Enginer PHEV DC/DC Overheating issues

Yes, Mottcells for the 4kWh kit. Mainly because they fit into the box. Compared to the TS battery, the volume of the cell is nearly the same, but the height dimension of the TS is too large. The Mottcell is shorter and stockier. They happen to be a better fit.

The other advantage of the Mottcell is that they are cylindrical encased in plastic which gives them the rectangular shape. Cylindricals don't need to be banded together like the TS and Prius Prismatics. That makes them slightly more compact and easier to change out a bad cell. Also, they are less prone to shipping damage.

 

The TS do not fit in the newer re-stylish case/carrier.........

 

I wonder how the Mottcell will behave when a rise in temperature start swelling their battery cases. .. . . . . .will they expand sideways, from their bottoms or balloon it.......

 

Hey guys,

I am back with a new converter/balancers. The balancers seem to be doing their job, unlike my other defective ones. Also, has anyone noticed that the converter is very slow in charging the OEM battery? I think it is too slow. Ttyl.

 

Absolutely! I'm thinking about getting a second converter so I can run 20 amps into the OEM battery instead of just 10. Not only will that allow for true EV mode for limited range, but allow me to use the full charge in my Enginer pack before I get back home from my daily commute.

 

any pictures of the motcells?

 

These are sligthly smaller in size and gray in color @39Ah.

 

http://priuschat.com/forums/prius-p...d-electric-vehicle-technical-information.html

Pics here.

 

and still from the same factory in china from thundersky? or somewhere else... also the same chemistry?

 

From Mottcell (different company) in China (same country), LifeP04 (same chemistry). Slightly lower capacity at 39Ah.

 

so now we have to learn about the motcells...what these will do in pratice.

the thundersky's whe all now know what we can expect from them..

i hope the motcells will be reliable.

 

According to Jack, Mottcell produces as many if not more batteries than TS. You just don't hear about them because most of thier business in in China. The chemistry is the same. The quality has more to do with process capability at the production facility than the chemestry or the technology.

Jack believes that the quality is good and since they are cylindrical cells packaged in a plastic case, they don't need to be banded together. This is an inherent advantage of cylindricals because that geometry handles pressure well. Another advantage is that they tolerate shipping better, less suseptible to damage.

 

yes i know its production thats the problem and not chemistry

i just wonder how these cells can give the same 39/40ah and have a smaller casing and inside you have cylinder cells.
cylinder cells are really unificient in using the space because of the cylindric shape.
there is always unused space inbetween

 

The Mottcells are not smaller, they have the same volume as the TS. They are shorter, but wider. The height dimension was the issue with the TS batteries.

 

ok
but the TS are prismatic shaped and the motcell are cylindrical from the inside
i guess then the TS are also cylindical in the inside?
because you lose a lot of space when using cylinder shaped cells so how can motcell have the same Ah in the same volume............ then TS must me cylindrical to inside.

 

TS is prismatic. That is why they need to be banded together, like the Prius NiMH.

 

yes ok but i still wunder how the same size and AH motcell with cylindric cells can work..
there must be unused space insite the motcellcase where the TS is fully used...
and then stil have the same AH....can that be?

 

Cylindrical cells can be fabricated (wound) w/ thinner material backing than prismatic cells (as a practical matter..not in theory) so the volume energy density can be higher......enough to (almost) make up the difference in total packaged volume....

 

Back to thermal management.
I just finished reading this whole thread and have a couple of thoughts.

I plan to put my pulg into the front of the car. I was thinking that we want the heat during charging under the hood(bonnet for our friends in UK). I am thinking of taking the charger out of the box and mounting it under the hood. I think I have room and some threaded bolt holes behind and below the driverside headlights. I would need to build a custom bracket. Then I would have 48v wires from there back into the box and would add a 10 amp safety fuse inside the box so that the batterys would not dump high current out to the 48v wires if they ever had a short or other problem. This gets the charging heat out of the passenger compartment.

Also if you have removed the spare tire anyway, move the converter to the spare tire well. I would then figure out how to get the bottom of the converter into intamate contact with the steel sheetmetal bottom of the spare tire well, probubly with the use of thermal grease. Then this steel becomes a big heatsink for the converter and the heat can go to air under the car. The result will be cooler temperatures and no fans or venting.

What do you thing about this?

Thanks
Dan