How Nickel, Copper, and Aluminum Determine Battery Performance

1. Conductivity: Who Is the Best Current Carrier?

• Nickel Sheets: Good conductivity, though not as high as copper. Suitable for most standard applications with moderate current demands.
• Copper Sheets: Excellent conductivity, making them ideal for high-current applications. They significantly reduce internal resistance, improving charge/discharge efficiency.
• Aluminum Sheets: Lower conductivity, making them suitable for low-current applications. However, they may cause significant voltage drops and power loss in high-power scenarios.

✅ Conclusion: If high-current transmission is needed, copper is the best choice. For lower current requirements, nickel and aluminum are also viable options.

2. Chemical Stability: Who Can "Survive" in Harsh Environments?

• Nickel Sheets: Excellent chemical stability and corrosion resistance. They can maintain low resistance over long-term exposure to electrolyte environments.
• Copper Sheets: Prone to oxidation, especially in humid or high-temperature conditions. Oxidized copper increases resistance, negatively affecting battery performance.
• Aluminum Sheets: Forms an oxide layer, which prevents further oxidation but increases contact resistance, reducing conductivity.

✅ Conclusion: Nickel offers the best chemical stability, making it ideal for long-term use. Copper and aluminum require additional surface treatments to enhance oxidation resistance.

3. Thermal Management: Who Can Efficiently Dissipate Heat and Prevent Thermal Runaway?

• Nickel Sheets: Low thermal conductivity, meaning heat dissipation is mediocre. However, its chemical stability ensures minimal resistance variation at high temperatures.
• Copper Sheets: Excellent thermal conductivity, allowing rapid heat dissipation. This makes copper ideal for high-power applications, reducing the risk of thermal runaway.
• Aluminum Sheets: High thermal conductivity, but lower electrical conductivity may cause localized heating, making heat dissipation less effective than copper.

✅ Conclusion: Copper provides the best thermal management, especially for high-power battery applications. Nickel and aluminum offer inferior heat dissipation properties.

4. Weight & Cost: Who Is Lighter and More Cost-Effective?

• Nickel Sheets: High density and relatively heavy. Costs are higher but justified for high-performance applications.
• Copper Sheets: Also high in density and weight, with a higher cost, but excellent performance makes it ideal for premium battery systems.
• Aluminum Sheets: Low density and lightweight, with lower costs, making them suitable for applications where weight and cost are critical factors.

✅ Conclusion: Aluminum is the best choice for weight and cost-sensitive applications such as consumer electronics. Nickel and copper are better suited for high-performance, high-cost battery systems.

5. Cycle Life & Safety: Who Ensures Longer Battery Life and Higher Safety?

• Nickel Sheets: High chemical stability extends cycle life. Corrosion resistance also contributes to improved safety.
• Copper Sheets: Excellent conductivity reduces internal resistance and extends cycle life. However, oxidation issues may affect long-term performance.
• Aluminum Sheets: Lower conductivity and oxidation susceptibility can lead to performance degradation and reduced safety.

✅ Conclusion: Nickel offers the best cycle life and safety, making it ideal for long-term and high-stability applications. Copper follows closely but requires oxidation management. Aluminum is more suitable for low-cost, low-risk applications.

Final Verdict: How to Choose the Best Connection Sheet Material?

• Nickel: Best for high-stability and long-life applications, such as energy storage and power batteries.
• Copper: Best for high-current and high-power applications, such as EVs and power tools.
• Aluminum: Best for lightweight and cost-sensitive applications, such as consumer electronics.

When selecting a connection sheet material, it's essential to balance application scenarios, performance requirements, and cost. Whatever the choice, ensuring compatibility with the overall battery system design is key to maximizing battery performance and lifespan.