Content Comparison

Plate

• Better for thermal distribution: helps to dissipate heat evenly across the cells

• Stronger/ more physically reliable: provides more structural support and reduces the stress on connections

• Easier for us to use / implement ( ? ): When we decide on a design we can machine it in batches ?

• Lower resistance variation: More consistent electrical connections across the cells

• Lower resistance at the point of connection if spot-welded properly

  • Is also easier to make consistently across hundreds of batteries

• Able to design the plates ourselves on CAD to suit whatever cell arrangement our specific module has

• Harder to replace individual cells: if one fuse blows, 1. as all cells are connected you cant just removed that one cell alone, 2. you’d probably need to replace the entire plate at that point

• Design issues:

  • if we’re designing it ourselves there's a lot of space for error, if it isn't made correctly there's possibility for uneven current distribution and some cells would end up with higher loads

• More material: considering the weight factor, these plates are definitely the heavier option

  • Don’t know if this is significant given the metal used will probably be around 0.1mm thick

• Generally more expensive to make:

  • requires laser cutting/waterjetting for the battery strips

  • requires one strip per module + any backup modules, test strips, failed attempts

  • testing will require extra stripes as well (can probably be offset by making smaller strips meant for testing, but this won’t simulate a full plate)

Wires

• Easier cell replacement: since each fuse is individually attached. if a fuse blows only that specific wire needs to be replaced

  • This assumes we’re replacing individual cells in a module as opposed to just replacing the module and protecting the other cells in said module

• More leeway with placement and design: we have more variety in choosing the fuses that are right for our cells compared to a harder search for the exact plate that fits all requirements of our cells

• Lighter weight: uses much less material

• Might be cheaper: this approach requires no custom machining, just spot welding we can do ourselves

• More work to implement: since each fuse is individually attached it will take a lot more attention and time to carry out

  • Easy to mess up joints when making hundreds, which might lead to some batteries becoming unusable

• Inconsistent resistance: subject to small variations in wire thickness or weld quality can create uneven current distribution (more room for human error to matter)

  • Also, has generally higher resistance, as much as 10x at the joints, when comparing both methods

• Weaker stability: no structural reinforcement like the plate

• More points of failure: since each wire is kind of doing their own thing they all have their own chances of weakening or breaking over time.