In a groundbreaking advancement in electric vehicle (EV) technology, ENNOVI, a leading mobility electrification solutions partner, has unveiled a cutting-edge approach to producing flexible circuits for low voltage signals in EV battery cell contacting systems. The introduction of Flexible Die-Cut Circuit (FDC) technology represents a significant leap forward in sustainability and cost-effectiveness within the EV manufacturing landscape.
Traditionally, Flexible Printed Circuits (FPCs) have been the go-to solution for EV battery cell contacting systems, despite being the most expensive component in the current collector assembly. However, the production process for FPCs involves multi-stage, batch photolithography procedures, utilizing corrosive chemicals to etch copper traces onto the flexible circuit. This process not only consumes substantial time and energy but also poses challenges for effective recycling due to the extraction of waste copper from the chemicals.
ENNOVI’s FDC technology offers a paradigm shift by introducing a more sustainable alternative to traditional FPCs. Unlike FPCs, which face size limitations of 600x600mm, FDCs are manufactured reel-to-reel, eliminating length restrictions and enabling faster, more efficient production processes. Moreover, the die-cutting process employed in FDC production allows for instant recycling of copper, mitigating environmental concerns associated with chemical etching.
The performance characteristics of FDCs have been rigorously tested in-house, encompassing dimensions, thermal shock, trace resistance, temperature rise, insulation resistance, and high voltage testing. These tests have validated the capability of FDCs to deliver comparable performance to FPCs, further affirming their viability as a sustainable and cost-effective solution for EV battery connectivity.
Gustavo Cibrian, Product Manager, Energy Systems, at ENNOVI, underscored the significance of adopting FDC technology in the pursuit of a sustainable battery value chain for EVs. “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,” stated Cibrian, emphasizing ENNOVI’s commitment to driving innovation in the EV ecosystem.
As ENNOVI leads the charge in revolutionizing EV battery connectivity with FDC technology, the automotive industry stands poised to embrace a more sustainable and efficient future in electric mobility.
