Discarded E-Cigarette Batteries Repurposed for Electric Bikes with 20-Mile Range

Recently, an overseas UP host shared his experience of transforming 130 disposable e-cigarette batteries into 48-volt, 1500-watt electric bicycle batteries. The creator had previously made a mobile power bank with disposable e-cigarette batteries. The transformation process includes collecting e-cigarette batteries, disassembling and extracting lithium battery cells, testing battery capacity and internal resistance, and fixing battery cells with 3D printing modules. By connecting 13 sets of battery cells in series and connecting them to the battery management system (BMS), he ensured the safety of the battery.

In the end, he successfully installed the battery pack on an electric bicycle for testing. The results showed that in power-assisted mode, the battery range reached 33 kilometers, the maximum speed could reach 32 miles per hour, and the expected range was more than 50 kilometers. This innovation has attracted the attention of netizens, who have ridiculed whether e-cigarette batteries can be used to make electric vehicles. UP host Chris Doel reminded that non-professionals should not attempt such transformations.

Recently, an overseas UP host shared that he transformed 130 disposable e-cigarette batteries picked up at a music festival into 48-volt, 1500-watt electric bicycle batteries, which can power more than 20 miles of riding.

This guy has previously transformed disposable e-cigarette batteries into a power bank: "Waste utilization! 35 disposable e-cigarettes transformed into mobile power banks".

Discarded e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

His transformation process is:

1. Collect a large number of disposable e-cigarettes and prepare to obtain lithium battery cells from them to make electric bicycle batteries.

Discarded e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

2. Understand the structure of ordinary E-byte batteries, which are composed of 18650 lithium battery cells, which are connected in parallel to increase capacity (single group is about 3.6 volts), and connected in series to achieve the required voltage (such as 36 volts requires 10 series, 48 volts requires 13 series), and the battery management system (BMS) is required to monitor the safety of the battery cell group. The BMS connects each battery cell group through wires to read the voltage and keep it in a safe range. This transformation will use e-cigarette battery cells instead of 18650 battery cells.

3. Prepare 130 e-cigarette battery cells (because the capacity of a large e-cigarette battery cell is three times that of a small one, a large one is used here. If a small one is used, nearly 400 are needed). Open the large e-cigarette battery cell by clamping the bottom with a vise and tearing it off, taking out the components, removing the insulating tape and desoldering the battery cell.

Abandoned e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

4. Test the battery cells, use a battery cell tester to measure their capacity (actually 15 mAh) and internal resistance, screen out battery cells with abnormally high internal resistance and completely dead (discharged below 3 volts) and group them, and group battery cells with higher internal resistance with other similar ones to ensure that the battery cells bear the same workload when used in pairs.

Abandoned e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

5. Use 3D printed modules to fix the battery cells. Each module accommodates 10 battery cells to form a parallel group. The module adopts a spring sheet design and can be spliced. When making the module, insert the battery core, pull the shrapnel to the middle, weld it to the copper strip, operate the positive and negative poles separately, and make a total of 13 groups.

Waste electronic cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

6. Connect 13 groups of battery cells in series, stack them by connecting the positive pole to the negative pole, connect them according to a specific layout and direction, and stick insulating tape on the copper busbar during the connection process to prevent the risk of short circuit (short circuit may cause fire and explosion).

Waste electronic cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

7. Connect the battery management system (BMS), which is connected to each battery cell through small wires and equipped with a temperature probe to monitor the battery temperature to ensure the safe operation of the battery and monitor its status.

Waste electronic cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

8. Connect the prepared battery pack to the electric bicycle for testing to check whether it can drive the bicycle normally.

Waste electronic cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

9. Install a 3D printed shell for the battery pack, with a power port, charging port, switch and battery level indicator on the shell. Foam pads are placed inside the battery to absorb shock and vibration. The level indicator estimates the battery level according to the voltage by connecting the positive and negative poles.

10. Perform actual riding tests and record data such as battery life and speed. In this test, almost no pedaling was performed in the power-assisted mode. The battery power was used up to 50%, and the total riding distance was 18 kilometers. When the battery power was completely exhausted, the total riding distance was 33 kilometers. The maximum speed reached 32 miles per hour, and it is expected to easily exceed 50 kilometers of battery life.

Discarded e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

Netizens joked, "Is the next step to use e-cigarette batteries to make electric vehicles?" UP host Chris Doel said it was a big challenge.

Discarded e-cigarette batteries are transformed into electric bicycles, which can be ridden for more than 20 miles!

Note that non-professional electrical engineers should not try such transformations.