Cell to Pack (CTP), Cell to Body (CTB) and Cell to Chassis (CTC) Integrated Battery Market 2024-2035

June 2024 | 205 pages | ID: C2F8FAD61185EN
Future Markets, Inc.

Abstracts

The growth in EV sales is driving demand for batteries, with the market for EV batteries surpassing 750 GWh in 2023, up 40% on the previous year. Electric cars account for approximately 95% of this growth. The EV market is rapidly expanding, and one of the significant challenges is the development of a reliable and safe battery that can provide a long driving range. The traditional lithium-ion batteries used in electric vehicles have limitations such as low energy density, poor thermal stability, and a tendency to catch fire. Vehicle OEMS and battery manufacturing companies are developing new batteries to address these issues for safe uses in electric vehicles. The key advantage of cell to pack (CTP), cell to body (CTB), and cell to chassis (CTC) battery technologies over traditional lithium-ion battery technologies lies in their improved energy density and enhanced performance parameters. These innovative battery integration approaches enable higher volumetric and gravimetric energy densities, allowing for more compact and lightweight battery solutions that occupy less vehicle packaging space while contributing to reduced overall vehicle weight.

Moreover, CTP, CTB, and CTC technologies facilitate more efficient battery packaging designs, minimizing manufacturing steps, reducing overall battery packaging volume, and enabling greater design flexibility. This translates into longer battery life and superior performance metrics, such as more stable battery characteristics, extended battery lifespans, and improved overall battery performance. A significant advantage of these advanced battery technologies lies in their potential to lower battery packaging and assembly costs. By streamlining manufacturing processes and reducing complexity compared to traditional methods, CTP, CTB, and CTC packaging techniques offer cost-effective solutions for automotive manufacturers.

Cell to Pack (CTP), Cell to Body (CTB) and Cell to Chassis (CTC) Integrated Battery Market Report 2024-2035 covers the latest technologies, key applications, manufacturing processes, advantages, challenges, and opportunities within this rapidly evolving industry across major global regions. The integration of batteries directly into vehicle bodies and chassis represents a transformative shift in automotive design and engineering. This report meticulously evaluates the technological capabilities, real-world applicability, advantages, disadvantages, and tangible benefits CTP, CTB and CTC offer the entire automotive value chain.

The report assesses the pivotal battery technology trends propelling advancements in on-road and off-road automotive and aerospace vehicles utilizing CTP, CTB and CTC integrated solutions. This comprehensive evaluation illuminates the key commercial opportunities and strategic entry points across different vehicle segments. Also covered are emerging next-generation battery chemistries, materials, and architectures poised to disrupt the market further. The role of transformative technologies like AI, IoT, and wireless battery management systems in optimizing performance, safety, and sustainability is examined in detail. Report contents include:

• Technology Overview including in-depth technical specifications on:
• Cell-to-Pack (CTP) Technology
• Cell-to-Body (CTB) Technology
• Cell-to-Chassis (CTC) Technology
• Thermal Management Systems
• Battery Management Systems (BMS)
• Market Analysis
• Global Market Overview
• Market Size and Forecast
• Market Segmentation
• Market Drivers
• Market Restraints
• Opportunities
• Challenges
• Competitive Landscape
• Key Players and Strategies
• Automotive OEMs
• Strategic Partnerships
• Regulatory Landscape
• Safety and Environmental Regulations
• Incentives and Subsidies
• Recycling and Disposal Regulations
• Future Outlook and Emerging Trends
• Battery Chemistry and Materials Advancements
• AI and IoT Integration
• Wireless Battery Management Systems
• Sustainability and Circularity Initiatives
• Emerging Applications and Markets
• Profiles of 44 companies including Company Overview, Product Portfolio and Recent Developments and Initiatives. Companies profiled include BYD, CALB, CATL, EVE Energy, GM, LG Energy, Leap Motor, NIO, Stellantis, StoreDot and SVOLT Energy (Full list of companies profiled in table of contents).

