In cell contacting systems, the voltage sense line is available with FDC or FPC.
Flexible die-cut circuit (FDC) technology is a production method for low voltage signals in EV battery cell contacting systems. FDCs are integrated into the Battery Management System (BMS), helping it monitor and control performance.
Furthermore, a flexible circuit can conform to various space limitations, sizes, and shapes (even irregular ones), and Flexible Printed Circuit (FPCs) also have high resistance to vibrations, high temperatures, and atmospheric conditions.
How Do Traditional FPCs Compare to Modern FDC Alternatives?
Traditional FPCs possess significant benefits, such as the flexibility to bend into small and irregularly shaped spaces, alongside a high resistance to vibrations, high temperatures, and atmospheric conditions. However, FPCs are manufactured using a multi-step batch photolithography process that relies on harsh, corrosive chemicals to dissolve excess copper.
In contrast, FDCs are produced through a reel-to-reel die-cutting process that involves far fewer steps. A major environmental benefit of this FDC technology is its highly sustainable process, which allows for the instant recycling of clean copper waste material.
What Are the Practical Benefits of Implementing FDC Sensing Lines?
Implementing FDC sensing lines achieves substantial cost reductions, saving 25% in costs compared to traditional FPC sensing solutions, without compromising technical capabilities. The streamlined reel-to-reel manufacturing path also realizes a 50% reduction in production process time.
Furthermore, FDCs are verified to maintain performance parity with FPCs, passing strict and rigorous tests for thermal shock, high voltage, insulation resistance, dimensions, trace resistance, and temperature rise.
Why Is FDC a Scalable Solution for Large Battery Configurations?
The reel-to-reel manufacturing process of FDC technology entirely eliminates these length and size limitations. By removing these constraints, FDCs can seamlessly support large-scale assemblies, enabling the integration of larger battery modules and advanced cell-to-pack (CTP) or cell-to-chassis (CTC) configurations. These scalable sensing lines are tough enough to support battery module capacities of 50A to 400A while easily maintaining a thin and lightweight profile.
Choosing the Optimal Sensing Path for EV Battery Safety
To ensure optimal EV battery safety and connectivity, it is crucial to evaluate your system’s spatial and budget requirements to determine the best fit between FPC, FFC, or FDC sensing lines.
Contact our technical team today to enquire about our custom interconnects.