Thermal management is an important factor influencing electric vehicle battery charge rates and cost. The latest BEV battery packs from Tesla, BYD, and Geely are simpler and scalable with lower cost and mass through cell-to-pack (CTP) and cell-to-chassis architectures. In parallel, thermal systems are evolving toward greater battery pack integration. A recent CATL CTP battery pack, with integrated thermal design, reduces complexity by 40%, cost by 50%, doubles thermal power, improves thermal control, and reduces thermal runaway risk.
Source: Manufacturers and The ITB Group, Ltd.
Thermal systems have been evolving from complex modular designs toward simplified scalable thermal structures. Furthermore, integrated battery thermal designs affect more than coldplate design. Integrated thermal systems can reduce the cost of fluid lines and connections, thermal interfaces, and other materials. For integrated battery pack designs, coldplates can have more functions beyond cooling. Integrated coldplate designs can increase battery pack stiffness, compensate for cell expansion, increase thermal surface area, plus contribute to reducing thermal interface materials and cell separators.
Virtually all automakers are developing cell-to-pack and/or cell-to-chassis battery pack designs. It is imperative that companies make battery design changes soon to remain competitive. At the same time, production processes and components must be scaled up rapidly as BEV vehicle volume increases. Companies able to rapidly evolve and innovate will be more successful in the transition to electric vehicles.
ITB provides insights into changing vehicle regulations, technologies, and markets
ITB gathers input from throughout the automotive value chain regarding unmet needs and innovations to improve system value. ITB’s 2023 thermal management research dives deeply into markets, designs, and materials plus effects on vehicle cost and performance, such as BEV range and charging rates. To learn more contact ITB.
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