WAE Technologies launches new structural battery pack for low-volume EV production

WAE, the world-leading technology and engineering services business, has debuted a host of electrification innovations at the Battery Show Europe, taking place in Stuttgart, including the launch of an advanced new structural battery pack for the low-volume automotive sector.

Held between 23-25 May 2023 at Messe Stuttgart, in Germany, Battery Show Europe is Europe's largest trade fair and conference for advanced battery manufacturing and technology, with over 10,500 attendees.

Visitors can see the global launch of the company’s new Cell2Pack demonstrator, a cutting-edge structural battery pack system, which features host of advances which combine to improve electric vehicle structural stiffness, lower weight and improve overall range, at low production volumes.   

A Lead Engineer of Battery Integration at WAE, Sian Wyles, will be delivering a presentation on this innovative new design, while the WAE stand will also feature the battery show debut of Elysia – Battery Intelligence from WAE, a ground-breaking new offering which delivers the latest in battery software to the mass market.

What is Cell2Pack?
Cell2Pack is a specific battery design for the automotive niche market and low volume applications of under 10,000 vehicles per annum. The cells are integrated directly into the battery pack without the need for individual module enclosures, therefore increasing volumetric energy density and improving vehicle range within a given package. To achieve this highly integrated solution, the cells become a load-bearing element and provide a load path directly through the battery pack from base-to-lid, and onwards into the vehicle body.

The Cell2Pack system incorporates a number of advanced technical features in order to provide an optimum battery design with maximum capability including:

Large Format Cylindrical Cells – market trends show that there’s now a move towards larger format cylindrical 46xx cells offering higher power and energy density, as well as increased fast charging capability due to reduce internal resistance.

Inflatable Side Cooling – flexible and inflatable side cooling ribbons offer double-sided cooling to the cells. The adaptive flexible shape ensures close contact with the cells without the need for gap fillers or thermal interface material, therefore improving heat transfer from the cells to the coolant. Manufacturing is also simplified with no need to attach the cooling ribbons to the cells.

Bent Extruded Case – one continuous 3D bent extrusion forms three sides of the battery case with a clip fit panel base. This design enables the package length and width to the scaled to the customer requirements without the need for high-cost tooling changes, ideal for low volumes.

Craig Wilson, WAE Technologies' CEO, said: “We are proud to be exhibiting at this year’s Battery Show Europe, in Stuttgart. As the largest event in the advanced battery manufacturing and technology industry, it’s the perfect place for us to be showcasing the very best of WAE’s innovations in cutting-edge electrification. With Cell2Pack we have an advanced new structural battery design that has huge positive implications for the low-volume automotive sector, while with our new Elysia battery intelligence offering we are bringing game-changing battery software to the mass market.”

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