Contents

1 EXECUTIVE SUMMARY

1.1 Market Overview
1.2 Market Drivers and Trends
1.3 Recent Market Developments and Technology Highlights
1.4 Competitive Landscape
1.5 Regulatory Landscape
1.6 Future Outlook and Emerging Trends
1.7 Market Forecast and Growth Projections
  1.7.1 EV Battery Demand, By EV Type
  1.7.2 EV Battery Demand, By Region
  1.7.3 EV Battery Demand, By Battery Type
  1.7.4 Battery Cell Materials
  1.7.5 Battery Pack Materials

2 TECHNOLOGY OVERVIEW

2.1 Overview of Integrated Battery Systems
  2.1.1 Battery Materials for Electric Vehicles
  2.1.2 From Cell to Pack
  2.1.3 Cell-to-Pack (CTP), Cell-to-Body (CTB), and Cell-to-Chassis (CTC)
  2.1.4 Cell-to-Module (CTM)
  2.1.5 Passenger Car Integrated Battery (Chassis)
  2.1.6 Comparative Analysis
2.2 Importance of CTP, CTB, and CTC in Electric Vehicles
2.3 Cost analysis
  2.3.1 CTP (Cell to Pack)
  2.3.2 CTB (Cell to Body)
  2.3.3 CTC (Cell to Chassis)
2.4 Cell-to-Pack (CTP) Technology
  2.4.1 Definition and Concept
  2.4.2 Key Components and Architecture
  2.4.3 Comparison between CTC and CTP
  2.4.4 Cell Design Optimization
  2.4.5 Advantages and Challenges
  2.4.6 Manufacturing Processes
  2.4.7 Design Considerations
2.5 Cell-to-Body (CTB) Technology
  2.5.1 Definition and Concept
  2.5.2 Key Components and Architecture
  2.5.3 Comparison between CTB and CTP
  2.5.4 Comparison between CTB and CTC
  2.5.5 Advantages and Challenges
  2.5.6 Manufacturing Processes
  2.5.7 Design Considerations
2.6 Cell-to-Chassis (CTC) Technology
  2.6.1 Definition and Concept
  2.6.2 Key Components and Architecture
  2.6.3 Advantages and Challenges
  2.6.4 Manufacturing Processes
  2.6.5 Design Considerations
2.7 Thermal Management Systems
  2.7.1 Liquid Cooling Systems
  2.7.2 Air Cooling Systems
  2.7.3 Thermal Interface Materials
    2.7.3.1 Properties for TIMs in EVs
    2.7.3.2 Gap Pads in EV Batteries
    2.7.3.3 Gap Fillers
    2.7.3.4 Thermally Conductive Adhesives
    2.7.3.5 Chemistry Comparison
    2.7.3.6 Gap Filler to Thermally Conductive Adhesives
  2.7.4 Cold Plates and Coolant Hoses
    2.7.4.1 Coolant Fluids in EVs
    2.7.4.2 Inter-cell Heat Spreaders or Cooling Plates
    2.7.4.3 Advanced Cold Plate Design
    2.7.4.4 Coolant Hoses for EVs
  2.7.5 Phase Change Materials (PCMs)
  2.7.6 Smart Thermal Management Systems
  2.7.7 Two-Phase Cooling Systems:
  2.7.8 Direct Battery Immersion Cooling
  2.7.9 Thermoelectric Cooling
  2.7.10 Graphene-based Thermal Management
  2.7.11 Thermal Energy Harvesting
  2.7.12 Thermal Metamaterials
2.8 Battery Management Systems (BMS)
  2.8.1 Functions and Components
  2.8.2 Centralized vs. Distributed BMS
  2.8.3 Communication Protocols
  2.8.4 Advancements in BMS
  2.8.5 Safety and Reliability Considerations

