Sunday, April 24, 2016

Battery Pack Failure Prevention

In my first YouTube video I showed the failure of a power tool battery pack that I had rebuilt with new cells I bought online.  The cells have great capacity and long life, but they have one problem.  The thin plastic heat shrink coating fails if the cells rub against each other, causing an internal short that causes the pack to overheat and fail.

In this video I show how I added paper separators between the cells to prevent the failures.  I cut paper strips and slid them in between the cells of the existing packs, in a winding pattern, to prevent shorts.  At the end I show how I wrapped every second cell with individual pieces of paper when I built a new battery pack.

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