Cell-to-Pack vs Cell-to-Chassis - Assembly & Protection Solutions Division | Parker US
EV Battery Pack

FAQ

As electric vehicles (EVs) continue to evolve, so do the technologies that power them. One critical area of innovation is battery architecture. The design and integration of battery cells can significantly impact the performance, safety and efficiency of an EV. We explore two primary battery architectures: Cell-to-Pack (CTP) and Cell-to-Chassis (CTC), comparing their advantages, disadvantages and applications.

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What is Cell-to-Pack Design?

"Cell-to-pack" (CTP) is a battery design where individual battery cells are directly integrated into a larger battery pack without additional modules or components. In this design, the individual cells are connected in series and/or parallel to create a larger battery that can provide the desired voltage and capacity. This approach is often used in electric vehicles, where the battery pack is a critical component that must be optimized for weight, volume, and energy density.

 

Advantages of CTP:

  • Increased Energy Density
  • Reduced Weight
  • Simplified Manufacturing

Disadvantages of CTP:

  • Thermal Management Challenges
  • Maintenance and Repair

What is Cell-to-Chassis Design?

"Cell-to-chassis" (CTC) is where individual battery cells are integrated into a modular system, which is then connected to the vehicle chassis. The modular system typically includes additional components such as cooling systems, control electronics and safety features. In this design, the battery cells are connected to the modular system, which is then mounted onto the chassis. This approach is often used in hybrid vehicles, where the battery system is not as critical to the vehicle's performance and can be optimized for cost and reliability.

 

Advantages of CTC:

  • Space Efficiency
  • Structural Benefits
  • Weight Reduction

Disadvantages of CTC:

  • Complex Manufacturing
  • Repair and Replacement

Comparing Cell-to-Pack and Cell-to-Chassis

Choosing the right battery architecture—Cell-to-Pack (CTP) or Cell-to-Chassis (CTC), depends on the specific requirements and priorities of the EV design. Each architecture offers unique advantages and challenges, influencing factors such as energy density, manufacturing complexity, thermal management and maintenance.

What role do thermal management materials play in Cell-to-Pack and Cell-to-Chassis designs?

Thermal management materials play a critical role in ensuring the safe and efficient operation of battery packs in electric vehicles in both cell-to-pack and cell-to-chassis designs.

In a CTP design, thermal management materials can be used to improve the heat dissipation properties of the battery pack. This can include the use of Cooltherm materials such as gap fillers and adhesives to help conduct heat away from the cells and distribute it evenly across the pack.

In a CTC design, thermal management materials can be used to manage heat and bond battery cells to the chassis and other components. This can include the use of thermal management materials to dissipate heat from the cells, regulate the temperature of the cells and prevent overheating. 

gap filler for CTP and CTC

Wrapping it Up

Understanding the differences between CTP and CTC is crucial for manufacturers and consumers alike, as the choice of battery architecture can significantly impact the performance, safety and overall efficiency of electric vehicles. As the EV industry continues to innovate, these architectures will play a vital role in shaping the future of sustainable transportation.

Cell to Pack Design

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