3 MARKET ANALYSIS

3.1 Global Integrated Battery Market Overview
  3.1.1 Production in China
3.2 Market Size and Forecast (2024-2035)
  3.2.1 CTP Market
  3.2.2 CTB Market
  3.2.3 CTC Market
3.3 Market Segmentation
  3.3.1 By Technology (CTP, CTB, CTC)
  3.3.2 By Vehicle Type (Passenger Cars, Commercial Vehicles, Others)
  3.3.3 By Region
  3.3.4 By Application (Battery Electric Vehicles, Hybrid Electric Vehicles, Plug-in Hybrid Electric Vehicles)
  3.3.5 By Battery Chemistry
3.4 Market Drivers
  3.4.1 Increasing Demand for Electric Vehicles
  3.4.2 Need for Lightweight and Efficient Battery Systems
  3.4.3 Advancements in Battery Technology
  3.4.4 Regulatory Initiatives and Incentives
  3.4.5 Government Policies and Emissions Targets
3.5 Market Restraints
  3.5.1 High Initial Costs
  3.5.2 Technical Challenges and Integration Complexities
  3.5.3 Safety Concerns and Reliability Issues
  3.5.4 Limited Infrastructure and Charging Facilities
3.6 Opportunities
  3.6.1 Performance Improvements
  3.6.2 Cost Reduction Potential
  3.6.3 Design Innovation
  3.6.4 EV Market Expansion
  3.6.5 Environmental Benefits
3.7 Challenges
3.8 Competitive Landscape
  3.8.1 Key Players and Strategies
  3.8.2 Automotive OEMS
  3.8.3 Strategic partnerships
  3.8.4 Battery Integration Policies in China
3.9 Regulatory Landscape
  3.9.1 Safety and Environmental Regulations
    3.9.1.1 Battery Safety Standards
    3.9.1.2 Emissions and Fuel Economy Standards
    3.9.1.3 Environmental Impact Regulations
  3.9.2 Incentives and Subsidies
    3.9.2.1 Government Incentives
  3.9.3 Recycling and Disposal Regulations
    3.9.3.1 Battery Recycling Regulations
    3.9.3.2 End-of-Life Vehicle Directives
3.10 Future Outlook and Emerging Trends
  3.10.1 Advancements in Battery Chemistry and Materials
    3.10.1.1 Solid-State Batteries
    3.10.1.2 Lithium-Sulfur Batteries
    3.10.1.3 Sodium-ion Batteries
    3.10.1.4 Silicon Anodes
  3.10.2 Integration of Artificial Intelligence and Internet of Things (IoT)
    3.10.2.1 Predictive Maintenance
    3.10.2.2 Smart Battery Management Systems
  3.10.3 Wireless Battery Management Systems
  3.10.4 Increasing Focus on Sustainability and Circularity
    3.10.4.1 Sustainable Battery Materials
    3.10.4.2 Battery Recycling and Reuse
3.11 Emerging Applications and Markets
  3.11.1 Aerospace and Defense
  3.11.2 Energy Storage Systems
  3.11.3 Marine and Shipping

4 COMPANY PROFILES

4.1 24M Technologies, Inc,
4.2 Automotive Energy Supply Corporation (AESC)
4.3 Beijing Hyundai
4.4 BAIC BJEV
4.5 Benteler
4.6 BMW
4.7 BYD
4.8 China Aviation Lithium Battery (CALB) Technology Co., Ltd.
4.9 CATL
4.10 Changan Automobile
4.11 Chery International
4.12 EVE Energy Co., Ltd.
4.13 Farasis Energy
4.14 FAW
4.15 FinDreams Battery
4.16 Ford Motor Company
4.17 GAC Aion
4.18 GM
4.19 Gotion High-Tech
4.20 Great Wall Motor (GWM)
4.21 Hycan
4.22 IAT Automobile
4.23 JAC Motors
4.24 LG Energy
4.25 Leap Motor
4.26 Neta Auto
4.27 NIO, Inc.
4.28 Our Next Energy (ONE)
4.29 REPT Battero
4.30 SAIC (Shanghai Automotive Industry Corporation)
4.31 Samsung SDI Co.
4.32 SEVB
4.33 SK On
4.34 Stellantis N.V.
4.35 StoreDot
4.36 SVOLT Energy
4.37 Tesla
4.38 Tuopu Group
4.39 Volvo
4.40 Volkswagen
4.41 Xiaomi Automobile
4.42 XING Mobility
4.43 Xpeng
4.44 ZEEKR

