Views: 0 Author: Site Editor Publish Time: 2026-01-30 Origin: Site
In the R&D journey of a New Energy Battery Pack, structural engineers are constantly gambling against the laws of physics: How do you safely transmit higher currents within an increasingly compressed physical space, while controlling temperature rise and reducing weight?
When standard off-the-shelf nickel strips can no longer meet the demands of complex module structures, you need more than just a "build-to-print" manufacturer. You need an engineering partner capable of Early Supplier Involvement (ESI).
Every innovative battery pack design deserves a unique connection "vascular system." Relying on standard components often means compromising on performance. Customized precision stamping is the key to unlocking a battery's full potential.
Mastering Complex Geometries: Whether it is navigating complex bends to avoid liquid cooling plates or adapting to hybrid arrays of cylindrical and prismatic cells, we utilize high-precision Slow Wire Electrical Discharge Machining (WEDM) and High-Speed Stamping technologies to translate complex 3D designs into reality.
Micron-Level Tolerance Control: We maintain stamping precision strictly within <0.01mm. This is not just for aesthetics; it is to ensure a "zero-gap" interface between the tab and the cell pole during automated laser welding, completely eliminating the risk of false welds.
In high-rate discharge scenarios, pure nickel tabs can become hotspots due to resistance, while pure copper tabs—though excellent conductors—are notoriously difficult to laser weld to stainless steel cans. How do you solve this paradox?
We provide mature Composite Material and Surface Treatment Solutions:
Copper-Nickel Composite Technology: We use a copper core to carry high currents and a nickel outer layer to ensure a wide welding window and corrosion resistance. This "sandwich" structure significantly reduces internal resistance while retaining established welding processes.
Partial Selective Plating: Say goodbye to the cost waste of full-surface plating. Through high-precision continuous selective plating technology, we apply Gold or Tin only to specific FPC contact points or connector pins. This ensures reliable signal transmission while drastically reducing precious metal consumption.
The iteration speed of the new energy industry is calculated in weeks. To align with your rapid New Product Introduction (NPI) process, we have built a highly elastic manufacturing system:
Rapid Prototyping: Before committing to hard tooling, we use soft tooling or wire-cutting technologies to provide engineering samples, helping R&D teams complete physical validation within days.
Seamless Scale-Up: Once the design is frozen, our cluster of high-speed presses engages immediately. Paired with Automated Tape & Reel Packaging systems, stamped parts are encapsulated right off the line, ready to dock directly with your high-speed SMT assembly equipment, achieving a closed loop from component to module assembly.
For power batteries, component cleanliness and traceability are just as critical as dimensional precision.
Deep Cleaning: All precision stamped parts undergo Multi-Tank Ultrasonic Cleaning to thoroughly remove stamping oils and microscopic particles. This eliminates the hidden dangers of spatter and porosity during the subsequent laser welding process.
End-to-End Traceability: We have established a digital traceability system extending from raw material melting batches to final shipment. Every reel of nickel tabs issued has its own unique "Identity ID," ensuring that every connection is documented and traceable throughout the vehicle's lifecycle.
