ENNOVI introduces a new flexible circuit board production process for low-voltage connections in battery interconnection systems for electric vehicles

     Mobile electrification solutions partner ENNOVI has introduced a more advanced and sustainable process for the production of flexible circuit boards for low-voltage signal connections in electric vehicle (EV) battery interconnect systems. Flexible printed circuit boards (FPCS), although commonly used in battery interconnect systems, are the largest source of cost for battery interconnect systems. ENNOVI's flexible die-cut circuit board (FDC) technology offers a more cost-effective and sustainable solution that not only simplifies the production process, but also increases the efficiency of continuous roll-to-roll production.

     At present, the industry usually uses a multistage batch lithography process to produce flexible die-cut circuit boards. This process requires etching copper foil lines on the flexible circuit board, that is, using corrosive chemicals to dissolve unwanted copper foil, but it takes a lot of time and energy to extract copper waste from the chemicals afterwards, so it is difficult to achieve effective recycling of copper. The die-cutting process allows for rapid recycling of copper and is therefore preferred over the chemical etching process.

     Flexible printed circuit board (FPC) size limit is 600mm x 600mm. In contrast, the flexible die-cut circuit board (FDC) has no length limit due to the continuous roll-to-roll production process. Under certain design conditions, flexible die-cut circuit boards (FDC) have similar performance characteristics to flexible printed circuit boards (FPC). This has been confirmed by rigorous internal sizing, thermal shock testing, line resistance testing, temperature rise testing, insulation resistance testing and high voltage testing.

     "Using FDC technology for flexible circuit board production is in line with our vision to create a sustainable battery value chain for the electric vehicle industry through innovation," explains Gustavo Cibrian, Portfolio Director, ENNOVI. "We are pushing ENNOVI to provide a CCS design solution that perfectly balances the pressing needs of battery manufacturers in terms of cost, time and performance to help them design to cost."