5 RESEARCH METHODOLOGY

6 REFERENCES

List Of Tables

LIST OF TABLES

Table 1. Comparison of Advanced Battery Chemistries.
Table 2. CTP, CTB and CTC Integrated Battery Market Drivers and Trends.
Table 3. Recent CTP, CTB and CTC Integrated Battery Market Developments and Technology Highlights.
Table 4. CTP, CTB and CTC Integrated Battery Market Competitive Landscape.
Table 5. CTP, CTB and CTC Integrated Battery Market Regulations.
Table 6.Trends in CTP, CTB and CTC Integrated Batteries.
Table 7. EV Battery Demand Market Share Forecast (GWh) 2021-2035.
Table 8. EV Battery Demand Market Share Forecast (GWh) 2021-2035, by region.
Table 9. Battery Market Value Forecast for EVs 2022-2035 (Millions US$).
Table 10. Battery Cell Materials Forecast for 2022-2035.
Table 11. Battery Cell Materials Market 2022-2035 (MT).
Table 12. Battery Pack Materials Market 2022-2035.
Table 13. Total Battery Cell and Pack Materials Forecast by Vehicle Type 2022-2035 (MT).
Table 14.Total Battery Cell and Pack Materials Market Value Forecast 2022-2035 (Millions US$).
Table 15. Battery Materials for Electric Vehicles.
Table 16. Main types of cells used in electric vehicle batteries.
Table 17. Cell vs Pack Energy Density.
Table 18. Comparative analysis of CTP, CTB and CTC.
Table 19. Summary of Cost Impact.
Table 20. Cost Analysis for CTP, CTB and CTC Integrated Batteries.
Table 21. Comparison of CTP Mode and Conventional Battery Pack.
Table 22. Comparison between CTC and CTP.
Table 23. Cell to Pack (CTP) Advantages and Challenges.
Table 24. Manufacturing Processes for Cell-to-Pack.
Table 25. Design Considerations for Cell-to-Pack.
Table 26. Comparison between CTB and CTP.
Table 27. Comparison between CTB and CTC.
Table 28. Cell to Body (CTB) Advantages and Challenges.
Table 29. Cell to Body (CTB) Manufacturing Processes.
Table 30. Cell to Body (CTB) Design Considerations.
Table 31. Cell to Chassis (CTC) Advantages and Challenges.
Table 32. Cell to Chassis (CTC) Manufacturing Processes.
Table 33. Comparison of Thermal Management Systems.
Table 34. Liquid Cooling Systems.
Table 35. Air Cooling Systems.
Table 36. TIM Application by Cell Format.
Table 37. Key Properties for TIMs in EVs.
Table 38. Key properties and characteristics of common TIM chemistries.
Table 39. Overview of the battery thermal management strategies employed by major OEMs.
Table 40. Types of PCMs.
Table 41. Comparison of Battery Management System (BMS) Architectures.
Table 42. Functions and components in Battery Management Systems (BMS) for Electric Vehicles (EVs).
Table 43. Centralized vs. Distributed BMS.
Table 44. Communication Protocols in BMS.
Table 45. Safety and Reliability Considerations.
Table 46. Global CTP Market Size and Forecast (2023-2035), billions USD.
Table 47. Global CTB Market Size and Forecast (2022-2035), Billions USD.
Table 48. Global CTC Market Size and Forecast (2024-2035), Billions USD.
Table 49. Integrated Battery Market Share by Vehicle Type, 2023-2035, Billions USD.
Table 50. Integrated Battery Market Share by Region, 2023-2035, Billions USD.
Table 51. Integrated Battery Market Share by Application, 2023-2035, Billions USD.
Table 52. Challenges in CTP, CTB and CTC Integrated Battery Market.
Table 53. Key Players in the Integrated Battery Market.
Table 54. Comparison of Automotive OEM integrated batteries.
Table 55. Strategic partnerships in the CTP, CTB and CTC Integrated Battery Market .
Table 56. Overview of key policies and initiatives in China.
Table 57. Battery Safety Standards for Integrated Batteries in EVs.
Table 58. Emissions and Fuel Economy Standards Affecting EV Battery Development.
Table 59. Environmental Impact Regulations Affecting EV Battery Production and Recycling.
Table 60. Battery Recycling Regulations.
Table 61. End-of-Life Vehicle Directives.

