FPC & CCS Dispensing for New Energy Applications
Precision dispensing solutions for flexible printed circuits and cell contact systems in power battery applications
PCB Printed Circuit Board
PCBs are widely used and typically made of FR4 substrate. They are rigid structures that cannot be bent or flexed. PCBs form the backbone of most electronic devices but have limitations in applications requiring flexibility or complex 3D layouts.
FPC Flexible Printed Circuit
FPC is manufactured using polyimide or polyester film as the base material. FPCs offer high reliability and excellent flexibility, allowing them to be bent, folded, and flexed freely. Due to their flexible substrate, FPCs can adapt to complex three-dimensional layouts that rigid boards cannot achieve.
Advantages of FPC
Key benefits compared with traditional PCBs
Application Fields
Consumer Electronics
Mobile phones, computers, tablets, and wearable devices leveraging lightweight and ultra-thin characteristics
Automotive Industry
LED lighting, instrument panels, ADAS, entertainment control systems, and BMS applications
Data Storage
Server and data storage equipment connections requiring high-density wiring
Aerospace & Defense
Satellites, testing instruments, and radar systems demanding high reliability
Industrial Control
Sensors, heating coils, and automation systems requiring flexibility
Medical Devices
Pacemakers, endoscopes, probes, and therapeutic equipment
Market Growth
FPC industry development and new energy applications
(2009-2019)
(2019)
(Expected)
PCB Share
FPC and CCS in Power Battery Systems
In power battery applications, particularly lithium batteries, FPCs are mainly used to replace traditional copper wire harnesses. Previously, new energy vehicle battery signal collection relied on conventional copper wire harnesses, which occupy significant space and limit layout optimization.
Compared with copper wire harnesses, FPCs offer clear advantages in safety, lightweight design, and organized layout due to their high integration, ultra-thin profile, and excellent flexibility.
The downstream integrated product of FPCs is CCS (Cell Contact System), also known as integrated busbars. CCS products are composed of FPCs, plastic structural components, and copper or aluminum busbars.
In new energy vehicles, the value of CCS per vehicle is expected to reach 2-3x that of FPC alone.
Dispensing Challenges & Key Considerations
Critical factors for FPC and CCS manufacturing processes
Adhesive Selection
Due to the flexible nature of FPC substrates, adhesive reinforcement is required. The adhesive must provide high bonding strength, resistance to impact and vibration, sufficient elasticity, and stable electrical properties.
Dispensing Quality
Flexible circuit boards have higher integration density and smaller spacing. This places stricter demands on dispensing accuracy. Insufficient precision can lead to internal short circuits or open circuits.
Manufacturing Process
Thin structures, high-density wiring, and lightweight designs introduce challenges during drilling, cutting, lamination, and dispensing. Any deficiencies may result in rework or scrapping.
Equipment Selection
Dispensing plays a critical role as it directly affects product performance and reliability. Precision dispensing equipment with accurate volume control is essential for meeting quality requirements.