Driven by the continuous demand to mitigate range anxiety in electric vehicles (EVs), battery pack integration has evolved from Module-to-Pack (MTP) and Cell-to-Pack (CTP) to the highly integrated Cell-to-Chassis (CTC) technology, increasing space utilization to over 75%. This study comprehensively investigates the impact of CTC technology, specifically incorporating an inverted cell structure, on vehicle structural stiffness and interior road noise. Through theoretical physical mechanism analysis, Finite Element Analysis (FEA), and experimental validation, the study reveals that the CTC configuration maximizes the second moment of area. Results demonstrate that the local dynamic stiffness of the CTC structure in the footwell area is approximately 20 times higher than that of a conventional floor-CTP system, which suffers from a lack of structural support due to design clearances. This overwhelming stiffness advantage inherently eliminates the need for additional stiffening corrugations (ribs) and damping layers. Furthermore, acoustic simulations indicate a noise reduction of over 10 dB(A) at the 25 Hz panel resonant frequency. Proving ground road tests corroborate that the highly stiffened CTC structure itself is not a contributor to interior road noise, which is instead dominated by the vibration of adjacent thin panels (e.g., the tailgate). Ultimately, this research concludes that the combination of CTC and inverted cells yields inherent benefits, significantly enhancing structural integrity while maintaining superior NVH (Noise, Vibration, and Harshness) performance.
Xueying Xu (Sat,) studied this question.