Battleborn LiFePo4 battery dangerous design flaw

Posted by Joyous0@reddit | overlanding | View on Reddit | 41 comments

There is a design flaw in popular Battleborn LiFePo4 batteries (12V, 100Ah and reportedly 50Ah) that causes the positive terminal to overheat above 250°F (120°C) under load or charging. The reason: there is plastic between the positive terminal and the busbar, only a screw is conducting the full load. The negative terminal is not affected due to different wiring. The heat melts the plastic, the screw becomes loose, worsening the situation over time. The BMS intermittently cuts out, this can be the warning symptom.

The issue is unfixable due to the sealed case. Many warranty claims and the issue itself were denied. If you have a Battleborn battery checking the temperature of the positive terminal under load would be a good idea from time to time. I don't see other safe solution than a recall and redesign of the positive terminal. This was a major oversight.

Video link in first comment.