Views: 0 Author: Site Editor Publish Time: 2026-01-26 Origin: Site
In the rapidly evolving landscape of New Energy Vehicles (NEVs) and high-end consumer electronics, the humble nickel sheet has transformed from a simple connector into a high-precision component. Serving as the "neural network" for current transmission and signal collection in battery modules, the manufacturing of these components requires a convergence of material science, micron-level stamping, and advanced automation.
This article explores the technical standards and manufacturing processes currently defining the industry top-tier production of nickel sheets, busbars, and FPC reinforcement components.
The production of battery connection sheets (such as nickel tabs) often involves working with materials ranging from 0.06mm to 0.5mm in thickness. Handling such thin metal strips at high speeds requires exceptional machinery and tooling stability.
Precision Control: Modern high-speed stamping presses (ranging from 25T to 160T capacities) are now expected to maintain a stamping accuracy of <0.01mm. This level of precision is critical not just for dimensional fit, but for controlling "burrs." In a battery pack, a microscopic metal burr can puncture the separator, leading to short circuits and thermal runaway.
High-Volume Consistency: With single production lines capable of outputting over 8 million pieces per day, the challenge lies in maintaining that <0.01mm precision across millions of cycles. This necessitates the use of advanced equipment like Slow Wire Cutting machines (Sodick/Seibu) for mold fabrication to ensure tool longevity and accuracy.
Raw material properties often need enhancement to balance conductivity, solderability, and corrosion resistance. Advanced electroplating facilities are integral to modern nickel sheet manufacturing.
Material Combinations: The industry utilizes various plating combinations, including Nickel-plated Copper (combining copper's conductivity with nickel's protection), Copper plated Nickel， and Tin-plated Nickel .
Precision Plating: Plating thickness is strictly controlled within a range of 0.5µm to 10µm.
Selective Plating: A key trend is "Partial Selective Continuous Plating". This process applies precious metals or specific coatings only to the functional contact areas (e.g., where welding or soldering occurs) while leaving the rest of the strip bare or differently coated. This optimizes electrical performance while significantly reducing material costs.
Capacity: Robust production lines can handle daily plating capacities exceeding 1,500 kg, supporting mass-scale battery production.
Before plating or final packaging, the surface cleanliness of nickel sheets is paramount. Contaminants like stamping oils or dust can cause welding failures in the battery pack assembly.
Ultrasonic Cleaning: Manufacturing flows now incorporate multi-tank ultrasonic cleaning lines. These systems ensure that components undergo rigorous pre-treatment before plating and final cleaning before shipment, guaranteeing a surface free of organic and inorganic residues.
The industry is moving beyond simple metal stamping toward integrated component manufacturing, particularly for Cell Contact Systems (CCS).
Engineering Plastics: To create robust modules, manufacturers integrate metal parts with high-performance plastics like PPA (Polyphthalamide) and PPS (Polyphenylene Sulfide). These materials are chosen for their high-temperature resistance and corrosion resistance, essential for the harsh environment inside a battery pack.
High-Precision Molding: Injection molding systems (using brands like Haitian) are employed to create these composite parts.
Adhesive Application: For complex assemblies, automated taping machines with algorithmic coordinate compensation are used to apply insulating films or adhesives with ±0.05mm accuracy on complex curved surfaces.
As battery pack assembly becomes more robotic, the delivery method of nickel sheets has evolved. Bulk packaging is being replaced by Tape & Reel solutions compatible with SMT (Surface Mount Technology) pick-and-place machines.
Efficiency: Automated taping machines can process components at speeds up to 15,000 pieces per hour, with daily capacities exceeding 6 million pieces.
Customization: Carrier tapes are customized to fit specific component geometries, supporting widths from 8mm to 72mm.
Mechanism: Components are automatically inserted into the carrier tape pockets, sealed with a cover tape via heat pressing, and wound into reels. This allows the end-customer (battery manufacturers) to feed the reels directly into their assembly lines, significantly reducing labor and increasing throughput.
To ensure reliability in automotive and safety-critical applications, manufacturers adhere to strict quality management systems (such as IATF16949 and ISO9001).
Key testing capabilities typically include:
Material Analysis: RoHS testing and Conductivity meters.
Durability: Salt spray testers (corrosion resistance) and High-temperature ovens.
Physical Properties: Vickers hardness testers, Tensile strength testers, and Coating thickness analyzers.
Dimensional verification: CCD Automated visual inspection and 2D imaging instruments are used to ensure every batch meets the strict geometric tolerances required by modern battery designs.
Summary
The manufacturing of nickel sheets for the new energy sector is a discipline of microscopic precision and massive scale. By combining ultra-precise stamping (<0.01mm), selective plating technologies, and fully automated tape-and-reel packaging, manufacturers are enabling the next generation of safer, more efficient power batteries.
