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Flexible Circuits Increase Range and Safety for Vehicle Batteries

June 01, 2020

Flexible Circuits Increase Range and Safety for Vehicle Batteries

The increased electrification of vehicles is a growing technology trend, driven in large part by advances in lithium (Li)-ion cells and battery pack design. In addition to high energy density, Li-ion batteries can be completely discharged and recharged hundreds of times with no reduction in performance. They don’t suffer performance decay when only partially charged and discharged. These performance advantages plus the increased adoption of electric vehicles is driving growth of Li-ion battery production.

Critical to safely obtaining the longest possible driving range from the battery packs are the battery management systems (BMS).  

During charging or discharging, Li battery cells generate heat, the BMS tracks and controls cell potentials, charge state and temperature to ensure safe operation.  The BMS, however, increases the size and weight of the battery pack. While the BMS optimizes battery performance and safety, they do not store energy, so the smaller the BMS, the more room for batteries in a given space.

 DuPont™ Pyralux® laminated circuit materials are thin bendable and conform to fit virtually any footprint requirement and tolerate high temperatures. In addition, DuPont™ Pyralux® flexible circuit materials tolerate high temperatures, providing a proven, reliable, IPC®-certified non-flammable product for building compact, form fitting BMS. These outstanding properties make DuPont™ Pyralux® an excellent choice for minimizing the size of the BMS and maximizing the space left for the battery cells. More cell space means greater driving range for the same size battery pack.

DuPont™ Pyralux® laminated circuit materials offer optimal solutions for an expanding Li-ion battery market. In addition to weight savings of up to 70%[1] and the ability to withstand elevated cell temperatures, DuPont™ Pyralux® laminated circuit materials can provide approximately 25-50% cost savings compared to traditional wire harnesses at high production volumes due to the automated manufacturing processes for flex circuits. DuPont™ Pyralux® product family comprises a range of laminates with capabilities that allow battery designers and fabricators to pick and choose one or more products that best suit their individual performance needs.

Find out which DuPont™ Pyralux® product fits your need at



[1] A Review of Flexible Circuit Technology and Its Applications, Peter Macleod, ISBN 1-84402-023-1, 2002.


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