Mach-E: Battery Tray and Battery Cell Features

[@Chucka1463]

"As they grow older they need a little more space." Yeah, me too.

[@mitchellbarnow1709]

Yes, even my skull seems larger with age!

[@Pikminiman]

I was a little worried that Munro Live would stagnate after the Model Y teardown series wrapped up, but it turns out I just love engineering porn, and this channel is probably the best out there. The insights we get for free from this channel are highly valuable.

[@bluetoad2668]

It's great but remember that's it's not for free, the KZbin algorithm and therefore Google and so Alphabet have sold your attention to the advertisers which you see on the platform - that's the business model. Munro live is great content but nothing on this platform is free.

[@detyelram2819]

@@bluetoad2668 true. But then you can just develop the power to literally ignore all ads

[@ronaldlenz5745]

Ben, you're getting a lot more comfortable in front of the camera! Keep up the good work.

[@MunroLive]

Thanks, will do!

[@genzigzag]

Love geeking out with Uncle Sandy and the team. Look forward to every upload! Always learning something new.

[@MunroLive]

Thanks for watching, Zak!

[@ipcress20]

The 52 second intro of the disassembly taking place could easily be extended for many minutes. It's fascinating! Thanks as always, Sandy, Ben and team.

[@MunroLive]

Glad you enjoyed it

[@mikeselectricstuff]

7:10 That's not a ribbon cable, it's a flexible PCB

[@Urgelt]

That's what it looks like to me, too.

[@ericsandberg3167]

In the Aero business we used to call them flex tapes.

[@torcek1991]

and its more expensive than a rigid pcb

[@martylawson1638]

@@torcek1991 Looks like it's riveted directly to the cell-interconnects with the flexibility taking up tolerances. Not needing connectors at each interconnect probably balances out the cost.

[@TheJoeSwanon]

@@ericsandberg3167 it’s amazing how many manufacturing techniques from the aerospace industry they are using to make more efficient EV‘s

[@LauwersFreddy]

Sandy, you have an amazing team! Thank you for making these videos!

[@MunroLive]

Thanks for watching, Freddy!

[@spencer04629]

Looking forward to hearing about the new battery tray designed by your team

[@ADOENDRA]

Industrial design is like cooking " you mix the best of everything " ;-)

[@Barskor1]

It will be Tray Magnifique!

[@flashback9966]

Lovely understatment from Sandy, 'death can ruin your day'

[@fred993a]

Sandy - You and you team are an engineering university! Thank you!

[@johnb7430]

Full stop, watch munro... Hey, Sandy! Can you go over the differences between pouches and cylinder cells. Things like energy per volume, energy/kg, ability to use as structural component, etc?

[@psdaengr911]

Higher energy capacity possible per unit means fewer cells Battery weight can be lower but harder to package cells a way that can provide structural support for a vehicle.

[@Conservator.]

There’s this wonderful new tool on the internet called Google but PS was very kind to answer your question.

[@bluetoad2668]

Well, Tesla's engineers decided against them - but what do they know?

[@fenderstratguy]

@@psdaengr911 Ive read the pouch-style cells can swell….not when they were old, but in normal use. Is that true

[@Fix_It_Again_Tony]

Watch this video: www.eevblog.com/2020/10/02/eevblog-1340-new-tesla-4680-battery-cell-explained/

[@hallkbrdz]

I agree, that's a pretty good design with a lot less assembly work than a 21700 or 18650 Tesla tray with all the aluminum ribbon cooling paths. Love these videos - you are doing a great job!

[@whowhy9023]

Occasional fires a small drawdown? This can never really be structural, bags are not structural… the case yes but that is extra weight.

[@bluetoad2668]

Be careful there, Tesla batteries have proven themselves over millions of miles, it's the most critical part of a BEV and it has to be right. My single biggest reason for going with Tesla is the high confidence I have in their tech and the no. 1 part is the battery.

[@spleck615]

Thanks Sandy and crew, great breakdown!

[@EVBud69]

With ya Kevin, love ya driving vids...

[@MunroLive]

Our pleasure, Kevin!

[@spleck615]

@@EVBud69 thanks :) appreciate the support

[@rick67hou]

I hit that notification faster than I do my chores.

