Cell to Pack Technology

Cell to Pack (CTP) technology connects the batteries directly to the pack, eliminating the need for modules and therefore decreasing the overall size, weight, and cost of a battery.

Pentatonic Cell to Pack Battery Enclosure

cell to pack monolith structure

Structural Monolith

The Kautex Pentatonic Cell to Pack Enclosure is a lightweight structural sandwich, with the cell block acting as the core to link the bottom tray and top cover, creating a single monolithic pack. When joined, the top cover with endless UD fibers and the bottom tray act as resistance against tensile and compression forces while the core resists bending, which allows for efficient vertical loading across the pack.

cell to pack underbody protection

Fully Serviceable Underbody Protection

The full composite underbody protection plate (UBP) is easily replaceable for serviceability without compromising the structural integrity of the battery pack. Customizable material stacks allow for UBP levels to be engineered for both on-road and off-road vehicle applications. 

cell to pack thermal runaway venting

Thermal Runaway Venting

Cell thermal runaway (TR) is vented downward out of the tray and into the UBP layer. Hot gasses are then collected within the UBP and evacuated without ever returning to the internal compartment, keeping the cell inside safe. By combining the cell TR venting and UBP zone, we are also minimizing the height of the pack altogether. 

Benefits

Advanced functionality
  • Reduce height with increased Underbody Protection and Thermal Runaway venting functionality
  • Non-conductive pack 
  • Scalable to suit electrical architecture and package
More streamlined assembly
  • No potting required
  • Repeatable block sub-assembly
  • Reduced assembly fail rate
  • Shorter assembly cycle time 
  • Structural welding of full thermoplastic pack
Precise cell positioning
  • Cell height tolerances can be equalized easily
  • Our structural cell holders are designed to provide exact Z positioning of the cells against a defined plane, such as the top of the housing, which facilitates subsequent electrical contacting
Improved recyclability
  • The serviceable UBP can be replaced in case of an underbody damage and recycled due to its thermoplastic material
  • Full pack end-of-life recyclability is enhanced by a consistent thermoplastic material system
  • Metallic electrical & thermoplastic enclosure components can be easily separated, as they are not bonded together by potting material