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From: D Yuniskis on 13 Dec 2009 19:31
Hi,

Replacing rechargeable battery packs in consumer kit
is a bane I suspect most of us share. You can't
"solder" to individual cells. And, you usually can't
slip a battery holder in place to make the connections
for you.

Sure, you can buy premade packs in a wide variety of
configurations. But, these often come at a premium
in price (to pay for the added labor of their fabrication)
*and* you can't just pick them up "off the shelf"
(well, *some* configurations are available like this
but not "in general").

Has anyone come up with a clever way around this problem?
Is there a poor man's approach to welding tabs onto
batteries? Or, some other conductive fastener that
doesn't put the cell at risk in the process?
From: Rheilly Phoull on 13 Dec 2009 21:23

"D Yuniskis" <not.going.to.be(a)seen.com> wrote in message
news:hg40gr$sba$1(a)aioe.org...
> Hi,
>
> Replacing rechargeable battery packs in consumer kit
> is a bane I suspect most of us share. You can't
> "solder" to individual cells. And, you usually can't
> slip a battery holder in place to make the connections
> for you.
>
> Sure, you can buy premade packs in a wide variety of
> configurations. But, these often come at a premium
> in price (to pay for the added labor of their fabrication)
> *and* you can't just pick them up "off the shelf"
> (well, *some* configurations are available like this
> but not "in general").
>
> Has anyone come up with a clever way around this problem?
> Is there a poor man's approach to welding tabs onto
> batteries? Or, some other conductive fastener that
> doesn't put the cell at risk in the process?

Most use a capacitve discharge to spot weld tabs on but if you are not doing
it all the time places like Jaycar have a good range of tabbed cells.


--
Regards .............. Rheilly P



From: isw on 13 Dec 2009 23:56
In article <hg40gr$sba$1(a)aioe.org>,
D Yuniskis <not.going.to.be(a)seen.com> wrote:

> Hi,
>
> Replacing rechargeable battery packs in consumer kit
> is a bane I suspect most of us share. You can't
> "solder" to individual cells.

You can do it easily, IF you use the proper solder and flux. Look for
something that can solder stainless steel.

Isaac
From: N_Cook on 14 Dec 2009 04:03
D Yuniskis <not.going.to.be(a)seen.com> wrote in message
news:hg40gr$sba$1(a)aioe.org...
> Hi,
>
> Replacing rechargeable battery packs in consumer kit
> is a bane I suspect most of us share. You can't
> "solder" to individual cells. And, you usually can't
> slip a battery holder in place to make the connections
> for you.
>
> Sure, you can buy premade packs in a wide variety of
> configurations. But, these often come at a premium
> in price (to pay for the added labor of their fabrication)
> *and* you can't just pick them up "off the shelf"
> (well, *some* configurations are available like this
> but not "in general").
>
> Has anyone come up with a clever way around this problem?
> Is there a poor man's approach to welding tabs onto
> batteries? Or, some other conductive fastener that
> doesn't put the cell at risk in the process?


Cheats "spot weld"

For only one spot weld though, so lowish current purposes. Connect both
parts each to one side of a high current transformer (with a thermal cutout
somewhere) with some cigarette paper separating the two parts of stainless
steel. Press the 2 parts together until current breaks through and
incinerates the paper. Check for integrity and repeat if weak.


--
Diverse Devices, Southampton, England
electronic hints and repair briefs , schematics/manuals list on
http://home.graffiti.net/diverse:graffiti.net/


From: Dave Plowman (News) on 13 Dec 2009 19:36
In article <hg40gr$sba$1(a)aioe.org>,
D Yuniskis <not.going.to.be(a)seen.com> wrote:
> Replacing rechargeable battery packs in consumer kit
> is a bane I suspect most of us share. You can't
> "solder" to individual cells. And, you usually can't
> slip a battery holder in place to make the connections
> for you.

> Sure, you can buy premade packs in a wide variety of
> configurations. But, these often come at a premium
> in price (to pay for the added labor of their fabrication)
> *and* you can't just pick them up "off the shelf"
> (well, *some* configurations are available like this
> but not "in general").

> Has anyone come up with a clever way around this problem?
> Is there a poor man's approach to welding tabs onto
> batteries? Or, some other conductive fastener that
> doesn't put the cell at risk in the process?

You can buy most cell sizes with tags already welded on - so you can then
solder them together. From most decent electronics suppliers.

--
*A dog's not just for Christmas, it's alright on a Friday night too*

Dave Plowman dave(a)davenoise.co.uk London SW
To e-mail, change noise into sound.
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