Final Battleborn Video: Overheating Cells

The video investigates a significant capacity issue with Battleborn batteries. After testing 12 batteries, each rated for 100 amp-hours, the results showed a drastic reduction, ranging from 26 to 60 amp-hours. This inconsistency prompted a deeper investigation, involving disassembling the batteries to test individual cell packs. These internal tests revealed that all four cell packs within each battery were heavily degraded. Further testing on a second battery yielded similar results, with individual cell packs showing capacities between 13 and 47 amp-hours. Thermal imaging during charging highlighted that some cells were drawing all the current while others remained cold, indicating a current-sharing problem. Upon disassembling further to test individual cells, it was discovered that a staggering 73% of the cells in the tested batteries were at zero volts. The remaining cells were operating at only 50% of their rated capacity, likely due to bearing the entire load. Potential causes discussed include factory mismatches, low-quality cells, and issues with the nickel sheet connections leading to poor current sharing between cells. The video emphasizes that this appears to be a 100% defect rate across all 12 batteries examined, regardless of the model, as they all use the same cells. The age of the batteries (9 years old) is also considered a contributing factor to degradation. The presenter strongly advises performing capacity tests on these batteries, especially if they are several years old, as it's the only reliable method to identify such internal cell failures. The video concludes by suggesting that batteries exhibiting such cell degradation may qualify for warranty claims, as demonstrated by the family whose batteries all failed a capacity test.