Hart via EV <[email protected]> wrote: > > > And don't solder the braid into the copper pipe. Just wack the sh*t out of > > the pipe > > onto the braid, you want the 2 copper metals to become homogeneous, on > > metal. > > I'm not sure that's a good idea. I rather doubt you can apply enough pressure > to cold-weld the copper with just a hammer. > > I have a Simpson 1699 Micro-ohmmeter. I've used it for years to check the > resistance of my battery connections. Hammer crimps are highly variable, so I > no longer trust them. In the days of lead-acid batteries with their leakage, > any exposed copper is certain to corrode. Soldering (I usually dip them in a > solder pot) was the only way to prevent corrosion. > > Even with today's non-lead-acid batteries, corrosion is still a problem. > Battery terminals are usually a different metal than the terminal you are > connecting to it, promoting corrosion. Condensation and atmospheric pollution > will still corrode the connections; just slower. > > Note that all commercial batteries use welded connections. That's about the > only way to insure reliability. > > -- > Excellence does not require perfection. -- Henry James > But it *does* require attention to detail! -- Lee Hart > -- > Lee A. Hart https://www.sunrise-ev.com > _______________________________________________ > Address messages to [email protected] > No other addresses in TO and CC fields > HELP: http://www.evdl.org/help/ > _______________________________________________ Address messages to [email protected] No other addresses in TO and CC fields HELP: http://www.evdl.org/help/
