Disposable vapes are out of control: In the UK, an estimated 260 million units are thrown away each year, and the vast majority contain rechargeable lithium cells that work perfectly after a single use. That brings us to Chris Doel's YouTube channel, a true enthusiast of disposable vapes... but he doesn't actually consume them; instead, he rescues them to extract their precious cells. What did he do with them? He prepared a total of 130 and built a 1,500-watt e-bike battery.
Previously we talked about the DIY battery revolution in Indonesia, stimulated by the partial subsidy received by e-bikes in that country, and the lack of regulations for pack construction. Despite the associated risks, the public seeks these batteries for cost reasons... but at the same time, in other regions they throw perfectly functional cells into the trash. How? With disposable vapes.
In September 2023, the BBC shared an investigation that talks about 5 million vapes discarded per week... only in the UK. That gives us 260 million vapes per year, equivalent to 1.3 million e-bikes. So, how difficult would it be to build an e-bike battery using disposable vape cells? Chris Doel on YouTube decided to find out... (Editor's note: For some reason, the author blocked embed support. Access the direct video here.)
Recycling disposable vapes to build an e-bike battery
Obviously, the video begins with some warnings: Lithium batteries are dangerous when handled incorrectly, and vapes have a certain profile of biohazard having been used orally. As for the design itself, it's quite simple: Ten cells in parallel, repeated thirteen times and connected in series to reach an average of 48.1 volts. That's 130 cells in total, but you need to add a BMS module to the configuration, which guarantees balanced and safe charging across all cells.
Now, processing 130 vapes is no small detail: The sponges tend to get disgusting over time, and many still retain fluid (meaning the manufacturer prevents the user from using the whole vape by omitting a charging circuit). The cells are known as 20400, and although Chris had trouble locating the datasheet, he finally received a copy from a seller on AliExpress. Under optimal conditions, this 48-volt battery can approach 1,500 watts, however, each cell needs an independent evaluation to determine voltage level and internal resistance. This is when battery testers come to the rescue.
The limit for motors on "pedal cycles with electrical assistance" in Britain is 250 watts, but I'm not convinced the battery itself is illegal. The support that holds the cells is excellent (since it allows expansion), and a short-circuit demo reminds us to be very careful. To finish, the battery's performance doesn't lag behind, with a range of 33 kilometers. In total, Chris invested about 60 pounds in materials, but the recovered cells allowed him to save more than 200 pounds.
Source: Ars Technica
