As the world electrifies, battery management systems (BMS) become ever more critical. Whether in an electric vehicle, grid-scale energy storage, or portable power tools, the BMS monitors and protects the battery pack while optimizing performance and longevity.
Flexible circuits offer unique advantages for BMS applications. Unlike rigid boards that require complex cabling, flex circuits can conform directly to battery cell arrangements, reducing connection points and improving reliability. Heavy copper capability handles the high currents involved, while the thin profile fits within space-constrained battery packs.
Our BMS flex solutions span from simple cell monitoring strips to complex multilayer circuits with integrated current sensing, temperature monitoring, and communication interfaces. We support both consumer electronics and high-voltage EV applications with appropriate design practices and certifications.
Up to 4oz copper weight handles high currents in battery applications. Power distribution and sense traces optimized for current capacity.
Design practices for high-voltage systems include appropriate creepage, clearance, and isolation barriers. Support for 400V and 800V EV architectures.
Integrated NTC thermistor mounting and routing for cell temperature monitoring. Critical for thermal management and safety.
Flexible construction follows battery cell arrangements. Direct cell connections reduce wiring complexity and improve reliability.
Flexible circuits serve battery management across all scales.
Cell monitoring, balancing, and pack control for automotive battery packs. High-voltage designs for 400V and 800V architectures with automotive reliability.
Grid-scale and residential storage systems use flex circuits for cell monitoring across large battery arrays.
Smartphones, laptops, and power tools use flex circuits for battery protection and charge management in compact packages.
Light electric vehicle batteries use flex circuits for BMS functions in cylindrical and pouch cell configurations.
Cordless tool battery packs rely on flex circuits for protection, monitoring, and communication with the tool.
Portable medical equipment batteries require reliable BMS with appropriate safety certifications.
EV and energy storage applications demand careful high-voltage design practices.
Appropriate spacing between high-voltage elements per IPC-2221 and automotive standards. We verify designs meet required distances.
Physical separation between high-voltage battery side and low-voltage control side. Slot routing and material selection for isolation.
Precision shunt resistor integration or Hall effect sensor mounting for accurate current measurement. Kelvin connection routing for shunts.
Integration of safety interlock circuits including service disconnect and crash detection interfaces.
Conformal coating and potting considerations for protection in harsh automotive environments.
Connecting to battery cells requires application-specific approaches.
Aluminum or copper wire bonds from flex circuit to cell tabs. Used for cylindrical cells (18650, 2170, 4680) where direct soldering is restricted.
Nickel or aluminum tabs welded to cells, then soldered to flex circuit. Common for pouch and prismatic cells.
Where cell chemistry and construction allow, direct soldering of flex to cell terminals. Requires careful thermal management.
Spring contacts or pressure connections for serviceable designs. Common in consumer electronics where battery replacement is expected.
Routing for active or passive cell balancing. Current capacity matched to balancing method requirements.
12-cell monitoring flex circuit for automotive battery module. Integrated NTC sensors, cell balancing traces, and CAN bus interface.
5S2P lithium battery management flex for cordless power tool. Integrated protection MOSFET mounting and LED indicators.
Distributed cell monitoring flex for grid storage battery string. 16-cell monitoring with daisy-chain communication.
We design BMS flex circuits for systems up to 800V (automotive). Higher voltages are possible with appropriate design practices. We verify creepage and clearance requirements for your voltage level.
Yes, we support both shunt resistor integration with Kelvin connections and mounting provisions for Hall effect sensors. Trace routing is optimized for accurate measurement.
Copper weight depends on current requirements. 1oz handles typical sense currents, 2oz for moderate power, 3-4oz for high-current applications. We help select appropriate weight for your current requirements.
Our flex circuits are designed for compatibility with wire bonding processes. We specify appropriate pad design and surface finish for reliable bonds. The bonding process is typically performed by the pack assembler.
Our manufacturing is ISO 9001 certified and supports UL recognition for appropriate material combinations. We work with customers to ensure designs meet automotive and energy storage safety requirements.
