Overview
In order for an electric vehicle to run, it needs various components, but among the most important is a flexible circuit, a type of printed circuit board (PCB) having a wide range of electronic applications.
As the name suggests, a flexible circuit can conform to various space limitations, sizes, and shapes (even irregular ones). A flexible circuit is also beneficial due to the reduced weight of the device and optimized thermal management.
Flexible circuits are also essential in different functions of EVs, such as the Battery Management System (BMS), infotainment systems, sensors and control systems, and power distribution, GPS, among many others.
What is flexible die-cut circuit technology (FDC)?
Flexible printed circuits, sometimes also called FPCs, are typically used in EV battery cell contacting systems. However, it tends to be the most expensive component of the current collector assembly. More than that, its lengthy manufacturing process and time-consuming extraction of waste copper makes it difficult to be sustainable.
How does flexible die-cut circuit technology differ from FPCs?
FDC technology has the capability to introduce a more sustainable wiring option that does not compromise performance. This is ENNOVI’s flexible circuit production method for low voltage signals in EV battery cell contacting systems.
As opposed to FPCs, FDCs are produced through reel-to-reel manufacturing, which entail fewer processes. It also cuts costs by 25 to 50%, and process time by 50%, compared to its printed counterpart.
Whereas FPCs manufacturing makes copper recycling difficult, FDC technology can instantly recycle copper thanks to the die-cutting process. Together, these offer greater efficiency and a lower impact on the environment.
Moreover, this type of circuit performs very similarly to FPCs, but unlike them, FDCs do not have a size limitation. These performance markers have been tested in terms of dimensions, thermal shock, trace resistance, temperature rise, insulation resistance, and high voltage.
FDC technology has a wide range of applications:
- EVs
ENNOVI’s battery interconnect system for prismatic cells, ENNOVI-CellConnect-Prism is a prime example of FDC technology at work. It enables the smooth integration of individual prismatic cells in order to create bigger battery modules, or advanced cell-to-pack (CTC) or cell-to-chassis (CTC) configurations. It also streamlines processes in a one-stop lamination process that can cut costs by up to 15%. - Commercial transportation: trucks, maritime, air transportation
- Energy storage: wind turbines, solar energy
- Personal mobility: hybrid vehicles, motorized scooters
How does FDC enable versatility for EV battery connectivity?
Flexible circuits are the key to strong EV battery connectivity. The flexibility of FDCs allows it to fit various vehicle designs and match a wide range of dimensions and configurations, thereby maximizing the space provided. Its compact size reduces the size and weight of the battery itself, resulting in enhanced efficiency. More importantly, FDCs are integrated into Battery Management System (BMS), helping it monitor and control performance.
Conclusion
Flexible die-cut circuit (FDC) technology is a more cost-effective and sustainable alternative for producing flexible circuits for low voltage signals in EV battery contacting systems.
Whereas the traditional flexible printed circuits involve a laborious manufacturing process, which also poses challenges with regards to recycling of waste copper, FDC technology uses reel-to-reel manufacturing that promotes easier recycling of clean copper.
This process also saves costs and production process time by up to half compared to FPCs.
