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

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    Report

  • 205 Pages
  • July 2024
  • Region: Global
  • Future Markets, Inc
  • ID: 5972988
Description Jump to:

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

Table of 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 Methodology6. References
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
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. “p” 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

Companies Mentioned (Partial List)

A selection of companies mentioned in this report includes, but is not limited to:

  • 24M Technologies, Inc.
  • Automotive Energy Supply Corporation (AESC)
  • BAIC BJEV
  • Beijing Hyundai
  • Benteler
  • BMW
  • BYD
  • CATL
  • Changan Automobile
  • Chery International
  • China Aviation Lithium Battery (CALB) Technology Co. Ltd.
  • EVE Energy Co. Ltd.
  • Farasis Energy
  • FAW
  • FinDreams Battery
  • Ford Motor Company
  • GAC Aion
  • GM
  • Gotion High-Tech
  • Great Wall Motor (GWM)
  • Hycan
  • IAT Automobile
  • JAC Motors
  • Leap Motor
  • LG Energy
  • Neta Auto
  • NIO, Inc.
  • Our Next Energy (ONE)
  • REPT Battero
  • SAIC (Shanghai Automotive Industry Corporation)
  • Samsung SDI Co.
  • SEVB
  • SK On
  • Stellantis N.V.
  • StoreDot
  • SVOLT Energy
  • Tesla
  • Tuopu Group
  • Volkswagen
  • Volvo
  • Xiaomi Automobile
  • XING Mobility
  • Xpeng
  • ZEEKR

Methodology

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