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Waterproof case for 4 280ah Eve or Lishen cells

Hugo

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Jan 9, 2021
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Design and execution of a waterproof battery box for 4 280Ah cells, BMS and thermostat and heating pad under the cells are included. Fuse is on top of the perspex cover for easy access. Any comments are welcome.
Now it is waiting for the battery cells.
 

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I have clear tops (10mm Optix Acrylic) so nothing will have any chance of going through that. Could not help it, I want to see inside easily if something goes awry. Polycarbonate & Acrylic has gotten so darn expensive now it's getting nuts TBH.
Is that box a 3D printed box or purchased or ??
Looks really solid and I definitely like the anchoring points at the bottom, very well thought out IMO.
 
Design and execution of a waterproof battery box for 4 280Ah cells, BMS and thermostat and heating pad under the cells are included. Fuse is on top of the perspex cover for easy access. Any comments are welcome.
Now it is waiting for the battery cells.
I have clear tops (10mm Optix Acrylic) so nothing will have any chance of going through that. Could not help it, I want to see inside easily if something goes awry. Polycarbonate & Acrylic has gotten so darn expensive now it's getting nuts TBH.
Is that box a 3D printed box or purchased or ??
Looks really solid and I definitely like the anchoring points at the bottom, very well thought out IMO.
the box is made from Coosa sheets, stitch and glue with epoxy then fibreglassed, taps for the lids are in thickened epoxy bushings
 

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Design and execution of a waterproof battery box for 4 280Ah cells, BMS and thermostat and heating pad under the cells are included. Fuse is on top of the perspex cover for easy access. Any comments are welcome.
Now it is waiting for the battery cells.
What is that made out of?
 
Now it is waiting for the battery cells.
I will do it the other way: put the battery together, then put a frame around it, then consider whether I actually need a box. My reasoning being that if this battery is ever immersed then my boat has sunk and keeping the cells dry for another hour or two is the least of my concerns. Two items that concern me are: 1) being able to tie it down securely and 2) maintaining good air flow around the cells. I have not yet estimated the charge/discharge heat production but I fully expect it to be significant, especially when I get to the point of using the power for propulsion.

That said, beautiful box. Did you fabricate it? If so, how did you make it so pretty?
 
I will do it the other way: put the battery together, then put a frame around it, then consider whether I actually need a box. My reasoning being that if this battery is ever immersed then my boat has sunk and keeping the cells dry for another hour or two is the least of my concerns. Two items that concern me are: 1) being able to tie it down securely and 2) maintaining good air flow around the cells. I have not yet estimated the charge/discharge heat production but I fully expect it to be significant, especially when I get to the point of using the power for propulsion.

That said, beautiful box. Did you fabricate it? If so, how did you make it so pretty?
I need to make to make it waterproof because the batteries are stored on my cat in boxes on deck which can be subject to water, spray and the environment. They are going as a replacement to the AGMs. I am also curious about any heat generation, the BMS is supposed to shut off when too hot, but normally there should be no more than 20 A either way per battery over an extended period of time, so heat generation should be pretty small.
I designed and built the boxes, the same way as parts of the boat.
 
I need to make to make it waterproof because the batteries are stored on my cat in boxes on deck which can be subject to water, spray and the environment.
Ah, that makes perfect sense. And more or less reinforces my plan to frame my own cells, not box them, because they will live below decks.
They are going as a replacement to the AGMs. I am also curious about any heat generation, the BMS is supposed to shut off when too hot, but normally there should be no more than 20 A either way per battery over an extended period of time, so heat generation should be pretty small.
And a quick crawl through a few papers convinced me that high temperature operation does not measurably harm performance, though it does apparently degrade performance faster. Details are no doubt well known on this forum. I'm not going to stay up late worrying about it.
I designed and built the boxes, the same way as parts of the boat.
I would love to hear the long story of how you built the boxes, they look really pro. I thought that if I needed battery boxes I would probably do them in fiberglass, but yours look molded.
 
That looks phenomenal! Do you have any information on the heater you are integrating?
 

Thermo TECH Polyester Heizfolie selbstklebend 12 V/DC, 12 V/AC 36 W Schutzart IPX4 (L x B) 320 mm x 137 mm​

 

TECH Polyester Heizfolie selbstklebend 12 V/DC, 12 V/AC 36 W Schutzart IPX4 (L x B) 320 mm x 137 mm
Sweet! I am thinking that the ideal place for that is between two rows of cells, or if more heat is needed, between each pair of cells.

Don't you hate it when the font metadata gets copied and you can't get rid of it?

Thermo TECH polyester heating film, self-adhesive
 
Getting there, now the cells are missing
 

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Looks really good! I'd love to make something similar for my sailboat.

Did you use fiberglass cloth on the outside, or just epoxy/thickened epoxy?

Awlgrip paint or gelcoat to finish it?

Coosa thickness?
 
Ooh that's nice. I just built wood boxes for my RV build. Great work.
 
Looks really good! I'd love to make something similar for my sailboat.

Did you use fiberglass cloth on the outside, or just epoxy/thickened epoxy?

Awlgrip paint or gelcoat to finish it?

Coosa thickness?
Coosa 6,35 mm, upper rim 20 mm strips, fibreglassed on outside, then painted with 2 pack polyurethane, interior is painted with white epoxy primer
 
Loaded with the cells
 

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