China 0.15mm nickel copper flat wire for battery links Manufacturer, Supplier, Factory
Advanced battery interconnects demand precision-engineered conductors that deliver low resistance and long-term durability. Our manufacturing portfolio covers a full spectrum of nickel-plated copper flat wires tailored for high-vibration lithium battery packs, energy storage systems, and electric vehicle modules. Among the most frequently specified options is the Flexible Nickel-Plated Copper Flat Braided Wire, which absorbs dynamic stresses while maintaining consistent current flow. For designs requiring thinner gauge solutions, the 0.1mm Nickel-Plated Copper Flat Braided Wire offers ultra-flat profiles for compact cell-to-cell connections. Our 0.15mm Nickel-Plated Copper Flat Braided Wire has become a popular middle-ground selection, combining handling ease with excellent weldability. When slightly larger cross-sections are needed, the 0.2mm Nickel-Plated Copper Flat Braided Wire steps in with higher ampacity margins while preserving flexible routing characteristics.
The 0.15mm nickel copper flat wire bridges the gap between ultra-thin foil and rigid busbars, exhibiting an ideal thickness for automated ultrasonic and spot welding processes. With a precisely controlled 0.15 mm (±0.008 mm) core thickness and bright, uniform nickel plating, the flat wire guarantees micro-ohm level resistance drops across series connections. It is rolled from high-purity oxygen-free copper (C10200) and tempered to half-hard condition, which provides enough stiffness for feeding in pick-and-place machines without sacrificing the conformability needed to follow curved cell terminal arrangements. The nickel layer, deposited via continuous electroplating, delivers exceptional oxidation protection up to 200°C and creates a hard surface that resists fretting wear common in mobile applications. Custom widths from 1.5 mm to 8.0 mm are available, allowing battery engineers to tune the exact current-carrying capacity and heat dissipation profile of each link.
0.15mm Nickel Copper Flat Wire – Core Specifications
- Base Material: Oxygen-free high-conductivity copper (Cu-ETP / C11000 or Cu-OF / C10200)
- Plating Type: Electroplated nickel (99.9% purity), sulfamate-based bath
- Plating Thickness Range: 1.0 – 2.5 μm per surface (configurable)
- Dimension Tolerance: Thickness ±0.008 mm, width ±0.05 mm
- Electromechanical Condition: Half-hard (HV 90-110), elongation ≥ 12%
- Packaging: Spooled on plastic reels (DIN 100-200), 500 m to 2,000 m continuous lengths
- Compliance: RoHS, REACH, UL 758 (AWM style 10286 pending)
| Parameter | Value | Test Standard |
|---|---|---|
| Flat Wire Thickness | 0.15 mm (±0.008 mm) | IEC 60468 / ASTM B193 |
| Width Availability | 1.5 – 8.0 mm (standard stock widths: 2.0, 3.0, 4.0, 5.0 mm) | Customer drawing |
| Nickel Coating Thickness | 1.25 μm nominal (up to 2.5 μm on request) | ISO 2177 / ASTM B659 |
| Conductivity (Base Copper) | ≥ 100% IACS (Cu-OF) / ≥ 98% IACS (Cu-ETP) | IEC 60028 |
| Flat DC Resistance at 20°C | ≤ 0.0148 Ω/m for 4.0 mm width | 4-terminal Kelvin method |
| Tensile Strength | 280 – 350 MPa | ISO 6892-1 |
| Elongation (after fracture) | ≥ 12% | ISO 6892-1 |
| Solderability Coverage | ≥ 95% after 8-hour steam aging | IEC 60068-2-20 / J-STD-002 |
| Thermal Stability (oxidation) | No discoloration at 200°C for 30 minutes | Internal Oven Test |
| Reel Package Length | 500 m, 1000 m, 2000 m (depending on width) | DIN 200 spool core |
Manufacturing the 0.15mm nickel copper flat wire involves precision slitting and skin-pass rolling to eliminate edge burrs below 0.01 mm, which is vital for automated tabbing lines. The nickel plating is stress-relieved through a thermal diffusion cycle that strengthens the copper-nickel interface, preventing adhesion failures during spot weld pulses. Every spool undergoes inline spark and eddy current testing to detect pinholes or plating voids, with full traceability back to the raw copper coil lot. The combination of a low-profile flat geometry and pure nickel surface makes this wire directly compatible with standard nickel tab recipes on major battery welders, reducing the trial-and-error often required when switching from pure nickel to nickel-plated copper alternatives. Typical applications include 18650 and 21700 cell interconnects, prismatic module serial links, and flexible voltage-sensing taps that must survive pack-level thermal expansion without cracking. With a thermal conductivity above 380 W/(m·K) and a continuous operating temperature range from -40°C to +125°C, the flat wire reliably manages heat both during high-rate charge/discharge cycles and passive soak in automotive environments.
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