Yeah, the best way to do it, is stack many thin layers of copper with a bent relief in the center. Stack as many as you need to achieve the current. It's a bad idea to use solid, as even 1/16" copper is really stiff and will impart significant load on the terminals. Even if your cells are mounted solid and don't move, the CTE of the copper is enough to create stress on the terminals and shear forces on your bolted joint which can cause it to carry less current over time, especially in an automotive environment. I don't like the braided type because they allow too much oxygen into the joint and carry less current overall.
If you look at the OEM EV makers, you will see they often use bus-bars constructed as a foil stack, sort of like what is shown here: (no affiliation) https://www.copperjumper.com/ That same applies to contactors and other bolted joints. Many contactors do not do well with stress on their contacts. On Thu, May 1, 2025 at 9:21 AM Lee Hart via EV <[email protected]> wrote: > I'm using flat copper buss bars, each 1" wide by 1/16" thick. They are > bent to have a slight "hill" in the center so as not to stress the > terminals if the cells move a bit. > -- > Excellence does not require perfection. -- Henry James > But it *does* require attention to detail! -- Lee Hart > -- > Lee A. Hart https://www.sunrise-ev.com > > -----Original Message----- > Dennis wrote: > > Looking to purchase (30) of the Braided Copper Battery Straps to tie the > CALB 180 Cells side to side. Center to center dimension > > is 76MM. Does anyone have these or name of a supplier. EVTV has the 70MM > but no 76MM. > > _______________________________________________ > Address messages to [email protected] > No other addresses in TO and CC fields > HELP: http://www.evdl.org/help/ > > -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20250501/dec6924d/attachment.htm> _______________________________________________ Address messages to [email protected] No other addresses in TO and CC fields HELP: http://www.evdl.org/help/
