Series Connection Between Battery Packs (Copper Vs. Nickel)

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papabear
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Series Connection Between Battery Packs (Copper Vs. Nickel)

I am working on a project and I now have to connect 150 Amp battery packs in series. The previous person working on this used Nickel. I am more inclined to use Copper. Does anyone know the advantages and disadvantages of either one. Also I wanted to make a type of busbar connection between the packs but I do not know how large the material connection needs to be (thickness, contact area, width).

The total battery connection in series is 75 Volts and each pack is 3.5 Volts.

Any advice is greatly appreciated.

sangesf
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

Copper is about 400% more conductive that nickel.
If you can get copper plated with silver you get about 10% more conductivity.
The more surface area you make contact with the better.
Thickness and width on such short connections is not really an issue. (although, I wouldn't use something that's thin enough that you can bend easily)
The only drawback I can see on using copper over is nickel IS the conductivity.
(on my Silver Plated Copper buss bars, I wrap them in thick electrical tape on the exposed areas to stop any kind of arcing associated with a metal that could short across them)
150ah batts that get shorted can release a gianormous amount of amps! Be VERY careful!

I'm not a metallurgist, but that's the basic premise from what I've been told over the years.
If anyone else has a more complete understanding of metals, please feel free to add or change anything I've said.

papabear
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

Thank you very much..
That makes a lot of sense now..
One more question..
Which of the two (nickel or copper) is more corrosive? Around a 5 year lifespan.

sangesf
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

About the same...
They are both quite corrosive resistant, one or the other is good..
The difference between them is what chemicals can corrode them, (as an example, copper has better protection against sulfuric acid then nickel does, but nickel has better protection against Hydrochloric acid, then copper does)
In the ebike world, none of the normal conditions (atmosphere, moisture, temperature, etc) will have any noticeable effect on them in the long term..
FYI, some copper alloys have been known to still look pristine, even after 1000's of years.

papabear
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

Great!
Thanks for all your help! The replies have been really useful. I hope to learn a lot more and be able to answer questions in the future.

Don Harmon
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

I am involved in designing the bus connector plates right now for our new P20 Battery Modules. What I have settled on after a great deal of research is Copper 2mm thick and tinned - also with a shrink wrapped band in between the two terminal holes to insulate from short circuiting like one of the posters suggested. Note these are Cell to Cell connectors. With connecting multiple packs of your voltage I would think Andersen Connectors rather than a bus bsr?

See Picture attached:

link-solid-type.jpg

Don Harmon
LiFeBATT, Inc.
www.lifebatt.com

7circle
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

I am working on a project and I now have to connect 150 Amp battery packs in series. The previous person working on this used Nickel. I am more inclined to use Copper. Does anyone know the advantages and disadvantages of either one. Also I wanted to make a type of busbar connection between the packs but I do not know how large the material connection needs to be (thickness, contact area, width).

The total battery connection in series is 75 Volts and each pack is 3.5 Volts.

Any advice is greatly appreciated.

What type of Battery Chemistry. (oops 3.5V sounds like Lithium most likely LiIronPOOOO )

The Venting of Lead-Acid batteries causes many issues, even if they are sealed batteries some can still vent.
Li_Ion and LiIronPOOOO are nicer again.

No one mentioned Gold (Au) plating.

Also what are the terminals on the batteries. Lead Batteries are usually a lead alloy.

If you showed a photo of the battery it would speak millions of words.

The links are metal and the expand with heat and contract with cooling.
And the Batteries move them selves, due to vibration and the plastic thermal expansion.
So a flexible coupling may be needed.

Some people use aluminium but the oxide layer is a problem and needs to be broken by star washers then sealed.

The copper braid links with copper foil crimps and soldered terminals are good too.

So I'd suggest 3 layers of copper foil with a "s" kink to allow flex and a tin or "pimped" with gold plating.
You can have the fun of plating them your self if you want to sacrifice some of your own gold.

Lots of options.

Depends on if the project is for.

If you where learning you could use different 19 options between the 20 batteries and see how they look and perform after a while.

papabear
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

Thanks for all your help.
I am getting a better idea of how to do this now.
Here is a photo of the battery that I am using.

battery.jpg

papabear
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

Hi,
I'll give those options a try. I also thought that maybe copper or nickel plated aluminum or steel might work. Has anyone tried this?
Thanks!

sandman12
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Re: Series Connection Between Battery Packs (Copper Vs. Nickel)

definitely copper

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