ENNOVI Introduces New Flexible Circuit Production Process for Low-Voltage Connectivity in Electric Vehicle Battery Cell Contact Systems

4 April 2024

ENNOVI , mobility electrification solutions partner, introduces a more advanced and sustainable method of producing flexible circuits for low-voltage signals in battery cell contact systems of electric vehicles (EV). Although flexible printed circuits (FPCs) are often used in these systems, they are the most expensive component of today's collector assembly. ENNOVI's Flexible Cut Circuit (FDC) technology offers a more cost-effective and sustainable solution, with fewer manufacturing procedures and faster continuous reel-to-reel production.

Typically, FPCs are manufactured using a multi-step batch photolithography process to etch the copper traces of the flexible circuit. This production process uses harsh chemicals that dissolve unwanted copper. Additionally, it takes a lot of time and energy to extract waste copper from chemicals, making effective recycling difficult. The cutting process instantly recycles copper, making it preferable to chemical etching.

Unlike FPCs, which are limited in size to 600 x 600 mm, FDCs have no length restrictions since they are manufactured from reel to reel. Under certain design conditions, FDC offers similar performance characteristics to FPCs. These results have been confirmed by rigorous internal testing covering dimensions, thermal shock, trace resistance, temperature rise, insulation resistance and high voltage.

“The adoption of FDC capability for flexible circuits aligns with our vision of thinking outside the box by creating a sustainable value chain for electric vehicle batteries,” said Gustavo Cibrian, product manager, energy systems, at ENNOVI. Our efforts enable ENNOVI to offer battery manufacturers a CCA design solution that balances their cost, schedule and performance requirements. It allows them to design within budget. »

For more information on ENNOVI's FDC competency, please visit  https://ennovi.com/fdc-technology