Cell to Pack (CTP) or no module technology eliminates or reduces the number of battery modules and directly arranges the cells …June 10, 2023

By arranging multiple batteries in the box, the number of parts is reduced, and the utilization rate of chassis space improves. CTP technology breaks the traditional three-level grouping design thinking of “single cells, modules, and then battery packs” and realizes the two-level grouping of “single cells directly into battery packs.”

How does cell to pack differ from cell to module?

The traditional integration method used for electric vehicles is Cell to Module (CTM), which represents the integration mode of integrating batteries on modules.

In CTM, space utilization rates are only at 40%, which greatly limits the area allocated to other components while also reducing battery life of the vehicle. The biggest difference between CTP and CTM is that CTP cancels the modules; hence, the way the battery is fixed changed.

When there was a module design before, the battery was mounted on the beam of the battery pack through the end plate or side plate, whereas now the battery cells are glued together, making the glue extremely rigid allowing it to enhance heat conduction.

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What are the advantages of cell to pack?

Cell To Pack provides several advantages such as:

• This approach reduces structural parts and materials used like beams and longitudinal beams that separated the modules and assisted with the modules’ connection.

• It simplifies the entire battery structure and frees up space

• Expansion of battery pack capacity and weight reduction for the same size

• Increase in battery energy density and decrease in cost

BYD’s application of Cell to Pack Technology

One member of the top ten lithium iron phosphate power battery manufacturers, BYD adopted the CTP (Cell-To-Pack) design concept where cells are installed directly in an array within the battery pack case, eliminating the step of assembling battery cells to a module.

BYD’s CTP design assures the strength of the battery pack, saves accessories such as beams, longitudinal beams, and bolts, and enhances space utilization within the battery pack shell from 40%-50% to 60%-80%.

After canceling the beams and longitudinal beams in the battery pack shell, BYD adopted other designs to ensure the battery pack does not readily deform under all-directional force. This is why BYD had to make blade batteries long and thin.

In the length direction, the blade battery can replace the beam structure while stacking “blade batteries” can replace the longitudinal beam structure in the thickness direction, ensuring ample structural strength within the battery pack.

At the same time, high-strength plates are mounted on the side ridge of the blade battery so that it can bear the load-bearing functions required for the blade battery.

These designs allow the blade battery to skip the module link and directly form a battery pack, thereby increasing space utilization.