How to choose the size for nickel sheets?

Sep 06, 2025

There are two criteria for selecting the length of the connecting piece: the magnitude of the current flowing through the connecting piece and the application length of the conductive connecting piece, while also considering the current and usage scenario.

 

1. There are two criteria for selecting the length of the connector:

 

A, The current flowing through the connecting piece is usually determined by the highest output discharge current of the battery during product operation. For example, in a portable power bank, the maximum output current of the battery is around 3-4 amperes; In electric bicycles, the maximum output current of the battery is 7-8 amperes; In the power battery pack of electric tools, the maximum output current of the battery is around 10-15 amperes;

B, The application length of conductive connection pieces is usually determined by the voltage drop caused by the current passing through the conductive piece, which is less than 1% to 1.5% of the total voltage of the battery pack. Simply put, the longer the length, the longer the length. By widening, the "line loss" of the connection piece can be reduced. For example, in an electric vehicle battery pack, a short connecting piece of 0.2x6mm can be used for connecting two adjacent batteries in series, but a longer connecting piece of 0.2x10mm is required for connecting batteries in series at a longer distance and for the battery pack terminal output.

 

pure nickel sheet

2. Determine the size of the nickel plated steel strip based on the current, as shown in the table below:

 

Current length

0~5cm

5~7.5cm

7.5~10cm

10~15cm

Below 5A

0.1x3mm

0.1x5mm

0.1x8mm

0.15x8mm

5~10A

0.1x8mm

0.15x8mm

0.2x7mm

0.2x8mm

10~15A

0.2x7mm

0.2x8mm

0.2x9mm

0.2x10mm

15~20A

0.2x9mm

0.2x10mm

0.25x10mm

0.3x10mm

 

3. Determine the nickel plating size based on the current, as shown in the table below:

 

Below 5A

0.1x2mm

0.1x4mm

0.1x6mm

0.1x9mm

5~10A

0.1x6mm

0.1x8mm

0.15x5mm

0.15x7mm

10~15A

0.15x5mm

0.15x6mm

0.15x8mm

0.2x7mm

15~20A

0.15x8mm

0.2x7mm

0.2x9mm

0.25x9mm

15~20A

0.1x2mm

0.1x4mm

0.1x6mm

0.1x9mm

 

4. Based on the rough selection of battery usage scenarios, please refer to the table below:

 

Product/Conductive Sheet Material

Nickel Plated Copper Sheet

Pure Nickel

Plated Iron Sheet

Suggested Material Selection

electric bicycle

0.10x4mm

0.15x8mm

0.2x8mm

Pure nickel/nickel plated iron

Electric handcart

0.10x3mm

0.15x6mm

0.15x8mm

Pure nickel/nickel plated iron

power tool

0.1x3mm

0.2x8mm

0.25x9mm

Pure nickel

Automatic emergency power supply

0.05x2.5mm

0.7x4mm

0.1x6mm

Pure nickel/nickel plated iron

unmanned aircraft

0.15x8mm

0.2x8mm

0.25x8mm

Nickel plated iron