Reusing modules out of Nissan Leaf Battery Packs

Functional Artist

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I've been doin' more research :thumbsup:

The battery in the Nissan Leaf is manufactured and assembled by the Automotive Energy Supply Corporation (AESC), a joint venture corporation between Nissan and NEC located just outside of Yokohama, Japan.

The battery pack consists of 48 modules & each module is made of four individual pouch (also known as laminate) cells. The four cells are electrically configured as 2 in series and 2 in parallel.

According to AESC each cell is rated at 32.5 Ah, or about 10X that of the 18650 cell used in the Tesla.
It uses a different material for the cathode called lithium-manganese-oxide with nickel oxide (LiMn2O4 with LiNiO2) that is inherently safer than the lithium-cobalt-oxide cathode material used in mobile devices and the Tesla pack.
The cell’s voltage chart shows a maximum cell voltage of 4.2V.
Rated nominally at 3.75V, one pouch cell can store a maximum 122 Wh of energy, or about 10 times what an iPhone 6 Plus battery can store.

The voltage chart shows that one cell can deliver at least 90A of current.

The added safety of the LMnO material, incurs some important penalties.
First, the intrinsic energy density of the individual pouch is only about 320 Wh/L. Compare this to nearly 700 Wh/L for the Panasonic cells used by Tesla.

Second, the use of large pouches makes it necessary to have dual levels of packaging, one at the module level, then again at the pack level. This adds unnecessary weight and volume to the pack.

Another way to look at this mechanical inefficiency:
The total weight of the 192 cells is 151 kg (332 lbs) — that’s the part that really stores energy — to which the steel boxes, plates, wire harnesses and electronics add another 144 kg (316 lbs) for a total pack weight of 295 kg (648 lbs). In other words, that’s 316 lbs of added weight that contributes zero to energy storage. Each pound of weight in the Leaf battery pack stores 37 Wh of energy. By comparison, each pound of weight in the Tesla S pack stores 64 Wh of energy!


https://qnovo.com/inside-the-batter...d NEC located just outside of Yokohama, Japan.

So, these cells are designed & made in Japan (NOT China) :2guns:
...each cell (can contain) 122 Wh of energy (~32.5AH) or 488Wh (~60AH) per module
...& can deliver almost 90A

Plus, they seem to be safer, to use, than 18650's :wai:
 

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Functional Artist

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I finally got around to workin' with these modules :thumbsup:

I tried stacking 'em a couple of different ways :cheers2:

First, all (7) in a row (I made some "end plates" with "feet" for mounting)
...but, the pack was HUGE (9 1/2"D x 9"W x 13"T) :huh:


Then, I tried (4/3) side by side (I added a "spacer" to "even out" the rectangle, (2) shinny aluminum "end plates" plus (4) "cross bars", to strengthen the pack & for mounting)
...but, this arrangement is even bigger (6"D x 17 3/4"W x 13" T) :furious2:

I went ahead & used my shinny new bus bars to connect 'em up "in series"
...had to use a short piece of 8g cable to "jump" from the left side to the right
...& then, checked the voltage level of the whole pack
The meter showed 49.4V (or 3.5V per module)

* So, it seems like they were sent (shipped) @ ~ the nominal voltage level (not fully charged &/but, also not discharged)

Next, Ima gonna charge 'em up & see what we get :popcorn:
 

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Functional Artist

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Back in the spring, when I ordered these Leaf modules, I knew I'd be needin' a charger.

So, I contacted Yewi battery chargers (in China) & ordered (1) 10A 14S charger for a (48V) pack
...& also (1) 10A 16S charger for a (60V) pack (for future use) :cheers2:

I had the factory to pre set them, to only charge the cells up to 4.15V ea.
...instead of the usual 4.20V (per cell) to give us a bit of a "safety margin" :thumbsup:

So, the 14S charger is preset to, only charge up to 58.1V
...& the 16S charger is preset to 66.4V
 

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Functional Artist

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It took ~4 hours to charge these modules up.

After charging I checked/recorded the voltage level :thumbsup:

The entire pack registered @ 57.4V
...& then, I checked the individual modules
#1 showed 8.28V
#2 - 8.28V
#3 - 8.30V
#4 - 8.31V
#5 - 8.31V
#6 - 8.32V
#7 - 8.32V

The next morning, I checked 'em again (in even more detail) :cheers2:
...& entire pack showed 57.1V
#1 - 8.1V - 4.1V - 4.1V
#2 - 8.1V - 4.1V - 4.1V
#3 - 8.1V - 4.1V - 4.1V
#4 - 8.1V - 4.1V - 4.1V
#5 - 8.1V - 4.1V - 4.1V
#6 - 8.1V - 4.1V - 4.1V
#7 - 8.1V - 4.1V - 4.1V

Well, they seem to be pretty well balanced so far :2guns:
 
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