[@zlcoolboy]

Cant be that fast then! :p

[@djwarren5081]

Me too. I really look forward to the next exciting episode of Munro Live.

[@djwarren5081]

Makes Sandy and Ben sound like Batman and Robin 🤣

[@DavidMG99]

😂😁

[@TheElectricMan]

Awesome, Finally the video we've all been waiting for!

[@MunroLive]

Hope you enjoyed it!

[@djwarren5081]

Does anyone else think that Sandy looks more like Albert Einstein every episode?

[@koolsolutionszx12r55]

Don't slam Albert like that. Sandy is a hack! I just watch him to remind me who the dirt bag is that's cheapened American cars to the point of junk. He needs a box of bolts rammed up his back side

[@psdaengr911]

He does, but he's not. I wish he'd shave and act his age. He's only 72., my age, and he looks and acts +10 years older.

[@djwarren5081]

@@psdaengr911 he thinks young though. Always thinking of ways to innovate. I like that. Long may it continue.

[@rzu7120]

No

[@djwarren5081]

@@rzu7120 you need to see an optician 😎

[@ninjakille316]

Mache-E is beginning making me begin to doubt the overall superiority of cylindrical cells, I can't wait to see your best of best design. Hats off to the Ford team and hats off to Munro and associates.

[@zxggwrt]

These pouches are def better and as they learn to get good connections and control swelling they will take over. I personally think they should wire them in spirals to cut down on collectors and bus bars.

[@videcomp]

I deal with a lot of batteries mostly pouch style but also cylindrical cells in industrial equipment. Seen several thermal runaways and caused one myself. I have a healthy fear of anyone or any machine handling pouches. Give me a good strong can any day.

[@MarkXHolland]

@@videcomp Amen to that.

[@ninjakille316]

@@videcomp Perhaps the foam in between the poach cells does more than just compensate for the expansion. kulrtechnology.com/hydra-thermal-runaway-shield/

[@toddw3nzel639]

@@videcompthanks for the reassurance. I’ve seen the trend is to move away from pouches towards cylindrical or prismatic.

[@alioshaalex2764]

200k subscribers in 1.3 years, Good !

[@ZzHasbrozZ]

I enjoyed the surprise ‘one more thing’!

[@davidoconnor6829]

Thanks for the detailed break down. Reviewing to use three of the smaller battery packs to replace the lead batteries in my 96v lead battery powered Wheego.

[@slartybartfarst9737]

Legacy automotive engineers and home shop mechanics the how's and why's of car 2.0 it's all here, free and entertaining. Thank you Mr Munro and crew

[@MrBadgas]

Excellent review guys. I am encouraged by what Ford has done on the Mach-E. I hope they can manage to be flexible and act quickly to evolve this and other vehicles. Your comparisons shed so much light on competing designs. I sure hope you sell your upcoming "composite design" I can only imagine how positive that would be for all OEMs. One this is for sure, you are helping advance the development of EV design in a BIG way.

[@EEI605]

Hard to remember what life was like b4 discovering Munrow, such fascinating content

[@djwarren5081]

Very interesting to see how different manufacturers go about producing a similar product.

[@markplott4820]

Very FEW can copy Tesla, except RIVIAN and LUCID. all other LEGACY OEM are using OUTDATED Lion pouch battery from the Laptop industry, not ideal

[@RafaAelM]

As a member of a Formula Student Powertrain team, this knowledge is GOLD. Looking forward to the "best-of-the-best" battery pack

[@andrewmagdaleno5417]

Thanks for you and your teams hard work on these videos.

[@Doctorbasss]

6:48 the orange pcb is a FLEX PCB and they cost more than the common rigid pcb.

[@lonsk5496]

It is noticeable that the assembly of packaged batteries is difficult to automate. It is very difficult to ensure the quality of the assembly of the cells. (Based on the experience of Kona and Bolt)

[@markplott4820]

FORD is using OUTDATED pouch LION cells from the Laptop industry , not ideal. SANDY says Cylinder LION is Superior.

[@rogerstarkey5390]

@@markplott4820 Go and talk to Warren.

