LFP (lithium iron phosphate) battery chemistries for EV (electric vehicle) and other applications have gotten greater attention for its safety, long cycle life, low-temperature performance, and sustainability benefits. The material is seen as a critical enabler of the green energy transition and accounts for a growing global battery market share. The International Energy Agency reports that, in 2023, LFP was supplied for more than 40% of global EV demand, more than double its share in 2020.

However, conventional LFP chemistries experience a reduction in usable capacity when batteries are operated at high discharge conditions such as prolonged periods of highway driving or in high-power applications such as electric mining vehicles. A new lithium manganese iron phosphate (LMFP) cathode active material developed by Integrals Power could increase the real-world range of EVs by extending the usable capacity of the battery under high discharge conditions. Tests carried out by testing and research company QinetiQ have demonstrated that the LMFP cells retain a significantly higher percentage of their nominal capacity than LFP types under these conditions.

For its LMFP cells, Integrals Power adds manganese to the LFP mix, increasing energy density by up to 20% while maintaining the safety and cost-effectiveness for which LFP is known. The company recently achieved a breakthrough with an 80% manganese content instead of the 50-70% typically found in existing blends (see Futurride’s coverage here). This offers greater performance in applications such as EVs, enabling the material to compete with NCM (nickel cobalt manganese) chemistries while being more affordable and less reliant on critical minerals.

In the QinetiQ evaluations, the LMFP cells retained 99% of their original capacity at 2C (30 min discharge time) and 95% at 5C (12 min discharge time). Even at an extreme 10C (6 min discharge time), which is far beyond the limits of any use case, capacity retention was an impressive 60%. This demonstrates the material’s ability to deliver high performance without compromising durability—attributes essential to demanding applications such as EVs, according to Integrals Power.

“We’re extremely proud of the test results QinetiQ achieved using our LMFP cathode active materials because they show that we’ve delivered higher C-rate performance and higher retained capacity compromise,” said Behnam Hormozi, Integrals Power Founder and CEO. “Together with the proven energy density improvements of up to 20% compared to LFP unlocked by our 80% manganese content and higher voltage profile of 4.1 V, we are able to demonstrate to our customers around the world that we can enable significant cost and weight reductions, and more compact, more sustainable, and longer-lasting battery pack designs.”

QinetiQ’s assessments follow other third-party testing last year that showed Integrals Power had achieved the breakthrough of incorporating a manganese content of 80% and delivering nearly 150 mA·h/gr specific capacity, while overcoming the reduction in energy density—and therefore EV range—that usually occurs at such high levels.

As a result, Integrals Power has demonstrated that its LMFP material can be used to make cells that will enable battery packs to deliver an optimal balance of high performance, long range, and long life that exceeds the capability of LFP but at less cost and less reliance on critical minerals than NCM (nickel cobalt manganese) chemistry. Using this technology, automotive OEMs could extend the real-world range of their EVs or achieve the same range using fewer cells, therefore enabling lighter, less expensive batteries.

QinetiQ conducted the tests on pouch cells made using Integrals Power’s LMFP material with standard commercial-grade graphite anodes and liquid electrolytes. Each cell was tested at an electrode loading of 2 mA·h/cm2.

The LMFP used in the tests is one of a range of 25 cathode active materials developed and patented by Integrals Power. All are developed and manufactured at the company’s UK facility, which includes a pilot plant capable of producing 20 t a year from high-purity raw materials rather than bulk precursors.