Flexible Printed Circuits (FPCs) are typically used in EV battery cell contacting systems. However, FPCs tend to be the most expensive component of the current collector assembly. This high cost is because they are manufactured through a multi-step batch photolithography process that etches copper onto the circuit.
This production process also presents significant sustainability challenges; it uses harsh chemicals to dissolve excess copper, which is hardly sustainable and makes copper waste recycling difficult.
How Does FDC Technology Overcome Size and Length Restrictions?
Flexible Die-Cut Circuit (FDC) technology overcomes these issues by utilizing a sustainable, continuous reel-to-reel manufacturing process. Unlike printed circuits, FDC technology has no length limitations, allowing it to support very large EV battery assemblies and battery module configurations.
What Are the Economic and Operational Benefits of Switching to FDC?
Switching to FDC technology offers profound advantages, as the reel-to-reel manufacturing method reduces the manufacturing process time by 50% compared to traditional FPCs. Additionally, FDC technology achieves cost savings by up to 25% without compromising on technical capabilities or performance.
Operationally, these circuits perform very similarly to FPCs and pass strict reliability tests for dimensions, thermal shock, trace resistance, temperature rise, insulation resistance, and high voltage. Because of this reel-to-reel production, FDCs do not have length limitations.
How Do Scalable Circuit Solutions Enable Advanced EV Architectures?
Unlike flexible printed circuits, FDCs do not have a size limitation. ENNOVI-CellConnect-Prism is a prime example of FDC technology at work, which allows for the smooth integration of individual prismatic cells to form larger battery modules or advanced cell-to-pack (CTP) and cell-to-chassis (CTC) configurations.
CellConnect-Prism combines step processes into a one-stop lamination process, thereby saving costs by up to 15%. By integrating voltage and temperature sensing into the assembly, these scalable solutions eliminate traditional insulation methods to optimize material usage and production efficiency.
Scaling EV Circuitry with Infinite Flexibility
Manufacturers should adopt FDC technology to eliminate length constraints and support the largest battery module configurations in the industry, as these circuits have no limitations and can readily support large assemblies.
ENNOVI-CellConnect-Prism is a prime example of FDC technology at work, which allows for the smooth integration of individual prismatic cells to form larger battery modules or advanced cell-to-pack (CTP) and cell-to-chassis (CTC) configurations.
Contact our engineering team today to request a technical consultation on scaling your battery interconnect system for next-generation EV platforms.