[@vidznstuff1]

That was a Tesla talking point. Packagingwise, they're a nightmare which is why Tesla is going to the much larger cell size

[@morrisg]

Watch this automated assembly of cells to bus bar sheet: kzbin.info/www/bejne/gZixZJ-MebSSoJY

[@brianb-p6586]

@@markplott4820 That's hilarious - the 18650 format of cylindrical cells were taken straight from laptops.

[@boebrow]

Thanks Sandy and crew! I feel like the videos you added lately are of amazing quality and very informative and show how much your channel has grown. I feel like you are educating the tech fans like me to a level that satisfies every expectation and I'm sure you are inspiring tons of people to get an education in engineering, design, and whatnot, this is what matters the most in the end!

[@Fix_It_Again_Tony]

This is a great channel. Sandy is right on top of the difference in effectiveness of turbulent and laminar flow in heat exchangers.

[@louisphuard5020]

Best automotive show. Period. Munro over Clarkson any time.

[@stevekight1955]

The dimples also increase the total surface area of the plate for more heat dissipation.

[@ΘάνατοςΧορτοφάγος]

Thats a nicely designed battery pack. Not bad for a first real try by Ford.

[@vidznstuff1]

Likely an LG design...

[@niravsheth4917]

Are you concerned that Mach-E might face similar battery issues as the Bolt if they are using similar modules?

[@carholic-sz3qv]

Nope, the issues might actually come from the bolt management system.

[@johnpublicprofile6261]

My guess is that the Bolt problem is a bad battery batch from LG. This would explain the failed fixes as GM try every work around that they can to avoid the immense cost of full battery pack replacement. A newer batch of batteries from LG should not have the same problem.

[@crtmojo2705]

@@johnpublicprofile6261 I am thinking it’s a software or hardware issue with their charging and power control.

[@Miata822]

Some Mach Es have already gone in for battery replacements. Replacing not repairing. I think Ford either wants whole units back to autopsy, but maybe just doesn't trust dealers to do the repair yet. I'm following this on the Mach E forum. I find it telling that the upcoming Ford Lightning electric pickup is using SK batteries.

[@crtmojo2705]

@@Miata822 yeah I thought SK was their supplier but they did have that lawsuit so they probably went with LG to get the first batch out.

[@seanz6586]

Very enjoyable. I bet you are encouraging many future engineers/ interns/employees to work at your place. Keep up the great work.

[@Firestorm637]

Love the explanation with very knowledgeable tesms

[@newscoulomb3705]

9:00 After you've separated the cells like that, you're not dealing with voltages high enough to require PPE. I'd still wear basic gloves, but that's only to prevent contaminants.

[@vidznstuff1]

Yeah. That was a dumbass remark. Even a fully charged module is modest in voltage (around 40V)

[@AndrewKuntzman]

I got my signed bumper sticker in the mail yesterday. Looking forward to when you guys get the plaid

[@wongman2001]

I know it’s bad habit to comment without watching the whole thing, but your intro music rocks & so happy Sandy s back!

[@tedbaxter5234]

Looking forward to seeing your Best of the Best Battery Mach-up. Pun intended! Really enjoy these videos - progress is made in small measures over time.

[@rogerstarkey5390]

Would you like fries with that? (Subtle Hyundai, GM ref?)

[@Suar32]

This feels a lot like character development, it's very interesting how our opinion about a car changes during this teardowns after the first impressions you get the out of the superficial stuff. A lack of attention to detail, or the opposite, at this level can really shift your impression of the car

[@610Alpha]

Glossed over the leak potential in the battery cooling but not with the motor cooling.

[@russellr1677]

Superb job with the breakdown and explanation Ben

[@MunroLive]

Glad you liked it!

[@tmyrdal]

Cool to see you again Munro, we missed you last time :) :)

[@MunroLive]

Thanks!

[@TomaOvidiu]

Sandy and the team, you are inspiring people doing this. Keep it up 👍

[@MunroLive]

Thank you! Will do!

[@grantos1361]

The boys!! Killing it Ben.

[@Hoggdoc1946]

It was interesting to see that LG's packs are using the same type of cells as I have used in electric model aircraft, while Tesla continues to use individual cells like 18650s.

