Accelerating the Future: FPC Manufacturing for New Energy Vehicles-Rotary Die Cutting Machines

In the charging system of electric vehicles, CCS (Combined Charging System) is a widely adopted charging standard. rotary die cutting machine plays a role in CCS applications in the following aspects:

1. Manufacturing charging connectors: CCS standard utilizes charging connectors with both DC and AC charging interfaces. The rotary die cutting machine can be used to manufacture the connector components, such as metal contacts for plugs and sockets. The machine accurately cuts and shapes the metal sheets to ensure reliable connectivity between the plugs and sockets.

2. Manufacturing charging harnesses: The charging harness in CCS system consists of multiple wires and connectors. The rotary die cutting machine can be used to cut the wires to the desired length and effectively connect the wires with connectors through die-cutting technology. This improves the reliability and durability of the harness.

3. Producing charging labels and tags: CCS standard requires labeling the type and performance of the charging interface on the charging equipment and vehicles. The rotary die cutting machine can be used to manufacture these labels and tags, such as labels indicating charging power and communication protocols. The machine accurately cuts and prints the labels, ensuring their adherence and durability.

FUMART is focusing on the development of the new energy vehicle sector, specifically in the areas of FPC (Flexible Printed Circuit) and CCS (Cells Contact System). Traditional automotive wire harnesses, which are bulky and have complex and cumbersome connection methods, are unable to keep up with the increasing number of electronic components in new energy vehicles. FPC and CCS products have emerged as viable solutions. Currently, FPC connection solutions have become the main choice for the power battery systems in new energy vehicles, and manufacturers are also actively developing integrated CCS products. FPC and CCS present new opportunities for growth in the development of new energy vehicles.

In this wave of development, FUMART has embraced the market trends and seized the opportunities by venturing into the research and development of new technologies for FPC and CCS battery systems, specifically in the field of circular blade die cutting. FUMART aims to achieve independent research and development as well as production of core components and complete systems for FPC and CCS. Why has FUMART excelled in the FPC and CCS tracks? How will FUMART continue to forge ahead in the future?

With the rapid development of new energy vehicles in the context of global carbon neutrality goals, the market for new energy vehicles is thriving. The global production of new energy vehicles reached 4.2 million units in 2020 and is expected to reach 18 million units by 2025. The compound annual growth rate from 2020 to 2025 is projected to be around 40%. It is estimated that by 2030, the penetration rate of new energy vehicles will reach approximately 50%, with a total of 40 million units worldwide. This growth provides ample opportunities for the FPC and CCS sectors. By 2030, the global and domestic markets for new energy vehicle FPC are expected to reach 14-24 billion and 7.2-12 billion yuan, respectively. The global and domestic markets for new energy vehicle CCS are projected to reach 35-60 billion and 18-30 billion yuan, respectively.

As the automotive industry moves towards electrification, intelligence, and lightweighting, the use of FPC in vehicle applications continues to increase. FPC is used in various scenarios such as vehicle lights, display modules, BMS/VCU/MCU power control systems, sensors, and advanced driver assistance systems. The estimated usage of FPC per vehicle is expected to exceed 100 pieces.

Compared to traditional copper wire harnesses, FPC offers outstanding advantages in terms of integration, ultra-thin thickness, and flexibility. It excels in safety, lightweighting, layout organization, and automated production. Currently, FPC has become the main choice for most new energy vehicle models.

CCS is composed of FPC, plastic structural parts, copper-aluminum bars, etc., and is a part of the automotive BMS power system. The FPC is used to replace the collection lines of the power battery. Previously, the collection lines used a traditional copper wire harness scheme, where the harness is made of copper wire surrounded by plastic. When connecting to the battery pack, each harness reaches an electrode. When there are many current signals in the power battery pack, many harnesses are needed, which occupies a lot of space. The flexible, lightweight FPC perfectly replaces the traditional harness solution.

For FPC and CCS, die-cutting technology is widely used in the power battery connector, power battery NTC, FPC nickel sheet and other parts, which directly affects the performance and reliability of the products, becoming a big stage for die-cutting technology.

Based on research and development, the advanced journey of FUMART FPC and CCS technology

Riding the waves and seizing new trends, embracing the new future with confidence. Faced with the hot track of FPC and CCS, as early as 2018, FUMART intensified its layout, utilizing its years of experience in the die-cutting industry, from flatbed die-cutting machines to rotary die-cutting machines, always grasping the forward-looking trend of industry development, continuously upgrading the FPC and CCS production processes to adapt to market trends and provide customers with diverse choices.

In 2018, FUMART closely followed the current market demands and developed the first generation of FPC and CCS production equipment: rotary die-cutting machine, realizing efficient and precise production of FPC.

From 2019 to 2020, based on the accumulation of the first-generation FPC and CCS die-cutting technology, continuous improvement in customer quality strategies and increasing capacity requirements, FUMART developed the second generation of FPC and CCS die-cutting technology: a series of rotary die-cutting machines, which realized functions such as cutting, automated control, embossing, CCD vision automatic positioning detection, and peeling.