EV Battery Charger Types and Hardware
The diverse EV battery charger types such as Level 1 Charging (120V AC), Level 2 Charging (240V AC), and Superchargers (400-800V DC) are tailored for specific purposes.
Level 1 Charger
Level 2 Charger
Level 2 chargers are equipped with a cable and connector, control unit, display, and enhanced safety features including ground fault protection and temperature monitoring. These chargers operate at 240 volts AC and offer variable charging speeds, typically ranging from 3,3 kW to 19,2 kW or higher, depending on their capacity. They are commonly deployed in public charging stations, workplaces, and residential installations, offering shorter charging times compared to Level 1 chargers.
Level 3 Charger
EV Battery Charger: Challenges
As EV charger technology advances, the electric vehicle charging landscape confronts a range of challenges encompassing charging infrastructure, charging speed, compatibility, energy supply, costs, range anxiety, and battery degradation. For instance, superchargers generate excessive heat due to the high current passing through relatively small-diameter cables and poses a risk for safe and reliable battery operation. Therefore, effective thermal management is a critical aspect of EV charging station performance, reliability, and safety.
Boyd’s Innovative Solutions for EV Battery Charging
Thermal Management
Boyd’s cutting-edge cooling technologies effectively dissipate heat and prevent thermal runaway without introducing excessive weight or size. Harness our extensive knowledge in air-cooling technologies, airflow management, and design and manufacturing to fine-tune cooling performance, ensure secure and reliable charger cable operation, extend charger lifespan, and improve overall performance. Boyd’s liquid cooling systems and customized cold plate applications effectively manage the substantial heat generated as a byproduct of crucial eMobility inverters and other power electronics, enabling the highest level of power conversion efficiency, extended range, and faster charge cycles to improve consumer adoption.
Display and HMIs
Elevate the quality and functionality of displays with Boyd's premium components, expertly engineered and manufactured to withstand the tough environmental and consumer use factors for your charging station. Our offerings include optically clear adhesives, polarizers, anti-glare films, light control films, brightness enhancing films, reflective films, and light diffusing films. We also provide durable nameplates and branding solutions crafted from a versatile selection of materials, including aluminum, stainless steel, acrylic, polyester, and polycarbonate. Enhance customer experience in outdoor environments without increasing weight or power consumption using our robust switch interfaces designed for optimal performance.
Insulation and Shielding
Optimize the performance of EV chargers while safeguarding against electromagnetic interference (EMI), radio frequency interference (RFI), and challenging environmental conditions with Boyd’s EMI shielding materials, such as foil tapes, fabric over foam, and conductive tapes, foams, and elastomers. Our range of thermal and electrical insulators, including SOLIMIDE®, polyimide, polycarbonate, and polypropylene UL 94-rated insulating films help maintain an ideal thermal operating range in extreme temperatures and provide protection against flame and spark voltages.
Environmental Sealing and Protection
Boyd’s comprehensive range of sealing and gasketing solutions utilizes materials such as silicone foams, closed-cell silicone sponges, polyurethane foam, EVA, vinyl, neoprene, and thermoplastics. We collaborate with flexible adhesives like very high bond tapes, double-coated tapes, transfer tapes, and other materials to efficiently and robustly assemble ingress seals to waterproof charging stations.
Innovate with Boyd
Boyd has decades of experience and expertise delivering thermal solutions for the power management industry and a track record of shipping over a billion eMobility components worldwide. Leverage our liquid cooling and material science heritage to incorporate multiple capabilities into vertically integrated eMobility solutions.
Whether your needs involve safeguarding and cooling EV batteries, enhancing brand identity, or protecting and cooling advanced superchargers, Boyd empowers you to innovate and accelerate your time to market. To learn more about our EV battery charger solutions or to discuss your project needs, schedule a consultation with our experts.
