Modules, cell-to-pack and structural packs
How manufacturers deleted the module to win back volume and mass.
- Explain modules, cell-to-pack and structural packs at engineering level
- Read the numbers that define the behaviour
- Apply the idea to a real pack
Overview
Classic packs nest cells in modules and modules in a case. Cell-to-pack removes the middle layer; structural packs make the battery part of the car's body.
In depth
- 1Cell-to-module-to-pack
Serviceable, well proven, but roughly 50–60% volumetric efficiency.
- 2Cell-to-pack
Cells bond straight into the enclosure with long blade or stacked formats. Efficiency rises to 60–72%.
- 3Cell-to-body
The pack lid becomes the vehicle floor and the cells carry structural load. Highest efficiency, lowest repairability.
What you give up
Every step of integration removes joints, mass and cost — and removes the ability to replace a single module. Repair strategy, insurance cost and end-of-life handling all shift accordingly.
Key takeaways
- Deleting the module wins volume, mass and cost.
- Structural packs stiffen the body but complicate repair.
- Volumetric efficiency is the metric to compare architectures.
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