By ATN Editorial Team
Summary: CATL has unveiled the CATL dual-electric range extension battery alongside the latest generation of its heavy-duty battery-swapping solution, aimed at the electrification of road freight transportation. The system combines QIJI’s standardised chassis-mounted swappable main battery with a behind-the-cab range-extension power system, currently equipped with a 77 kWh battery capable of 3C charging, which provides backup power.
Key engineering takeaway: According to CATL, backup power from the range-extension pack increases the main battery’s depth of discharge (DOD) from approximately 70% to over 95%, so the main battery can be returned for a swap at less than 5% state of charge (SOC), at which point switching technology transfers power delivery to the range-extension battery within milliseconds. The CATL dual-electric range extension battery uses a “1+X” architecture: one standardised main battery keeps compatibility with the QIJI battery-swapping network, while the range-extension battery can be customised for ultra-high energy density, low-temperature resistance or ultra-high power, and the two systems can be developed and upgraded independently.
Why it matters: The release frames the problem as battery utilisation: in conventional battery-swapping trucks, drivers often return for a swap with unused capacity because they are reluctant to run the battery low. With the CATL dual-electric range extension battery, the range-extension pack stays with the vehicle as an asset throughout its service life, reducing reliance on immediate access to a swapping station, while the main battery can be leased according to seasonal freight demand.
CATL today unveiled the innovative dual-electric range extension battery and the latest generation of heavy-duty battery-swapping solution to accelerate the electrification of road freight transportation.
Competition in electric heavy-duty trucking is moving beyond technical specifications toward full-lifecycle value. While battery swapping has made energy replenishment faster and more predictable, concerns about battery utilization, operating costs and residual vehicle value continue to affect fleet economics.
To address these challenges, CATL combines its dual-electric range extension battery with QIJI’s strategy of standardization, new infrastructure and a full commercial ecosystem, bringing battery swapping and industry-wide collaboration together to accelerate heavy-duty truck electrification.
How The CATL Dual-Electric Range Extension Battery Works
CATL’s dual-electric range extension battery combines two independent yet complementary battery systems.
The main battery uses QIJI’s standardized chassis-mounted swappable battery to maximize efficiency. A behind-the-cab range-extension power system, currently equipped with a 77kWh battery capable of 3C charging, provides backup power. Together, the systems maintain uninterrupted power delivery and provide redundancy for demanding operating conditions.
In conventional battery-swapping trucks, drivers often return for a swap with unused capacity because they are reluctant to run the battery low. Backup power from the range-extension battery increases the main battery’s depth of discharge (DOD) from approximately 70% to over 95%, allowing it to be returned at less than 5% state of charge (SOC). At this threshold, CATL’s seamless switching technology transfers power delivery to the range-extension battery within milliseconds, maintaining a continuous and stable power supply.
The system uses a “1+X” architecture. One standardized main battery maintains compatibility with the QIJI battery-swapping network, while the range-extension battery can be customized for specific conditions with options including ultra-high energy density, low-temperature resistance for cold climates, or ultra-high power.
The two battery systems can be developed and upgraded independently to meet their respective technical and operational requirements.
The independently owned on-board range-extension battery stays with the vehicle as an asset throughout its service life, reducing reliance on immediate access to a swapping station. The main battery can be leased according to seasonal freight demand, helping fleets reduce rental costs during quieter periods and manage battery assets more flexibly.
This architecture combines the benefits of standardization with flexible vehicle configurations, making electric heavy-duty trucks more practical and economically viable across a wider range of applications.
QIJI Battery-Swapping Blocks, Stations And Leasing Models
QIJI complements these improvements with a three-pillar strategy of standardization, new infrastructure and a full commercial ecosystem. It seeks to speed heavy-duty truck electrification with a value-chain ecosystem co-created by all stakeholders, where benefits are shared collectively.
To accommodate a wider range of truck models and operating conditions, QIJI has introduced the 260# (432 kWh) and 300# (513 kWh) standardized battery-swapping blocks alongside the existing 75# block.
The system enables battery swaps in just five minutes, with a 99.99% first-time success rate, helping fleets minimize downtime and maintain operational efficiency.