[@ADOENDRA]

Sandy starts talking Adoendra's " we take the best part of everything and combine it to something super " :-)

[@hazarjdm786hazar]

Man another great Friday with Munro Live! I think it's kinda nice the whole battery tray could be disassembled in sections, Great Channel, Yes Ford is Taking Notes

[@Heckofadeal]

As always a great job !!

[@MunroLive]

Thank you so much 😀

[@simonthebroken9691]

Hey Ben. Great to see you on camera.

[@MunroLive]

Hey, thanks!

[@Merlmabase]

I'm curious - are there any built-in protection features at the cell level? Overcurrent, over/under-voltage? Or is that redundant when you have a sophisticated BMS managing the whole pack?

[@fredbloggs5902]

Great question, my understanding is that different cells can degrade at different rate, so they need smart charging down to the cell level. But I have no idea if anybody actually does that.

[@TheBusyDaddy]

Same concern since the battery is similar to Chevy Bolt and the multiple Bolt fire caused by charging. The Bolts that had battery fire issues were from 2019 and earlier so let's hope Ford is up to sniff with their software and hardware .

[@fabriziom]

Cell voltage is always the same for the ones in parallel. So never at a single cell level but by rows of 2 here on these modules. You cannot charge the cells independantly. Current flows in series from the tabs, and only time with deep discharge or high charge can rebalance things. The BMS can track this, but cannot correct it independantly. Just imagine a bath tub with multiple cavities that have slightly different levels. It's only when you reach the top that you can balance all cavities...

[@brianb-p6586]

Just like every other EV, the BMS handles the cell at the lowest parallel group level; individual cells in a group function as a single larger cell.

[@YouT-DJ]

High amperage very dangerous. Way back when, a fellow GI leaned over a jamming pod that had a large capacitor bank 600V 25,000 AMP. His hands were on the bare metal housing. He had a metal bead chain lanyard holding his badge, touching his neck. The chain contacted the circuit... his chest was blown out, died instantly. This is how new safety rules are born.

[@martinultimatevw3779]

Keep em coming guys, loving the frequent uploads 👌👌🙏

[@MunroLive]

More to come!

[@morrisg]

Note the compressing bolts in the four corners of the modules and the rigid metal webbing to reinforce the end plates to prevent warping. This provides compression across the pouch cells to keep them in contact with the cold plates and to keep the individual layers internal to each pouch in close contact. Since the anodes swell when charged and shrink when discharged this is why you need the compression of the pouch stack along with the foam to compensate for the swelling / shrinking. Compare this to a cylindrical cell where the jelly roll is built to a certain diameter, placed in the can and then the electrolyte is added and the can capped. The metal cylinder provides the compression force to the jelly roll. The amount of swelling on charge / shrinking on discharge increases as you add more silicon to the carbon of the anode. Adding silicon adds energy capacity to the cell, but if it swells / shrinks too much it can fracture the anode coating and ruin the cell. A delicate balance must be maintained.

[@vidznstuff1]

Thanks for the Google research

[@Mark-gw4iy]

Your statement about swelling is only true for the first 400 charge cycles for state of charge then it changes. After 400 cycles swelling will not change due to state of charge and will become permanent and grow with age. FYI stiffness of jelly roll change drastically with state of charge.

[@glenmcneill1675]

Curious about the need for the longitudinal bolts. If the battery end plates are properly processed they are weldable, thus only using a couple of metal strips on the sides.

[@Mark-gw4iy]

You do need a bit of preload to hold the assembly together. I looked at plates before but aluminum bolts are cheaper and lighter.

[@glenmcneill1675]

@@Mark-gw4iy the end plates that I see on most batteries are structural and certain they are preloaded and all have to contend with thermal expansion adding more stress.

[@patmcdaniel2016]

Can't wait to see this battery! Wow.

[@prblakeslee]

What does Ford/LG use for their terminating connectors of the module ribbon cable? I need to get hold of 4 of the male connectors. Thanks

[@prblakeslee]

Forgot to mention question is in context to the 10S3P modules.

[@altonriggs2352]

Love this channel. The media is dead asleep. The future is here.

