EV batteries comprise multiple small singular cells connected with cables. This poses multiple challenges, such as connecting cables in the wrong positions, creating high costs, and adding much weight to the final product. 

Replacing these cables with printed electronics or flat cabling cell-connecting solutions ensures no faults can be made with the connections. With flexible printed electronics foil or plastic-coated flat cabling sheets, each connection point is assigned to a predetermined area, ensuring no faults and reflecting a ‘poka-yoke’ system. Eliminating cables in car battery production massively increases output safety and economy. 

Thermal management is becoming increasingly important in electric vehicles, as batteries radiate a lot of heat and also need to work at an optimal temperature. There is also high demand to reduce the weight of these vehicles to promote safety and performance.

Printed electronics can replace typically printed circuit boards (PCBs) by printing sensors and conductive traces on a flexible substrate such as PET and then mounting surface mount devices (SMDs) components such as integrated circuits (ICs).

Benefits of working with ALT Technologies for Battery Management Wire Harnesses and Printed Electronics:

• Our printed electronics and flat cabling cell connection system solutions provide design freedom and are application-specific engineered solutions.
• Adding adhesive for easy mounting, automotive dispersing options, and connecting via conductive tape, welding or soldering is possible. The Poka-Yoke design ensures fixed cabling and no mix-up of wires. 
• This powerful technology is lightweight and can be used in a wide variety of automotive applications, including car heaters, sensors, HMI (human-machine interface) and lighting systems.

ALT Technologies has been working within the automotive industry for over 20 years, ensuring flexible solutions in both development and design.