List Of Figures

LIST OF FIGURES

Figure 1. EV Battery Demand Market Share Forecast (GWh) 2021-2035.
Figure 2. EV Battery Demand Market Share Forecast (GWh) 2021-2035, by region.
Figure 3. Battery Market Value Forecast for EVs 2022-2035 (Millions US$).
Figure 4. Battery Cell Materials Market 2022-2035 (MT).
Figure 5. Battery Pack Materials Market 2022-2035 (MT).
Figure 6. Total Battery Cell and Pack Materials Forecast by Vehicle Type 2022-2035 (MT).
Figure 7. Total Battery Cell and Pack Materials Market Value Forecast 2022-2035 (US$).
Figure 8. Li-ion batteries packaging schemes for EVs.
Figure 9. Types of integrated battery packs.
Figure 10. Component Breakdown of a Battery Pack.
Figure 11. CATL's CIIC skateboard chassis.
Figure 12. Battery pack with a cell-to-pack design and prismatic cells.
Figure 13. Battery pack with a cell-to-pack design and prismatic cells.
Figure 14. BYD CTP schematic
Figure 15. Qilin battery.
Figure 16. CTP Technology Architecture.
Figure 17. The structural design of blade cell, cell arrays, and battery pack.
Figure 18. Gravimetric Energy Density and Cell-to-pack Ratio.
Figure 19. BYD Cell-to-body.
Figure 20. CATL Cell-to-chassis.
Figure 21. Tesla CTC Technology.
Figure 22. CTC Technology Architecture. The battery pack is a structural component of the vehicle, where cells are assembled directly into a car’s structure.
Figure 23. Passenger NEV production in China 2020-2024.
Figure 24. Passenger BEV production in China 2020-2024.
Figure 25. Passenger PHEV production in China 2020-2024.
Figure 26. Global CTP Market Size and Forecast (2023-2035), billions USD.
Figure 27. Global CTB Market Size and Forecast (2022-2035), Billions USD.
Figure 28. Global CTC Market Size and Forecast (2024-2035), Billions USD.
Figure 29. Integrated Battery Market Share by Technology (2023-2035), Billions USD
Figure 30. Integrated Battery Market Share by Vehicle Type, 2023-2035, Billions USD.
Figure 31. Integrated Battery Market Share by Region, 2023-2035, Billions USD.
Figure 32. Integrated Battery Market Share by Application, 2023-2035.
Figure 33. Integrated Battery Market Share by Battery Chemistry, 2023-2035, Billions USD.
Figure 34. Rolling chassis developed by BENTELER and Bosch.
Figure 35. BYD CTB technology.
Figure 36. CALB “U type battery.Figure 37. CATL CTP 1.0-3.0.
Figure 38. CTP 3.0: Shenxing Batteries.
Figure 39. CATL Skateboard chassis.
Figure 40. “?” Battery System.
Figure 41. Farasis Cell-to-Pack Battery System.
Figure 42. Farasis Energy Super Pouch Solution (SPS).
Figure 43. GAC Aion's magazine battery.
Figure 44. GM Ultium.
Figure 45. Batteries with CTP mounted on a mock-up design of an automobile.
Figure 46. LG Energy’s cell-to-pack technology for pouch batteries.
Figure 47. Leapmotor CTC 2.0.
Figure 48. Nio Hybrid Chemistry Cell-to-pack.
Figure 49. Our Next Energy: Aeris.
Figure 50. SAIC CTP battery design.
Figure 51. StoreDot I-BEAM XFC Cells.
Figure 52. Dragon Armor Battery.
Figure 53. Short Blade Battery LCTP Technology.
Figure 54. L400 Short Blade Batteries.
Figure 55. Tesla Cell-to-Chassis.
Figure 56. IMMERSIO™ Cell-to-Pack (CTP) architecture.
Figure 57. Xpeng CIB technology.
Figure 58. Gold brick battery.