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I-BEAM XFC : TM

STOREDOT'S CELL-TO-PACK
APPROACH TO IMPROVING
EV THROUGHPUT

December 2023

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Technical advances improve range and safety and enable fast charging in
cell-to-pack EV batteries
Any discussion around electric vehicles (EVs) will inevitably
turn to advances in batteries, and more specifically
battery cells - and rightly so. They govern the total storage
capacity, influence energy density and range, are integral
to safety, and remain a critical supply chain consideration
when scaling up to meet the growing demand for EVs.
However, as EVs evolve manufacturers are beginning to
take a more holistic approach to onboard electrical energy
storage. In so doing, instead of focusing on performance,
cost, and safety at a cell level, these challenges are now being
deliberated at a pack level and even beyond that, at a vehicle level. Thus, cell-to-pack (CTP) battery design,
where the battery cells are integrated directly into the battery pack without the use of modules, is gaining
interest as an alternative to traditional modular battery packs. This eliminates many components used in the
typical Li-ion battery.

Cell-to-pack reduces the number of components in the battery pack

By doing away with the module housing, terminal plates, side plates, internal connectors, battery
management, and complex cooling systems the packaging space and overall weight can be reduced.
As a result, CTP design significantly improves the weight, volume, and energy density of the battery pack
thereby enabling an increase in the range of the EV.
However, the challenge is not only about energy storage and density but also the physical design that
influences critical aspects such as thermal management and overall efficiency.

Battery pack

Pouch battery cell

Battery module
Prismatic battery cell

Cylinder battery cell

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The benefits of cell-to-pack design in EVs

With CTP batteries eliminating modules entirely, CTP designs that integrate large format cells directly into
the battery pack can improve volume utilization by about 15 to 50 percent, depending on the battery cell
format. Moreover, the number of parts can be reduced by up to 40 percent.

This saving in the parts used not only cuts costs by eliminating the step of bundling individual battery cells
into modules before final assembly into the battery pack, but the weight reduction also boosts gravimetric
energy density leading to an increase in the range travelled on a charge.
This increase in energy density at a pack level also offers manufacturers the option of reducing the installed
capacity of the battery for the same level of performance. By so doing, the all-important EV ownership cost
can be reduced, in turn stimulating the mass adoption of EVs.
While these benefits are attractive enough to prompt several manufacturers to consider offering more
models underpinned by the technology research is producing even more, exciting, benefits.

Structural cooling boosts fast charging in CTP EV batteries

StoreDot, a trailblazer in Li-ion battery technology for EVs, is well known for its
industry-leading extreme fast charging (XFC) batteries that can be charged to
80 percent in just 10 minutes. Using proprietary materials and processes,
the XFC technology enables extreme fast charging without sacrificing battery life,
energy density, or safety. Moreover, this XFC battery technology is ideally suited
to CTP battery architectures as shown in I-Beam XFC - StoreDot's approach to CTP.
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With thermal management of Li-ion EV batteries crucial to safety, long-life cyclability,

and particularly important when fast charging, StoreDot has lodged a patent (18/450,355)
for an innovative cooling system ideally suited to large format CTP designs.

StoreDot’s patent-pending CTP approach outlines a method of structural cooling

that significantly improves thermal conductivity when applied to CTP batteries.

Unlike traditional cooling systems, StoreDot's I-BEAM XFC features a unique,

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patent- pending structural cooling mechanism integrated directly into the core of
the cell, providing enhanced thermal management by preventing localized hotspots
and maintaining uniform temperatures across the battery pack.

StoreDot’s pending patent 18/450,355, ideal for CTP batteries, describes a simple
way to connect several cells in serial and/or parallel configurations using structural cooling.

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When compared to other CTP designs, StoreDot’s I-BEAM XFC concept shifts the emphasis from charging
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a cell in minutes to charging an entire pack in minutes - extreme fast charging at the vehicle level, which can
significantly reduce range anxiety for EV drivers. With StoreDot's XFC technology offered at the vehicle level,
EV drivers can be confident that they will always have enough power to get where they need to go.

Unlike traditional cooling systems, I-BEAM XFC features a unique, patented structural
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cooling integrated directly into the core of the cell, providing enhanced thermal
management by preventing localized hotspots and maintaining uniform temperatures
across the battery pack.

What is more, researchers at StoreDot have also applied for a patent for a battery pack that not only improves
the thermal performance of the system but also allows the battery to double as a structural component of the
chassis, in a concept known as Cell-To-Chassis (CTC).

The pending patent (US20220093988) describes an electrochemical device with improved thermal conductivity
attained by connecting the internal elements of a series of cells to a common plate, thereby improving the
torsional rigidity of the chassis. This allows engineers to reduce the overall weight of the vehicle without
compromising the strength or safety of the structure.

By connecting the cells to a common external plate,

StoreDot’s pending patent US20220093988 allows the entire battery
pack to serve as a structural platform.

However, replacing a malfunctioning or underperforming cell integrated into the vehicle’s chassis could have
far-reaching consequences. Consequences that StoreDot’s patented self-healing system can help overcome by
rectifying the problem in situ instead of calling for an expensive and difficult repair or replacement.

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StoreDot’s self-healing innovation saves costly repairs while maintaining

performance
To ensure all cells in the pack perform at their peak StoreDot patent US20200287248 details methods for
recovering defective branches and/or cells of battery packs.

This “self-healing” system makes use of a suite of software algorithms with corresponding hardware to
identify and proactively recondition a cell or string of cells back to an optimized performance level.
This ensures homogeneous cell performance across the pack at all times.

In CTP architectures, using large format cells, this will be crucial in ensuring consistent performance as the
battery ages. Any significant drop-off in performance as a result of a single large format cell failing could lead
to a noticeable loss of range and general performance, leading to an increase in consumers’ range anxiety.

Self-repairing cell technology described in StoreDot’s patent US20200287248

allows longer battery life and better EV performance critical to CTP applications.

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Conclusion
StoreDot's I-BEAM XFC , its innovative CTP battery technology is making it possible to create more
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affordable EVs, that have longer range and are safer than ever before. As a result, StoreDot is well-positioned
to play a major role in the widespread adoption of electric vehicles.

Driven by a comprehensive understanding of the demands and challenges of e-mobility StoreDot's CTP
EV battery technology offers:
• Faster charging: StoreDot's CTP battery technology with XFC capabilities allows to charge an entire
EV to 80 percent in just 10 minutes. This can significantly reduce range anxiety for EV drivers.
• Increased energy density: CTP battery packs can have up to 20 percent higher energy density than
traditional modular battery packs. This means that CTP battery packs can store more energy in the same
space, which can lead to longer-range EVs.
• Reduced weight: CTP battery packs are lighter than traditional modular battery packs.
This can improve the handling and efficiency of the EV.
• Lower cost, reduced complexity: CTP battery packs are less expensive to manufacture than traditional
modular battery packs. This can make EVs more affordable for consumers. I-Beam XFC is a solution to
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the complexity and cost that come with integration of extreme fast charging capability in the vehicle,
while also improving packing efficiency.
• Self-healing: StoreDot's self-healing system can detect and repair battery damage in real-time,
preventing the battery from failing. This can improve the safety and reliability of CTP battery packs.

StoreDot's I-BEAM XFC fast-charging CTP battery technology is a major breakthrough that has the
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potential to revolutionize the EV industry. By making EVs more affordable, having a longer range,
and being safer, StoreDot is helping to make electric vehicles a more attractive option for everyone.

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