[@Chris-ut6eq]

Love the channel, but you should consider getting a EE on staff that can talk about the electronics from an electrical perspective. Love the assembly/manufacturing perspective but a skilled electrical/electronics engineer to dig into the EE details.

[@florenciovela7570]

we visited there last Oct. & it was awesome.. i've ordered the tri motor fsd ct & i can't wait for it to get here!! I may buy the S or the Y in the meantime..i got lots of solar & back up battery system as well.

[@TD_YT066]

Also consider open protocol management, repairability and end of life recycling for your design.

[@DiegoAndrade]

Great stuff guys!

[@MunroLive]

Thanks so much!

[@MunroLive]

Glad you enjoyed it!

[@Eric-xp1kl]

Sandy & Corey, whatever level you need to pull or decal you need to sell to get one of the first Rivian R1T's & Tesla CyberTruck Tri-Motor in a tear-down comparison will blow your channel up! I have reservations on both, plus the Lightning. Love what your team is doing! Thank you

[@lightmange774]

love the design of 'Dimples' it may help with extent the coolant

[@sonyajones]

Thank you for these videos.

[@MunroLive]

Glad you like them!

[@sonyajones]

@@MunroLive - I really do like them. I have learned to appreciate the simple build quality and dependability of my ICE powered pickup so very much over all of the electronic and plastic electric vehicles currently being produced. Just my honest opinion. I look forward to when EV's really are quality built like some of the older ICE vehicles.

[@Avboden]

Given the Bolt was just recalled *again* for battery fires, it may not be a good thing this is so similar to the Bolt's!

[@unitrader403]

Just read a video title today (didn't get around to watch the video yet) and it seems it's a manufacturing defect from LG, so construction method is unrelated to the Bolt fires.

[@vidznstuff1]

No fires with these cells

[@heinzruffieux5817]

Well done, guys! I wonder, why they put the cooling plates at the bottom of the packs. Wouldn't they be more efficient at the top as heat raises and the cold sinks in the pack?

[@brianb-p6586]

heat isn't a fluid - it doesn't rise or fall. Cold doesn't even exist - it's just the absence of heat. Hot air rises compared to cold air, but the heat transfer in the battery is by conduction (exchange of heat through stationary materials) not convection (movement of heated fluid such as air). Putting the plates on the top wouldn't make any difference to the heat flow.

[@Dave5843-d9m]

This battery construction makes a stack of 18650 or 2170 cells look simple by comparison.

[@brianb-p6586]

I guess you've never seen a Tesla battery, which has modules (like this) with fluid connections to every module, and layers of structure to hold everything together. There's little difference in complexity.

[@psdaengr911]

Ben and Sandy are smart guys. Imagine what they'd be like if 20 years ago somebody had told them they were going to be on camera doing videos. I'm sure they would have been practicing and developed presentation skills equal to their analytic skills. The thing is that Sandy might have found it easier to sell his ideas within companies and we wouldn't have him doing this work today.

[@toddmarshall7573]

13:00 Hopefully we'll see compare/contrast analysis of "flat packs" vs "cylindrical" packaging. Flat packs seem obviously more efficient from many points of view.

[@rogerstarkey5390]

Those being?

[@toddmarshall7573]

@@rogerstarkey5390 Among others, fewer parts. Additionally they can fit into complicated spaces. You think differently?

[@brianb-p6586]

Although "flat pack" is descriptive, the standard industry term is "pouch cell".

[@johntlarkin]

Around 8:00 -- there might be some thermal transfer -- but plastic is a good thermal insulator! How are they getting heat out through the plastic to the aluminum plate?

[@brianb-p6586]

With stamped aluminum plates between the cells, which is moulded right into the plastic frame, so it runs through the frame on one side to reach the cooling plate.

[@johntlarkin]

@@brianb-p6586 ah, so there's no layer of plastic between the plate and the strip? That'd help a lot

[@per-hakongraarud6946]

Great Video Agian Munro Team:-)!

[@markplott4820]

Glass molded plastic would be a game changer for battery tray, light but strong.

