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Donna Kim

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  1. Remove the top plate and use MG Chemicals 8800 to attach Sigma Clad to the top cell plate (the Sigma clad should align flush with the top cell plate holders)

    1. Begin with measuring the materials in a 2-to-1 ratio of liquid A and B, respectively. Approximately, 2.5mL of A and 1.25 of B should be sufficient for this step.

    2. Use the heat gun to apply heat to both liquid A and B to rid any air bubbles

    3. Pour mixtures into the same container ensuring to scrape excess material from the side of the container to get as much as possible

    4. Use heat fun again to briefly flash heat (not too long as the mixture will set faster after cooling)

    5. Mix mixture for 2 minutes

    6. Wait until the material has reached a viscous state that is easier to work with (still liquid but congeals together better than the freshly mixed liquid)

    7. Gently place the mixture onto the top cell plate (preferably with a popsicle stick or something to apply)

    9. Press on the Sigma clad to their according sides of the module

    10. Use clamps to hold down Sigmaclad, placing popsicle sticks down across the material ensures more of the surface area of the Sigmaclad contacts the cell plate

    11. Leave for a minimum of 2 hours before moving, it takes 24 hrs to fully set

    12. Once finished setting, remove any extra material and wipe the sigma clad with rubbing alcohol to clean the surface

  2. Attach standoffs to the bottom cell holder

    1. Begin by using LOCTITE SF4769 on the interior of an aluminum standoff

    2. Place LOCTITE 262 on the appropriate screw for the stand-off (6-32 Thread Size, 1/2" Long Bolt, refer to Master BOM to find it)

    3. Screw together the connections using an allen key to make sure it is secured

      Image Added

  3. Solder voltage tap wires onto Sigmaclad tabs after setting is complete

    1. Cut 4 wires to ~1 ft in length

    2. strip one end of all 4 wires

    3. Coat the end of the stripped wire with solder

    4. Add flux to the Sigmaclad tabs and begin heat up the tab

    5. Melt a pool of solder of the tab

    6. solder the wire and Sigmaclad together, important to keep the solder as clean and close to surface so it fits through the top plate cover later on

    7. Heat shrink the connection with ~2 cm of heat shrink

      Image Added

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  1. Place cells in the correct placement

    1. Begin with filling the first parallel line with cells, positive side upwards. Positive ends of the terminal should be where the 3D protrusions (bumps) are on the 3D printThe cells should run in 8 parallel and 4 series looking like the image below (no standoffs here as it is an example):

    2. Place tape on the top of cells

    3. Then place the 2nd pair of parallel cells.

    4. For the modules located in the center, place thermistor on the center of the cell using kapton tape, ensure it is secure.

    5. Push wires to side and continue placing cells in parallel groupings, continously taping up the top of the cells

SIDE NOTE:

Soldering Nickel:

  • 5 total voltage taps:

    • 4 nickel strips with 1 wire attached, 1 nickel strip with 2 wires attached

  • Solder them to the center and fray wires before soldering making sure to make the connection as low as possible

  • 6 wires @ ~45cm or 1 1/2 feet, need to order more

TO BE CONTINUED

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