DIY Lithium Battery by Jeremy A. Hampton

Author:Jeremy A. Hampton
Language: eng
Format: epub
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Publisher: Jeremy A. Hampton
Published: 2019-04-16T00:00:00+00:00

Soldering Joints

Many people often ask whether it’s possible to solder lithium cells to connect them? While it is possible to solder lithium cells together, and many beginners, as well as experts, do so, it is not recommended.

Soldering will definitely work; however, it is not advisable to solder cells together as it may lead to problems later. Instead, try using other methods of connecting cells that are not only safer but also durable and long lasting.

Grouping cells in a battery

Once you know the necessary voltage, maximum discharge current, and capacity required by your battery, you must choose your cells, after which you may begin to design the layout of your battery.

The method of this choice depends on your usage and the types of cells that you plan to use. For instance, if you plan to use prismatic or pouch cells, you must choose a stacked setup. In this method, you must stack cells in stacks or rows in alternative directions where the positive terminal of one cell must be stacked against the negative terminal of the next cell.

If you plan to use 1p parallel groups i.e. just one cell, then this process becomes extremely simple. You merely need to stack or line up cells in an alternating pattern of anodes and cathodes. Connect them with each other one by one.

If you plan to use more than one cell in parallel, then you need to connect them in parallel groups. Once you have stacked and connected the parallel groups, you can then combine the groups to form a series connection.

The order will depend on the shape of the battery and the kind of connection you desire to create. In some cases, it might be easier to work with parallel connection while in others, it may show no difference. If you want to lay busbars on linear battery cells, it is recommended to lay the busbars all at once. They must obviously be long enough to cover all of them though.

It is difficult to be too creative with prismatic or pouch cells as their shapes are often quite rigid and cannot be packed in different ways. Regular rows or stacks method is best for these two kinds of cells.

Cylindrical cells are much more versatile and offer you more freedom in packing thanks to their layout, form factor and shapes. With cylindrical cells, you can arrange them in almost any way and can build a pack with ease.

In the case of cylindrical cells, there exist two major styles of stacking orientations: offset packing and linear packing. Linear packing is comparatively less efficient than offset packing as it leaves gaps in the center of the battery pack.

Linear packing is commonly seen when snap-together battery holders are used. Most of these blocks are designed in such a way that they can snap together. Some types of molded plastic battery holders use offset packing, however, they are available in less modular varieties and often come in premade sizes only. This allows them lesser freedom as compared to single snap-together.

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