Next-Generation Cell-to-Pack Battery Configurations - Assembly & Protection Solutions Division | Parker US
Next-Generation Cell-to-Pack Battery Configurations

With the significant growth and development of battery pack technologies, manufacturers of electric vehicles (EVs) are placing an increased emphasis on optimizing pack design. For immediate and long-term solutions in battery packs, new thermally conductive (TC) adhesive technology is necessary. That's why we have developed thermally conductive (TC) urethane adhesives that will enable direct bonding of battery cells with cooling plates. 

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What is Cell-to-Pack?

Why is thermal management crucial in cell-to-pack applications? Our application engineer explains how materials improve efficiency and performance in electric vehicles. Learn how our thermal adhesives help achieve optimal thermal conductivity for better battery performance.

 

Watch our video now to learn more. 

Cell to Pack Question Video

Current Versus New Battery Pack Design

Pack design is shifting from a modular-based design to cell-to-pack. Cell-to-pack (CTP) battery design is a manufacturing process used to create lithium-ion battery packs by directly integrating individual battery cells into the pack without using module-level electronics.

Cell-to-Pack Current

Current Battery Pack Design

In today's modular-based configuration, a minimum of two discrete thermal interface materials (TIMs) are employed to regulate the modules' temperature and ensure safe, efficient performance. However, the added weight and volume from the design's inactive portions lead to compromised pack energy density. Plus, the many discrete parts increase the complexity of the design, manufacturing and supply chain logistics.

New Battery Pack Design

New Battery Pack Design

Given the challenges of the current battery pack design, many EV and battery manufacturers are eliminating modules entirely and directly bond batteries to the cooling plate. This new module-free approach, referred to as “Cell-to-Pack” (CTP), reportedly increases volume-utilization space from 15-50%, depending upon battery cell design. Moreover, the number of parts is claimed to be reduced up to 40%.

Benefits of Cell-to-Pack Adhesives

  • Increases volume-utilization space from 15-50% 
  • Reduces the number of parts up to 40%
  • Uses less expensive, lower energy density cells given the extra space
  • Improves battery pack energy density
  • Decreases heating or cooling loads by the cooling plate
  • Provides high levels of adhesion at 85°C and 85% RH
  • Lowers manufacturing costs for electric vehicle OEMs
Benefits of Cell-to-Pack Adhesives

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The Next Generation of Battery Technology

Battery pack design and technologies are shifting. Old pack designs have included modular-based battery pack configurations that pose challenges, including added weight and volume. With new Cell-to-Pack technology, EV and battery manufacturers are seeing benefits, including increased volume-utilization space and reduced number of parts.

The Next Generation of Battery Technology
Cell-To-Pack Whiepaper

Featured Whitepaper

To address the emerging trends in battery pack design, new thermally conductive adhesive technology is needed, especially given the imposition of more demanding environmental and mechanical performance conditions.

This paper will review new developments in thermally conductive urethane adhesives that enable direct bonding of prismatic battery cells to aluminum cooling plates with the above requirements in mind. Comparisons to traditional battery pack configurations and associated adhesive solutions will also be discussed. 

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Want to know more about the fundamentals of Cell-to-Pack configurations? Interested in speaking to an expert about our newest thermally conductive urethane adhesive? Then contact us now to speak with one of our experts. 

FAQs

Expand each section below for answers to frequently asked questions on cell-to-pack adhesives and technology.