Development of Cell to Body Technology towards High Levels of Integration, High Strength and High Stiffness

Rapid technological advancement of electric vehicles (EV) contributed to a significant increase of its market share worldwide. Among them battery technologies are key in extending the range of battery electric vehicles (BEV) and easing range anxiety for drivers. To further enhance the range for BEVs, continued downsizing of the battery system together with an increased energy density would be required. Cell to body (CTB) technology was release by BYD Auto in 2022 as its answer to the next generation of battery pack design and system level integration. The battery pack features a sandwich structure that consists of an upper cover, the company’s signature Blade Battery cells, and an underbody protection tray. The battery pack features a higher level of integration, with the volume utilization rate increasing to 66%. The integrated battery pack-body structure enhances its structural strength, with significant reductions in the intrusions across front, small-overlap and side pole impacts. 70% and 57% increases in the torsional and the bending stiffness of the body results in better handling performance and improved passenger comfort. The CTB technology has shown its great potential for high performance BEV design.