Idea for Copper/Nickel bus variation for high current (variation on infinite slot)

Apologies if this has already been posted at sometime, but thoughts on this variation of the Cu/Ni sandwich?

The thinking being:
- The nickel tabs distance from cap to copper bus are very short
- The weld/s could be made with each of the probes across each cell's tabs (diagonally), hopefully forcing the weld-current through the battery cap
- The tabs could be soldered to the copper to fully minimise resistance of the Cu/Ni connection
- If the copper is laser cut, these busses should be realatively easy to build?

Isn't that so common you can just buy them off the shelf?

Yep, of course you are right Inanek

I was thinking more about the busses being completely customisable diy, not that I explained that very well! I really shouldn't post things with covid-brain

Those should work fine. There's an article here on ES about converting a microwave transformer into a spot-welder. If the nickel was spot-welded onto the copper without the cells, you can use very high amps to spot-weld these.

Found it:

argo said:

Yep, of course you are right Inanek

I was thinking more about the busses being completely customisable diy, not that I explained that very well! I really shouldn't post things with covid-brain

Click to expand...

There are also a few shops on AliExpress that can make custom shaped versions of this pre-welded cut-copper-with-nickel-holes setup. Don't have the links on hand, but it's gotten popular enough it wasn't hard to find when I last looked it up.

Thank you very much guys!

I'm thinking I will order a Kweld and see what I can make it do

Will also look at AliExpress for the pre-welded offerings. Last time I looked, most folks in that part of the world were enjoying Chinese New Year.