BLF Interest list for Very High Current Beryllium Copper springs Pt1(ENDED)

With a 1mm wire diameter, it is better than a 23AWG wire, and a bit less than 22AWG wire.

With a 1.1mm wire diameter though, it is about as good as 22AWG wire.

With a 1.2mm wire diameter, almost as good as 21AWG wire.

So no need for a bypass for once with these springs.

I personally don’t like doing spring bypasses on steel springs. They just suck too much solder, and tend to fail if you don’t have enough experience.

If a bypass is truly not needed even with this length spring maybe thicker is better. Idk. Will be interested to see what the others think

Thicker is always better when resistance is concerned at such high currents we do(10A+).

However, there are design limitations in the case of a compression spring for a battery, mostly memory elasticity.

From the info I have gathered, 1,3mm is probably the limit, but a bit thinner for more room for elasticity is needed. So 1.2mm will probably be what I pick if there is a small cost difference, if any since I’m ordering more than a 1000pcs.


∅1.2mm wire has π(½(1.2mm))² = 1.131mm², with 38% IACS that equals almost 0.43mm² of copper wire.

My Electrodroid app lists 0.41mm² for AWG21 wire, thus it should be a little bit better.

Cheers :-)

I’m in for 20 big, 20 small. Thank you!

A spring is longer run of wire though so the drop is greater. However im not sure how to calculate that when the spring is compressed. Would it take a shorter path or would it have its own resistance? A 22 gauge wire and 19 gauge wire of double the length are almost the same

I'm in for 20 big and 20 small thanks!

You do not want a spring this size in 1.2mm wire thickness, it is too thick, will be mechanically inferior and the coils will get in each others way. 1mm is plenty thick, already thicker than most steel springs the same size out there.

20 small as well. :+1:

I would like to add 20 small to my order.

Change please , not 20 but 30 for me , big size .

Thanks

30 Large
30 Small

OK then.

I will keep the spring thickness at 1mm.

I knew something would be wrong if we increased the wire thickness. Thanks for confirming my doubts djozz :+1:

List updated.

We are at 961 big springs, and 407 small springs.

Since there are so many people wanting small springs too, I will now inform the manufacturer to make a batch of smaller spring with these dimensions along with the big springs:

- Spring top diameter: 4,5mm

- Spring bottom diameter: 5mm

- Spring thickness: 0,8mm

- Spring height: 8mm

- Plating: Zinc plating

Doing this allows for lower shipping costs and lower bulk costs per spring.

If anyone wants to change something about these dimensions above, say it to me.

Thanks again for the community. :laughing:

Oh well, I still have a few djozz-springs leftover but I’m curious how these turn out.

10x big, 10x small please.

The manufacturer has said that while it is possible to make 1.2mm wire without a cost increase, making a 1.1 mm is not directly available without a cost increase, so I will keep the thickness to 1mm as initially said, and corrected by djozz, as 1.2mm is too thick and will hurt memory elasticity and may make the spring collapse under a cell.

Is there a limit on them?
Might be in for 20 big and 20 small.

No limit. 1000pcs is just the minimum order. The more spring we can get manufactured though, the lower the price per spring will be.

Bulk purchases really help getting the cost down by a huge factor.

Please add 30 small to my original order post #8
Thanks

List has been updated.

One other thing: would you prefer better spring mechanical properties using Beryllium Copper 38% IACS C17530, or slightly better conductivity using Beryllium Copper 45% IACS C17510?
I would like to know your choices.