[@fabriziom]

No way. A tenth of the stiffness, a third of the strength. You can redesign it but will need to increase the pack height by at least half an inch. That's either less batteries, or even less room in the cabin... Steel and aluminum are good materials. Plastic is not for structural applications (and I'm a plastic automotive engineer....)

[@kevinvisser6538]

Thumbs up for Ben! 👍🏻

[@lyokofans]

Something tells me this video is really gonna blow up now that there is a recall.

[@johannel8104]

Should I do the Correy thing? 😂😂😂. Thanks for keeping it real Sandy!

[@human_brian]

Given GM and Hyundai Motor Group's recent issues with LG Chem pouch cells, I'd be seriously worried about the long term safety of this battery pack. Ford needs to do some serious testing on these cells to make sure they aren't going to cause vehicle fires as they have in Hyundai and Chevy's EVs.

[@bluetoad2668]

They don't care, it's a tiny portion of their business.

[@fabriziom]

So it's basically a larger Bolt design. Far too many parts, assemblies... the MEB pack looks simpler with its extruded aluminum modules. However, these extruded modules have one additional layer of thermally conductive gap filler, an inner insulation that's coated, and welded end caps making it tough to disassemble. So it's a trade off, clearly!

[@gordoncharles7611]

Could you expound upon how the pouch cell was removed from the aluminum plate (the plate between the pair of cells which provides heat spreading to the bottom of the module). There appears to be an adhesive between the cell and the aluminum plate. Were the separated mechanically or was a solvent used?

[@inediblenut]

I would imagine that these companies have patents on almost every aspect of their designs, so it will be interesting if you take the best ideas from each to make a better, cheaper battery. Better factor in some significant royalty costs for that bad boy.

[@ploppyploppy6554]

Friday satisfaction and I didn't lift a finger .

[@mattglandorf9600]

With the new Contactor WElding recall, Im curious to see if you compared any of the contactors on the Mach E to anything else.

[@corpierro]

Soo much better than the sticking, gluing, casting bending of the Tesla battery packs! Also much better to repair and recycle. And a automotive sound design rather than powertool battery pack design

[@carlping8205]

These LG pack look like what is used in some PC and hobby electric drones, planes and cars they tend to swell up during high discharge and the Tesla Panasonic 18560 cell seem to keep it shape under many cycles of discharging. I wonder if those LG Pack tend to swell up as they get older?

[@Mark-gw4iy]

They swell up to 11% of the thickness at end of life. if you get the right amount of pressure with with foam the end life swelling will be about 9% . Abuse the cell it will be a lot more

[@inscrutableone]

amazing, you can get a 101 course on manufacturing something as state-of-the-art at car batteries, right on your closest screen. I only hope this helps bring home manufacturing to my city, state and country. Watch and learn young geniuses!

[@Lonewolf201011]

So, wait, if the Mach-E is using the same batteries as the Bolt, will Mach-E's start lighting on fire soon like the Bolts are today? Are the differences in the battery enough to have fixed the Bolt's problem?

[@morrisg]

So, doing a few calculations shows the Mach E battery pack is 10 modules of 30 cells in 10S3P configuration and 2 modules of 24 cells in 8S3P configuration. That's 116S3P overall which means a pack voltage of about 464 volts @ 4v/cell (nearly fully charged) and nominal 417.6 volts @ 3.6v/cell for the majority of the discharge curve. For a 77 Kwh pack (useable energy) that's about 221 watt-hrs per pouch cell. Sorry, just nerding out online.

[@brianb-p6586]

There are only eight of the 10S3P modules (and yes, two 8S3P modules), so the pack overall is 96S3P (not 116S3P) with a total of 288 cells. That's 267 Wh/cell for 77 kWh, at proportionately lower voltages.

[@JFabric500]

Reminds me of how a beehives cools themselves. Only problem is heat rises and there is no way to cool the tops of the cells properly

[@brianb-p6586]

Heat doesn't rise. Hot air rises, but the heat transfer within a battery like this is by conduction, not by moving air (convection).

[@khuo0219]

did not realize that these were pouch cells until I read the comments. I am familiar with the cylinder cell dimensions but the MachE pouch cell look bigger than the Bolt's. Any tradeoffs between larger vs. smaller pouches?

