Mechanical Design and Packaging Strategies of a Cell-To-Pack Battery for An Automotive Electric Vehicle Based on Economic & Sport Vehicle Requirements

The world is moving towards a green transportation system. Governments are also pushing for green mobility, especially electric vehicles. Electric vehicles are becoming more popular in Europe, China, India, and developing countries. In EVs, the customer's range anxiety and the perceived real-world range are major challenges for the OEMs. The OEMs are moving towards a higher power-to-weight ratio. Energy density plays a crucial role in the battery pack architecture to increase the vehicle range. Higher capacity battery packs are needed to improve the vehicle's range. The battery pack architecture is vital in defining the gravimetric and volumetric energy densities. The cell-to-pack battery technique aims to achieve a higher power-to-weight ratio by eliminating unnecessary weight in the battery architecture. The design of battery architecture depends on the cell features such as the cell shape & size, cell terminal positions, vent valve position, battery housing strength requirements, etc. This work analyzed different LFP cell-to-pack architectures based on the production-ready battery cells to achieve optimized cost, vehicle range, structural rigidity, and safety to meet economic & sporty vehicle requirements.