Mobility electrification solutions partner Ennovi has introduced a new approach to producing flexible circuits for low-voltage signals in electric vehicle (EV) battery cell contacting systems.
Traditionally, flexible printed circuits (FPC) have been used for this purpose, albeit at a high cost. Ennovi’s introduction of flexible die-cut circuit (FDC) technology has been designed to offer a more cost-effective and sustainable alternative, simplifying manufacturing procedures and enabling faster continuous reel-to-reel production.
Unlike the multi-stage, batch photolithography process used in FPC production, which involves the use of corrosive chemicals to etch copper traces, FDC manufacturing employs a die-cutting process. This enables instant recycling of the copper, avoiding the challenges associated with extracting waste copper from chemicals.
While FPCs are limited to dimensions of 600 x 600mm, FDCs have no length restrictions as they are manufactured reel-to-reel. FDCs can achieve similar performance characteristics to FPCs under certain design considerations, making them a more suitable alternative in terms of size and flexibility.
Their performance has been confirmed via in-house dimension, thermal shock, trace resistance, temperature rise, insulation resistance and high-voltage testing, Ennovia says.
“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,” explained Gustavo Cibrian, product manager, energy systems, 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.”