International Harvester Scout 800 conversion
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What do you mean by "Gen2"? If you mean the 40 kWh packs... yes, like the 24 kWh and 30 kWh packs, they are smaller in physical volume and weight than the 62 kWh pack. The 24 kWh, 30 kWh, and 40 kWh packs and modules are all the same size and about the same weight.
Yes, the 62 kWh pack is basically the same on top (fits against the same vehicle floor), but the case is deeper. The closer packaging and deeper case accommodate the almost 50% increase in module volume resulting from 50% more cells of essentially the same size.
There shouldn't be nearly that much difference. The 62 kWh pack has 50% more cells of essentially the same size and weight each. The current (40 kWh and 62 kWh) packs use essentially (or maybe exactly) the same cells, so 50% more of them means 50% more capacity. The weight increase should be less than 50%, because the 62 kWh pack's modules are more efficiently packaged (they don't have end covers for every eight cells).
For the purpose of minimizing weight for the same energy storage, modules from either the 40 kWh or 62 kWh packs should be used (because they have the same cells, each containing much more energy than the older cells).
This project used, and showed in detail, both the older (24 kWh, 30 kWh, 40 kWh) and newer (62 kWh) styles of modules:
Toyota 4Runner 4x4 Race truck Leaf conversion
The 24 kWh, 30 kWh, and 40 kWh should all weigh roughly the same, because they have the same cell volume of similar materials (about 914 g/cell). Apparently the cells of the 40 kWh pack are a bit thicker or denser, but packaging changes made the later modules slightly lighter than the cells would suggest; Marklines reports:
24 kWh pack: 225 kg (a bit more than 440 lb) {3.8 kg per module, as per GreenTecAuto}
40 kWh pack: 303 kg {8.7 kg per bonded pair of modules, or 4.35 kg each}
This is more difference between the 24 kWh and 40 kWh packs than I expected.With the 40 kWh pack at 303 kg and 50% more of the same cells in lighter packaging, the 62 kWh should be less than 450 kg (less than 900 lb) - PushEVs estimated 410 kg.
450kg is 1000lb, while 410kg is 904lb.
Also note that among the DIYers the "gen X" terminology refers to the battery module design. So like sardine cans is gen1, then the symmetrical design of the same capacity (newer) is gen2, and the final one is gen3. Not a reference to the vehicle itself.
Or the single modules in cans are gen1, the doubles are gen2, and the 62 kWh type are gen3. And what would you call the 62 kWh, since they don't replace the 40 kWh? Since Nissan doesn't define the generations, the generation naming is unclear. Of course, if Nissan has authoritatively defined them somewhere, I'll happily follow and refer to that.Also note that among the DIYers the "gen X" terminology refers to the battery module design. So like sardine cans is gen1, then the symmetrical design of the same capacity (newer) is gen2, and the final one is gen3. Not a reference to the vehicle itself.
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I think Nissan's definition is somewhat irrelevant for practical purposes when there is a secondary market for these with its own rules. Either way, not the most important data point for the OP. Difference in weight between smallest Leaf pack and largest pack is what I was trying to highlight.
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