Application of FPC in new energy vehicles

FlexiblePCBsupplierchina learned the acquisition line is an important component required for the BMS system of new energy vehicles, which can monitor the voltage and temperature of the new energy power battery cells;  Connect data acquisition and transmission with overcurrent protection function;  Protect the car power battery cell, automatic disconnection of abnormal short circuit and other functions.

Previously, the power battery acquisition line of new energy vehicle adopted the traditional copper wire harness scheme.  The conventional wire harness was made of plastic surrounded by copper wires, and each harness reached an electrode when connected to the battery pack.  When there are many current signals in the power battery pack, many harnesses are required to cooperate, and the space is squeezed out.

In the pack assembly process, traditional wiring harnesses rely on workers to manually fix the ports to the battery pack, and the degree of automation is low.  Compared with copper wire harnesses, FPC has outstanding advantages in safety, lightweight, and regular layout due to its high integration, ultra-thin thickness, ultra-softness and other characteristics.

In addition, the thickness of FPC is thin, the battery pack structure is customized, and FPC can be directly placed on the battery pack through the robotic arm during assembly, with a high degree of automation, which is suitable for large-scale mass production, and the trend of FPC replacing copper wire harnesses is clear.

Advantages of FPC in power battery modules

1.  Highly integrated: self-embedded Fuse, connector, chip NTC, aluminum/nickel terminal.  It not only provides excellent and consistent electrical performance, but also meets the design needs of smaller and higher density installations.  The three-degree space wiring and the appearance can be changed according to the limitations of space, which is suitable for the development of high density, miniaturization and high reliability, so as to achieve the integration of component assembly and wire connection.

2.  Automatic assembly can be realized: fast and accurate assembly, which is conducive to automation.  In assembly and fault tolerance, many manual errors in the design of wiring harnesses can be avoided, and many opportunities for insertion errors can be reduced at the connector level.

Using FPC sampling, the complexity of the module integration process can be reduced, and the connection between FPC and battery busbar can realize automatic welding, effectively reducing labor costs.  Even if the customer cannot mature to realize automatic welding, the traditional screw locking method can still effectively reduce the labor input.

3.  Ultra-thin thickness: 0.34mm in the line area, 2mm at NTC.

4.  Super softness: the line area can be bent and assembled at 90° and 180°.

5.  Lightweight: When the whole vehicle is used, the weight can be reduced by about 1kg compared with the wiring harness solution.

6.  Cost advantage: From the cost point of view, the cost of FPC itself is not high, and it is a great reduction in connection costs.

Compared with copper wire harnesses, FPC has outstanding advantages in safety, lightweight, and regular layout due to its high integration, ultra-thin thickness, ultra-softness and other characteristics.

In addition, the thickness of FPC is thin, and the FPC can be grabbed by the robotic arm and placed directly on the battery pack when the battery pack structure is customized and assembled, which has a high degree of automation and is suitable for large-scale mass production, and the trend of FPC replacing copper wire harnesses is clear.

At present, FPC solutions have become the most important choice for most new energy vehicle models.  FPC is integrated into CCS (Cells Contact System).

PCBmanufacturer learned CCS products are composed of FPC, plastic structural parts, copper and aluminum rows, etc.  The copper and aluminum busbar connects multiple cells in series and parallel by laser welding, and the FPC is connected with the copper and aluminum busbar and plastic structural parts to form an electrical connection and signal detection structural component.