The wire is the "blood vessel" for energy transmission in lithium batteries. It should be selected based on the current size, voltage level and environmental conditions to avoid fire or performance degradation caused by wire overload.

1. Core parameters: Wire diameter (cross-sectional area) matches the current

The wire is the "blood vessel" for energy transmission in lithium batteries. It should be selected based on the current size, voltage level and environmental conditions to avoid fire or performance degradation caused by wire overload.

The relationship between current and wire diameter:

Wire diameter (AWG)       cross-sectional area (mm ²)     continuous current (A)                            applicable scenarios

      22AWG                                    0.34                                   3-5A                                 small current equipment (such as remote controls)

      18AWG                                     0.82                                   8-12A                              power bank, small fan

      14AWG                                     2.08                                   15-25A                            electric vehicle controller connection

      10AWG                                     5.26                                   30-50A                            electric vehicle battery main circuit

      8AWG                                      10.37                                  50-80A                            energy storage system for high current scenarios

Note: In high-current scenarios (such as the connection of electric vehicle motors), silicone wires (heat-resistant and flexible) or multi-strand twisted wires (to reduce skin effect) should be used, and single-strand hard wires should be avoided.

2. Material and insulation layer

Conductor material

Pure copper wire: It has the best electrical conductivity (low resistivity). Oxygen-free copper (purity ≥99.97%) is preferred, and copper-plated aluminum wire (prone to oxidation and high resistance) should be avoided. Nickel-plated wire: It is used for internal connection of lithium battery packs (nickel strip spot welding is convenient), with a thickness of ≥0.15mm and a width adjusted according to the current (for example, a 10mm wide nickel strip is required for a 10A current).

Insulating layer material

PVC: Low cost, but poor heat resistance (usually ≤70℃), suitable for indoor low-power scenarios.

Silicone rubber (silica gel) : Heat-resistant (-60℃ to 200℃), soft and flexible, suitable for outdoor, high-temperature or frequently moving scenarios (such as electric vehicles, drones).

Teflon (PTFE) : Heat-resistant (≤260℃), corrosion-resistant, used in extreme environments (such as industrial equipment, aerospace), but relatively expensive.