[@brianb-p6586]

The cell length and width are basically just selected to work with the module dimensions, which are selected to work in the overall battery package. The Mach-E just has a thicker pack than the Bolt, because it needs more capacity.

[@vidznstuff1]

Same cell. Same size.

[@brianb-p6586]

@@vidznstuff1 As the video illustrates, the cells in the Bolt and those in the Mach-E are different sizes; they're about the same length and thickness, but the Mach-E cells are wider. That results in taller (thicker) modules for the Mach-E, which makes sense for the required higher energy capacity - each Mach-E cell has about 10% more energy capacity than the original Bolt cell (the new Bolt cell has more capacity than the old one, but still less than the Mach-E).

[@giga-chicken]

"These cells have been discharged already, that's why we can touch them" That's not why you can touch them. A single cell is only 4 volts fully charged, as long as you don't short the cell or damage it then it's safe enough. A discharged cell still has enough energy to start a fire, so the precautions are the same either way. "We send them out to have it done, we don't have that capability here." That also doesn't make sense, I discharged one of these using a space heater (which is just a 9.8ohm resistor) and a multimeter. If you have 30 bucks you have the space heater, and if you don't already have a multimeter you shouldn't be handling a battery.

[@MarioDallaRiva]

Lightening round, coming soon to Munro Live!

[@dtomaz1]

That’s a lot of fluid carrying rubber hose, hose clamps & push connectors inside the sealed battery pack. Service nightmare if a clamp or o-ring leaks.

[@brandoYT]

6 connectors for cooling EACH tray ??? color me confused - 6 holes but 1 or 2 quick tube connects. confused.

[@danneil8778]

thanks, folks.

[@apt6975]

Hey guys! Thanks a lot for another interesting and educational video! About the battery pack and refrigeration system, is it then feasible for you to study the problems in the Bolt leading to the 3 recalls so, now having the similarities found in the Mustang, discern whether or not we may start to find fire risks elevate for the Mustang also through time and volumes?

[@zodiacfml]

i think this pouch format should have shielding or aluminum housing for each cell. It makes more for a more expensive cell but simplifies battery pack design and improves physical protection and cooling.

[@brianb-p6586]

There is an aluminum plate against each cell for cooling, which is shown and described in the video. There is no reason for more housing around the cells; the polymer stacking frames and the metal battery case do the job.

[@zodiacfml]

@@brianb-p6586 much has happened and i've learn more since and the Chevy Bolt has a terrible battery problem and will not be built in till the last week of January 2022. The BYD Blade battery has safer, weaker LFP battery cells but still has shielding for each cell.

[@brianb-p6586]

@@zodiacfml "shielding for each cell" in the BYD "Blade" battery just means that they are metal-cased prismatic cells, not pouch cells. BYD uses the cell case as structure in the Blade pack design, so one very long cell spans the width of the pack, supporting itself when packed against other cells. It doesn't do any more for cooling than the plates sandwiched in the pouch stack by LG. If prismatic cells are used in the same size as pouch cells - so there is no structural benefit - the extra cell container is just extra weight and cost... which is why that sort of construction is now rare.

[@serta5727]

Thanks for your awesome reviews! You are inspiring thousands of engineers 👷‍♀️👷

[@MunroLive]

Glad you like them!

[@marcm1088]

since when is a flexible PCB less expensive than a FR4 PCB?

[@psdaengr911]

A one sided one can be. The process for mass production using continuous fed plastic ribbon requires less material handling than rigid board. Ribbon can be punched and cut to odd shaped with lower cost tooling than rigid board. Flexible boards can connect to directly to other nonplanar components, eliminating added connectors and harnesses.

[@ESGFishing]

Love watching things get reverse engineered

[@trengilly01]

It seems so odd that they made the 1st bay slightly smaller than the other 4. I would have thought making all five identical would have been easier and a little extra battery wouldn't hurt range.

[@jamesengland7461]

And there's empty space in that bay as well

[@brianb-p6586]

The pack tapers at the front a bit so the vehicle structure can tuck in for the front wheels. Many packs have a few modules of a different size to make the packaging work, and to reach the desired total cell count.