In new energy vehicles, the traction battery functions as both the energy source and a core safety subsystem—far beyond the role of a fuel tank in ICE vehicles. A complete pack integrates cells, modules, the BMS, thermal management, HV/LV connections, insulation components, and a protective enclosure to deliver stable energy storage, power output, and system-level safety.
Battery chemistry and architecture directly determine an EV's range, performance, cost, and market positioning. Today, the global market is dominated by two chemistries: NCM/NCA and LFP.
Main EV battery chemistries include:
NCM/NCA Lithium-Ion Batteries
LFP (Lithium Iron Phosphate) Batteries
LMO (Lithium Manganese Oxide)
LCO (Lithium Cobalt Oxide)
Ni-MH (Nickel-Metal Hydride) – used mostly in hybrid vehicles
Among these, NCM/NCA and LFP have become the industry's mainstream choices, each serving distinct EV platforms—from long-range passenger cars to commercial and cost-optimized vehicles.
Battery competition ultimately comes down to cathode chemistry.
NCM/NCA batteries rely on nickel, cobalt, manganese, or aluminum-based cathodes.
LFP batteries use lithium iron phosphate and feature strong P–O bonds that deliver outstanding thermal stability.
Each chemistry aligns closely with specific EV requirements:
NCM/NCA → High energy density for long-range vehicles
LFP → High safety, long cycle life, and excellent cost competitiveness
This is why the market has consolidated around these two technologies.
1) NCM/NCA Lithium-Ion Batteries
Advantages
Very high energy density → longer driving range
Strong low-temperature performance
High charge/discharge efficiency
Limitations
Reduced thermal stability at high temperatures
Higher material cost
Requires robust thermal management
Best suited for: long-range and mid- to high-end passenger EVs.
2) LFP (Lithium Iron Phosphate) Batteries
Advantages
Excellent thermal safety and resistance to thermal runaway
Lower cost and no cobalt content
Long cycle life and stable performance
Limitations
Lower energy density → larger battery pack size
Noticeable winter range reduction
Moderate low-temperature behavior
Best suited for: commercial fleets, taxis, and cost-optimized EVs prioritizing durability and safety.
Battery chemistry is ultimately chosen based on application scenarios:
Long-range passenger cars → NCM/NCA
Commercial vehicles and entry-level EVs → LFP
Cold-climate regions → NCM/NCA or enhanced thermal-managed LFP
Key decision factors include energy density, safety, cycle life, cost, temperature performance, charge/discharge behavior, and overall system integration.
Technologies like LCO and LMO have shifted to niche applications, while Ni-MH remains relevant mainly for hybrid systems.
Inside a battery pack, electrical and signal connections operate on three levels:
Signal-Level (BMS Sensing)
Collects voltage and temperature data—acting as the “nervous system” of the battery.
Energy-Level (Cell-to-Cell or Cell-to-Module)
Flexible connectors accommodate mechanical expansion during cycling.
Power-Level (High Voltage)
Carries high current between modules and pack terminals, requiring excellent insulation and vibration resistance.
Across all levels, busbars are essential for achieving stable, low-resistance, and safe current pathways.
RHI provides tailored busbar solutions engineered for modern LFP, NCM, and NCA battery packs.
1) Aluminum Busbars — For BMS and Signal-Level Circuits
Lightweight and cost-efficient
Good formability for integrated layouts
Suitable conductivity for low-current applications
2) Flexible Copper/Aluminum Connectors — For Module Interconnections
Absorb vibration and thermal expansion
Support high current and high C-rate cycling
Increase durability under dynamic loads
3) Rigid HV Busbars — For 100–800 V High-Voltage Circuits
Available with insulation technologies such as:
Dip coating
Extrusion
Injection overmolding
Heat-shrink insulation
Performance attributes:
High current-carrying capability
Integrated insulation for enhanced safety
Supports 3D forming for compact packaging
Materials engineered for high dielectric strength and thermal durability
These HV busbars form the electrical backbone of the battery pack, ensuring reliable, safe power delivery.
With deep expertise in copper/aluminum busbar manufacturing and HV connection design, RHI delivers:
Custom busbar engineering
Material selection guidance
Electrical and thermal optimization
High-reliability insulation processes
Lightweight structural integration
RHI supports global EV manufacturers with engineered solutions that enhance safety, performance, and cost efficiency across all mainstream battery chemistries.
