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Lipo - rebuilding packs

Old 04-08-2008, 02:48 PM
  #1  
rhuber40
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Default Lipo - rebuilding packs

I have been using lipo batteries for a year now and have several single batteries from packs that have experienced some sort of failures.

QUESTION: How can I connect the tabs of each battery (mechanically)? Soldering is not recommended and infact does not work!
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Old 04-08-2008, 04:40 PM
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fr4nk1yn
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Been there' tried that. From what I've been told the pos. terminal is aluminum and that the problem. Regular solder doesn't stick. I know a guy that fixes high end electronics and builds car ecus and he had nothing that would stick either. My searc at the local electronic shops got me nowhere as well. I think it's a plot to keep us buying packs (:
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Old 04-08-2008, 05:56 PM
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Balil
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solder may not work, BUT this is just an idea. because the melting tempature of almunium is so much lower than steel, we use a special type of wire electrode to weld aluminum together, it would give you the same conductivity as the regular aluminum tabs, but you can create your own packs. its just an idea
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Old 04-08-2008, 06:10 PM
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Bub Steve
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Originally Posted by rhuber40 View Post
I have been using lipo batteries for a year now and have several single batteries from packs that have experienced some sort of failures.

QUESTION: How can I connect the tabs of each battery (mechanically)? Soldering is not recommended and infact does not work!
rhuberBub::I take my puffed packs and make one & two cells out of um, This is something you must be VERY carefull do'in but it's do'able if your handy with a sod-gun , There some Alum,solder left on tabs an I use that to hook-up or wire little extentions to hook um up, I just do um in single cells and run um together to add up to what I need, as I charge um one at a time theres no need for ballance'in plug's, your bub,steve
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Old 04-08-2008, 06:45 PM
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rhuber40
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Default connecting single cells

Thanks for all who replied to my original post. I thought there were more out there than myself with this problem.

This is what I have been doing rather than solder:

Cut a groove (all the way through the wall) of a copper 1/8" tubing, then cut that section to about 3/16". so you have a "C" looking piece of copper looking at it from the end. Place this over the "lipo Tab" and insert a wire into the "C" section and squeeze this combination with a pair of plyers. I don't know if it is the best, But that is how I have been attaching copper wires to a single lipo.

I have tried aluminum paste, regular flux solder, acid flux, etc without results.

Again, Thanks all for you help
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Old 04-08-2008, 09:12 PM
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Sir Raleigh
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I found this on the web and have no idea if it will work, but the procedure seems simple enough to at least give it a try...

"Tin the aluminum under oil, then solder as normal.

Aluminum normally won't accept regular solder. That's because
of the oxide coating on its surface. By covering the surface with
oil, you can scrape away the oxide coating while preventing oxygen
getting to the surface and reforming it. You can then tin the surface
with an iron, through the oil coating, and get a proper bond. Then
you can clean the oil off and solder as usual.

This is a home shop technique. There are probably better solutions
in a production environment."

EDIT: Additional information:

Q: What kind of oil do you use?
A: I use mineral oil, but ordinary motor oil will work, smokes a bit though.

Last edited by Sir Raleigh; 04-08-2008 at 09:30 PM.
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Old 04-08-2008, 11:19 PM
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rhuber40
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Default tinning lipo tabs under oil

Sir Raleigh

THANK YOU SO MUCH!! I built two packs today from salvaged lipo cells that I didn't know what I was going to do with. have three full flights on my E-SKY King II with the salvaged packs. Worked like a charm.

Pass the word, And thank you again.
Bob Huber
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Old 04-09-2008, 01:20 AM
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Sir Raleigh
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Thanks for the feedback, Bob. I'll pass the word around.
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Old 06-22-2013, 12:43 AM
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To all who have posted here, today I tried to tin the aluminum tabs on several lipo single cell batteries. I used Crisco vegetable oil and it worked like a charm. A few drops of the oil, a little iron heat, a little smoke and it would take the solder. I fixed three batteries after that. Thanks for the help, hope this helps someone else.
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Old 06-22-2013, 09:06 AM
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JetPlaneFlyer
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Originally Posted by stevecooper View Post
rhuberBub::I take my puffed packs and make one & two cells out of um,
+1.. i've soldered wires to the tabs on LiPos many times. Providing you have the part of the tab that is pre-tinned with solder it works fine using a normal iron and normal solder.
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Old 06-22-2013, 11:21 PM
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Walt Thyng
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I regularly harvest the tabs from dead LiPos. I then use them to solder up new packs.

If you have a situation where the tab on the cell has no solder on it try this: perforate the tab on the cell. Then place a harvested tab with solder on it under the perforated tab and the lead or tab you are soldering on top. Heat and smile !
Walt

Last edited by Walt Thyng; 06-22-2013 at 11:23 PM. Reason: to clarify
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Old 06-24-2013, 04:22 PM
  #12  
quorneng
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I have found re-built LiPo packs can have a benefit.
Unless you buy the most expensive packs it seems that the individual cells are likely to have different 'lives' before failure.
I have one 3s pack that has been rebuilt twice from cheap batteries so it has the best cells from 2 others and despite being 2 years old it performs as well as (and gets no warmer than) a brand new one.
I guess when this does eventually puff up it will really puff!
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