CATL Develops Thinner Battery Cell Design for Low-profile Electric Vehicles
CATL introduced its latest innovation in the mechanical design of its battery cells with the aim of overcoming the limitations of floor thickness in high-performance electric sedans. This development is focused on reducing the vertical space barrier that has been a challenge in battery packaging in vehicles with a low body design.
Launching from Carnewschina, Wednesday, June 24, through a newly approved hardware patent, CATL presents an integrated thin area placed just below the terminal cover. This design allows the electrode tabs inside the battery cell to be folded closer together without coming into contact with the metal outer wall.
This configuration is designed to reduce the risk of micro-short circuits in the battery when the vehicle experiences vibrations during use. Until now, the thickness of the battery pack has been one of the main obstacles in the development of low-profile electric cars.
To accommodate large prismatic batteries, vehicle manufacturers often have to raise the roof of the car or reduce the comfort of the rear passenger space. With the new design, the vertical dimensions of the cells can be trimmed so that it is possible to use a lower chassis without sacrificing cabin space.
The refinement of the cell geometry is also related to safety aspects.The developed structure serves as a mechanical protection layer that separatesthe internal electrical components from the battery container wall whenpressure from various directions occurs.
This approach complements CATL's previous safety strategy, which focuses on strengthening hardware design at the battery pack level to minimize the risk of thermal failure. The development of this technology is supported by large research and development (R&D) investments. Throughout 2025, CATL allocated 22.147 billion yuan for various innovation projects.
The investment is not only used to improve liquid electrolyte battery technology, but also supports the development of the next generation of solid-state batteries. With strong capital support, the company can prioritize improving the physical security of batteries in addition to software development.
The size of the R&D spending is in line with CATL's continued financial performance. In the first quarter of 2026, the company posted a net profit of 20.7 billion yuan or around Rp. 47 trillion. This achievement even surpassed the total combined net profit of a number of major Chinese automotive manufacturers, including BYD, Geely, and Chery.
In terms of the market, CATL's position is also getting stronger. Based on monthly registration data from China EV DataTracker, CATL's total battery installation reached 33.08 GWh in May 2026. The figure increased 13.8 percent compared to the previous month and jumped 35.2 percent compared to the same period last year.
The performance makes CATL dominate the domestic electric vehicle battery market share of 46.1 percent. Lithium iron phosphate (LFP) based battery technology is still the largest contributor to the company's total installation volume, followed by lithium nickel manganese cobalt (NMC) batteries.