Cell Design and Materials: Li-Ion

Technology NCM-latest Technology Focus Layered electrode architecture

This year brought a strong focus on new cathode electrode-level architecture. Manufacturers have been experimenting with layered designs, blended layers, and hybrid layered+blend structures. CATLʼs Freevoy Super Hybrid, which stacks NCM and LFP in a layered electrode, is set to debut in the Leapmotor D19 in 2026.

Cathode architecture including current collector CC|Blend CAM, CC|CAM1|CAM2 (figure a), CC|Blend A|Blend B, and Blend A|CC|Blend B

The chemistries in these architectures range across NCM, LFP, LMFP, and sometimes LMR. Each layer can use the same chemistry or mix different ones depending on the performance target. LFP particle engineering is the key to minimize gas evolution in blend CAM system.

A dedicated interfacial protection layer between the two materials, combined with a film-forming electrolyte, helps suppress undesired reactions at high voltage and stabilizes the mixed-chemistry system

CAM for Dry Process and SSB

Another major theme is CAM surface coatings design tailored for dry-electrode manufacturing and solid-state electrolytes.

For NCM, these coatings improve adhesion between the CAM surface and the dry binder, strengthen the conductive pathway with the carbon additive, limit particle agglomeration, and help increase active-material loading. Dry processing is especially important for solid-state systems, particularly those using sulfide electrolytes.

Teams are also exploring cathode-side coatings specifically for solid-state batteries. Approaches include applying thin layers of solid electrolyte and/or dedicated coating materials (figure b, CATL) that boost ionic transport while reducing interfacial resistance and contact degradation. Source: Leapmoter D19, CATL Report

Extracted from the PDF; charts and images may read imperfectly.