To validate the compression design, we decided to build a prototype of 3 modules in series. Our goal was to:
- Verify electrical conductivity
- Identify pain point in manufacturing
- Size materials appropriately
Retrospective
Participants: Adam Marchand, Titus Chow
- Overall: Relatively simple to manufacture, used 4mm threaded rod
- The copper plates we built weren't quite up to spec, but still seemed to work well - very tolerant to error!
- Didn't actually sit flush in the grid, so they were a little annoying to align
- We just did vertical strips for ease of manufacturing which worked, but was annoying to align (didn't sit flush in the plastic)
- Try avoiding handling to copper and/or electroplate it - picked up a lot of grime really easily
- Foam + backing plates could probably be thinner
- Backing plate cracked - add torque specs?
- Copper could be thinner and reduced in width
- 3D print caps to isolate the copper
- Add top plate to support busbars and hold modules in place
- We should deburr the plastic holders when we drill holes - they caught on the heatshrink of the threaded rod
- Heatshrink is very annoying to deal with - recommend coating rod with silicone or something
- The heatshrink may have caused the pressure to be distributed unevenly, probably want a bit of play or at least make it easier to slide
- Batteries + plastic holders are extremely rigid - don't need to worry about batteries coming out, especially with the threaded rod
- Remember to use fujilocks for all the battery-related fasteners!
- Remember to use a non-flammable material for the backing plates!