Flexible Buss Bars

misterpat

New Member
Joined
Mar 11, 2021
Messages
11
Watched a recent video from Will on cells bloated and got me thinking. I'm thinking of using flexible buss bars between cells instead of solid ones. I found some on Ebay, but before buying them, I wanted to get everyone's opinion first. I'm using 280AH cells in the DIY plastic battery cases, so compression is going to be tough to do.

Link to Ebay listing I found.

Thanks all!
 

misterpat

New Member
Joined
Mar 11, 2021
Messages
11
If you do , go diagonal bat to bat. Itll give some flexibility. I'll know this week on the flexables and if I can get them tinned.
Got a picture of what you have for 4$ each? I'm not worried about them being tinned as I still have my jar of nickle plating solution and can plate them at home.
 

Marinepower

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Joined
Apr 24, 2020
Messages
98
Watched a recent video from Will on cells bloated and got me thinking. I'm thinking of using flexible buss bars between cells instead of solid ones. I found some on Ebay, but before buying them, I wanted to get everyone's opinion first. I'm using 280AH cells in the DIY plastic battery cases, so compression is going to be tough to do.

Link to Ebay listing I found.

Thanks all!
I have ordered some of these flexible busbars from Aliexpress (not arrived yet).


Under the heat shrink are layers of thin copper.

Not sure how flexible they are or what the quality will be like. The terminal surfaces look a bit rough in the photos. Anyone using this style of flexible bus bar?

Pyrofx's braided busbars look much better. Would like to know where I could get my hands on some of these....
 

Pyrofx

Flux capacitor builder
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Jul 27, 2020
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Oatman Az
He got back to me. The issue I see is he said they are rated at 70 amps . Even at the 2mm thickness. Up north said his were fine at 150. So I'm leery of bringing them in for others. My system devidesb250 amps between 6 battery sets so I'm not worried.

Thoughts?
 

Tigercjn

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Aug 10, 2021
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4
I don't think it is suitable, It will add a loss and could generate heat, Yes in your system you are going to run 6 sets but it would be better to run 2 groups of 3 sets so you can take 1 group offline for maintenance at any time and still keep working. 250 Amps may be initially higher.
You need to build in some extra redundancy if you want a great setup. I have one of the Aliexpress links in my 4S 100A setup, My table collapsed, broke and they all dropped on the floor and are now bloated around 5mm on each side, luckily they are still seem to be working fine.20211019_182645.jpg
 

Marinepower

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Apr 24, 2020
Messages
98
I have ordered some of these flexible busbars from Aliexpress (not arrived yet).


Under the heat shrink are layers of thin copper.

Not sure how flexible they are or what the quality will be like. The terminal surfaces look a bit rough in the photos. Anyone using this style of flexible bus bar?

Pyrofx's braided busbars look much better. Would like to know where I could get my hands on some of these....


These above linked busbars arrived. Long wait.

The quality and fit appears to be quite good and they are very flexible, able to easily expand and contract 2 - 3mm. Have not load tested them, but they are beefier than the solid busbars that come with the cells - which were fine for my maximum power draws / charging rate.

MP
 

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jamiegreen

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Nov 8, 2021
Messages
43
Any thoughts on using something like 40mm (1 guage) flexible welding cable with lugs crimped on and bent 180• from Terminal to Terminal?

@Marinepower those look pretty good and considering they have them rated for up to 300a, but don't like the look of an estimated delivery date of next year..

I've found that braided copper needs to be either very wide or very thick to meet amp ratings of 200-300a, and maybe just for me but not the easiest stuff to get ahold of. Although I do like the idea of buying a roll of it and pressing the ends into copper pipe.
 

houseofancients

Solar Addict
Joined
Nov 29, 2019
Messages
555
Any thoughts on using something like 40mm (1 guage) flexible welding cable with lugs crimped on and bent 180• from Terminal to Terminal?

@Marinepower those look pretty good and considering they have them rated for up to 300a, but don't like the look of an estimated delivery date of next year..

I've found that braided copper needs to be either very wide or very thick to meet amp ratings of 200-300a, and maybe just for me but not the easiest stuff to get ahold of. Although I do like the idea of buying a roll of it and pressing the ends into copper pipe.
weldibg cable will add double the resistance per connection to a busbar
 

kuranaga

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Joined
Sep 24, 2021
Messages
137
use normal 35 or 50mm^2 cable with lugs. cheapest option.
you can google also for car battery grounding cable, same thing as flexible "busbars". may be bit too long tough
 

kuranaga

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Joined
Sep 24, 2021
Messages
137
I don't think it is suitable, It will add a loss and could generate heat, Yes in your system you are going to run 6 sets but it would be better to run 2 groups of 3 sets so you can take 1 group offline for maintenance at any time and still keep working. 250 Amps may be initially higher.
You need to build in some extra redundancy if you want a great setup. I have one of the Aliexpress links in my 4S 100A setup, My table collapsed, broke and they all dropped on the floor and are now bloated around 5mm on each side, luckily they are still seem to be working fine.View attachment 70346
you have mini studs. they cant make more than 50 amps
 
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