Mobility electrification solutions partner Ennovi have introduced a new way of producing flexible circuits for low voltage signals in EV battery cell contacting systems. The automotive-grade flexible die-cut circuit (FDC) capability gives engineers a more sustainable wiring option for new battery designs without compromising on performance.
Historically, Flexible Printed Circuits (FPCs) are often employed in these systems, and they are the most expensive component in the current collector assembly. FPCs are manufactured using a multi-stage, batch photolithography process to etch copper traces for the flexible circuit. This production process uses corrosive chemicals that dissolve the unwanted copper. In addition, it takes a lot of time and energy to extract the waste copper from the chemicals, making it challenging to effectively recycle. The die-cutting process allows for instant recycling of the copper, making it a more substance preference to chemical etching.
Compared with FPCs, which have a size limitation of 600x600mm, FDCs boast no length restrictions as they are manufactured reel-to-reel. Under certain design considerations, the FDC provides similar performance characteristics to FPCs. These results were confirmed through rigorous in-house dimension, thermal shock, trace resistance, temperature rise, insulation resistance and high voltage testing.
“Adopting the FDC capability for flexible circuits aligns with our vision to think outside the box in creating a sustainable battery value chain for EVs,” explains Gustavo Cibrian, Product Manager, Energy Systems, at Ennovi. “Our efforts enable Ennovi to offer battery manufacturers a CCA design solution that balances their imperatives in terms of cost, time, and performance. Allowing them to design to cost.”