QIJI has also pioneered a battery-as-a-service (BaaS) model in which customers pay for the net energy charged rather than the energy discharged. This allows customers to retain the value of energy recovered through regenerative braking, reducing per-kWh battery rental costs for users on basic plans by up to 20%. Flexible battery leasing options allow customers to tailor rental periods to their needs, from second-hand vehicle transitions to seasonal demand. This will minimize idle costs and offer more flexible options for off-season downtime, further helping fleets manage operating costs.
QIJI aims to make better use of four critical resources in long-haul freight: time, land, payload capacity and grid electricity. Rapid battery swapping reduces waiting times, while efficient station layouts serve more vehicles within the same footprint. Battery capacity is matched to transport needs, and centralized, coordinated charging makes better use of grid electricity. These measures aim to improve both resource efficiency and operational returns.
CATL plans to deploy 900 battery-swapping stations by the end of 2026 and 2,000 by 2027, with a long-term target of 10,000 stations nationwide in collaboration with its partners.
By connecting major freight corridors through a coordinated swapping network, QIJI aims to improve the efficiency and commercial viability of electric heavy-duty trucking.
QIJI connects truck manufacturers, financial institutions, insurers, channel partners and aftermarket service providers across the vehicle lifecycle, from purchase and operation to maintenance and resale, working together to build a comprehensive ecosystem of integrated products and services.
QIJI has introduced two partnership models: Battery Asset Service Partners and Energy Replenishment Service Partners. These models allow partners to participate in battery asset services and energy replenishment, extending their role beyond one-off vehicle sales to ongoing operations.
Through this integrated ecosystem, QIJI aims to turn the costs of the low-carbon transition into new growth opportunities, enabling stakeholders across the value chain to share the benefits of the new-energy era.
“The combination of the dual-electric range extension battery and QIJI battery swapping offers the best solution for electrifying heavy-duty trucks,” said Jesse Yang, CEO of QIJI Energy.
Heavy-Duty Truck Battery Lineup And 13,000-Unit Agreements
The initiative has also gained commercial traction, with agreements signed for 13,000 units at the event.
Aside from the dual-electric solution, CATL also introduced a new lineup of heavy-duty truck batteries tailored to different vehicle configurations and operating requirements at the event. The lineup includes rear-mounted ultra-light and ultra-thin batteries for weight- and space-sensitive applications, as well as chassis-mounted solutions for short-haul and long-haul operations.
CATL Dual-Electric Range Extension Battery: Frequently Asked Questions
What is the CATL dual-electric range extension battery?
The CATL dual-electric range extension battery is a heavy-duty truck battery system that combines two independent yet complementary battery systems: a standardised chassis-mounted swappable main battery from QIJI and a behind-the-cab range-extension power system that provides backup power. In the version CATL announced, the range-extension battery is 77 kWh and capable of 3C charging. CATL says the two systems together maintain uninterrupted power delivery and provide redundancy for demanding operating conditions.
How does the range-extension battery increase depth of discharge?
CATL says drivers of conventional battery-swapping trucks often return for a swap with unused capacity because they are reluctant to run the battery low. With backup power from the range-extension battery, the main battery’s depth of discharge rises from approximately 70% to over 95%, so it can be returned at less than 5% state of charge. At that threshold, CATL’s switching technology transfers power delivery to the range-extension battery within milliseconds.
What is depth of discharge in a battery?
Depth of discharge (DOD) is the proportion of a battery’s usable capacity that has been drawn out, expressed as a percentage. It is the complement of state of charge (SOC), the proportion of capacity remaining, so a battery at 5% SOC has reached 95% DOD. For a swappable battery, a higher depth of discharge before each swap means more of the battery’s energy is used per swap cycle.
What is the “1+X” architecture?
In CATL’s description, “1+X” means one standardised main battery that stays compatible with the QIJI battery-swapping network, plus a range-extension battery that can be customised for specific conditions. Options CATL lists include ultra-high energy density, low-temperature resistance for cold climates and ultra-high power. The two battery systems can be developed and upgraded independently.
What battery-swapping block sizes does QIJI offer?
QIJI has introduced the 260# (432 kWh) and 300# (513 kWh) standardised battery-swapping blocks alongside the existing 75# block. According to the release, a battery swap takes five minutes, with a 99.99% first-time success rate.
Further Reading
- CATL TECTRANS II Battery Platform Standardises Truck Packs
- CATL Unveils Six Battery Innovations at Super Technology Day
- MAHLE Range Extender For Electric Trucks Adds 400 Kilometres
- What Is A Range Extender (EREV)? An Engineer’s Guide
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