Flexible circuit optimised for EV battery production

Ennovi introduces a new automotive-grade flexible die-cut circuit designed to offer a more sustainable wiring option for new battery designs without compromising performance.

Ennovi has introduced a more advanced, sustainable way of producing flexible circuits for low voltage signals in (EV) battery cell contacting systems. While flexible printed circuits (FPC) are often employed in these systems, they are the most expensive component in the current collector assembly (CCA). Ennovi’s flexible die-cut circuit (FDC) technology is engineered to offer a more cost-effective and sustainable solution, with fewer manufacturing procedures and faster continuous reel-to-reel production.

Generally, FPCs are manufactured using a multi-stage, batch photolithography process to etch copper traces for the flexible circuit. This production process uses corrosive chemicals that dissolve the unwanted copper. In addition, it takes a lot of time and energy to extract the waste copper from the chemicals, making it challenging to effectively recycle. The die-cutting process allows for instant recycling of the copper.

Compared with FPCs, which have a size limitation of 600 by 600mm, FDCs boast no length restrictions as they are manufactured reel-to-reel. Under certain design considerations, the FDC provides similar performance characteristics to FPCs. These results were confirmed through rigorous in-house dimension, thermal shock, trace resistance, temperature rise, insulation resistance and high voltage testing.

Ennovi’s product manager, energy systems, Gustavo Cibrian, said: “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. Our efforts enable Ennovi to offer battery manufacturers a CCA design solution that balances their imperatives in terms of cost, time and performance.”