I am working with a company that has donated battery thermal management to my friends electric motorcycle project. The company is AllCell Technologies and it is a graphite wax material that holds the 18650 cells. as the cells heat up, the phase change material acts as a heatsink but does not raise above 55 C until it absorbs a considerable amount of heat. Everything this company has done is for much lower current then we are looking at (scooters at ~50amps).
My friends motorcycle is going to have an AC 20 or 35 with the Curtis controller. I think this is a peak of 550 amps.
We have set his bike up for 28s56p. The cells are 3.7v nominal and 2Ah each. We are creating 28 modules that are each 56p, so a nickel plate will be tabbed to every cell on a side putting them all in parallel. In trying to determine how to connect each module together and handling 550amp peak I am having trouble. All the calculators online are for copper and aluminum.
Pictures attached are of one module and the planned arrangement. The nickel is 5 mil thick. It is set up to have a connection 5.75inches long between each series set. We have a couple spots where it would be better to connect on the short side of the module. But then, the connection would only be ~3.75 inches wide.
Please help me calculate how much current this nickel can actually handle.
If the embedded pictures dont work, click this link: http://picasaweb.google.com/lh/photo/LtFhUIyqSZgijbjBFP6b-w?feat=directlink