Terminal Protection in Cased Battery

[alferz]

Building this portable waterproof battery from 4xEVE LF150's in a Nanuk T20 case. Everything just barely fits and I'm wondering about terminal protection. Would you protect these terminals? If so how? What is the risk assuming the cover is closed at all times and nothing else is inside the case? Not shown: Some battery packing foam from the supplier cut into squares that make the battery sit snugly inside the case so it won't move at all if the case is dropped, turned upside down, etc.

 

[wpns]

Doesn't look awful, if nothing can move, then nothing can short out.

 

[ScrodusGargleRotten]

I would put kapton tape on them. 2 layers 3 inch

 

[42OhmsPA]

I'd add insulators between each cell.
I'd wrap them in kapton tape to keep them secure and use kapton on the terminals.

 

[42OhmsPA]

I would put kapton tape on them. 2 layers 3 inch

Dang you, beat me to it

 

[ScrodusGargleRotten]

Dang you, beat me to it

I second your idea of insulators between the cells.

 

[alferz]

I'd add insulators between each cell.
I'd wrap them in kapton tape to keep them secure and use kapton on the terminals.

You mean like the yellow fiberglass sheets? If so Docan provided them and you cant see in the photo but they are there between each cell, and all 4 cells are wrapped together with kapton as well. Never thought to use kapton on the terminals so I'll try that, thanks.

 

[740GLE]

What’s the point of that zip tie?

Uneven pressure?

 

[alferz]

What’s the point of that zip tie?

Uneven pressure?

Its a cheap handle. Its one of those 60" HVAC heavy duty zip ties. Just helps get the battery out of the case for maintenance in the future

 

[chrisski]

You may be able to find battery terminal boots at your local shop


I use these in similar projects.

I have used Kapton tape also, but these boots allow access if needed without retaping.

 

[Hedges]

If dropped upside down would the cells be stopped by studs hitting lid?
Hard foam in open area between studs.

 

[alferz]

If dropped upside down would the cells be stopped by studs hitting lid?
Hard foam in open area between studs.

Yeah didn't include them in the pics but i have battery packing foam from the box from china cut into squares that fit snugly on the sides and top so if it turns upside down the cells will stay put.

 

[wpns]

This is a great project, you should have a build thread!

 

[ScrodusGargleRotten]

Im just spit balling here but...

The inside of the main case neg bolt might rub thru the positive line after the breaker if there was prolonged vibration.
Im thinking of 3 years in a car. If this is stationary or on a cart, ignore me.

 

[alferz]

Im just spit balling here but...

The inside of the main case neg bolt might rub thru the positive line after the breaker if there was prolonged vibration.
Im thinking of 3 years in a car. If this is stationary or on a cart, ignore me.

Great point, in this case two of these are going to be semi-permanently sitting on two battery shelves and part of a shed backup system, but I can take them out to provide portable power too. So they won't see a ton of vibration.

 

[DC_Ripple]

If it makes you feel better, cut a rubber sheet to fit:

Amazon.com