Prius


Cleaning the corroded buss bars from a Prius battery pack

Cleaning the corroded buss bars from a Prius battery pack
Cleaning the Prius hybrid battery buss bars
The prius hybrid batteries have been having cronic issues with the copper buss bars between modules getting corroded by Potasium Hydroxide weeping through the terminal seals. The effect is a crust of hard material that is non conductive, eventually causing battery failure.
I want to build up more of the 48V modules for my EV's, and wanted to find a way to clean the strips more efficiently than sanding and using steel wool, which can take as much as several minutes of hard work each.
I remembered my Dad showing me how to make old copper pennies shine buy dunking them in muriatic acid (Hydrochloric acid). I still had a container of the stuff which can be bought at most hardware stores, so I gave it a try. It immediately causes the crust to dissolve in a flory of bubbles, and then it stops, and the strip is mostly shiny copper. A thorough wash in running water finishes the job by washing off all the acid. Time will tell as to how it look a year from now, but it looks good now.

Those useful Prius subpacks

Prius NIMH batteries are called on to produce over 100A, and can be charged at 100A as well. I have been collecting the batteries and have quite a few, and have been finding some nice uses for them. I have several vehicles that I only use occasionally, and keeping a good 12V battery in each is wasteful, and is not that good for the batteries. I tend to carry a battery to the vehicle whenever I use it, and remove it when finished. Lugging a 50-75 lb battery over 100 feet is a lot of work. Just to see how it would work, I connected two 7.2V prius subpacks in series, and using a 100A Anderson connector, plugged them into a dodge caravan. The car cranked just like a new 12V battery. I put a connector on my 1965 John Deer tractor, and bang, it cranks effortlessly.
My lawn tractor uses the same configuration. The batteries do not need charge regulation, as the alternator or vehicle charging system will regulate to 13.6V , about 80% SOC on the NIMH.
A 5 lb starting battery compared to a 50 lb one. What a labor saver.
Those useful Prius subpacks
prius subpacks start van