The electric vehicle (EV) market is expected to grow rapidly as automakers upgrade their designs and EVs become more popular around the world, with EVs expected to account for 20% of global new car sales by 2025 and 50% by 2030, according to UBS Investment Bank.

But these predictions face some harsh realities. For example, limited driving range, long charging times and a lack of public charging stations have made many potential electric vehicle buyers hesitate. The good news is that government efforts to build charging infrastructure and recent improvements in battery technology may accelerate the mass adoption of electric vehicles.

Faster charging

A persistent concern about electric vehicles (EVs) is that they take much longer to charge than to refuel.

Charging time depends on the charging method, vehicle type and when the charging facilities were built. According to the U.S. Department of Transportation, Level 2 facilities are used for home and commercial charging and require drivers to wait 4 to 10 hours. The fastest charging method is direct current fast charging (DCFC), which allows commercial customers to charge their batteries to 80% in 20 minutes to an hour.

Despite the convenience of charging at home, consumers have shown a clear preference for fast charging, with more than half of respondents in a 2020 Fuel Institute survey saying they would be willing to pay more for DC fast charging.

Manufacturers are well aware of customers’ desire for faster charging methods, but charging too quickly can damage the battery, shortening its life and degrading its performance, and in the worst cases, leading to catastrophic failure. More power does not necessarily equate to an overall faster charge, as charging rates slow as batteries age.

Charging is also affected by battery configuration, which varies widely, not only between manufacturers but also between models. Battery configuration is very important to automakers, who use it as a differentiating factor in creating electric vehicle designs ranging from sporty to strictly utilitarian.

Some manufacturers are investing in charging stations, where different battery configurations can lead to different results. Tesla, for example, has built a nationwide network of Supercharger stations that can fully charge an electric car in just 15 minutes.

Battery Experiments and Innovations

There are so many battery configurations for a simple reason: Batteries still need considerable improvement. For example, not every electric car can be charged with DC fast charging, which limits the benefits of fast charging infrastructure.

It’s clear that we need to experiment and innovate on the battery front in order for electric vehicles to take full advantage of the rapidly growing charging infrastructure. The challenge is that electric vehicle batteries are difficult and expensive to manufacture. However, this is also changing.

For example, the new battery connection system uses a flexible printed circuit (FPC) board to connect the battery to the monitoring system and various ports. Thanks to this innovation, we no longer need to use daisy-chain connections with manual wiring, which may lead to configuration errors. The setup is also less prone to degradation than discrete wires, while being lightweight and reducing shipping costs.

Making batteries faster and more cost-effectively will give manufacturers more time and money to innovate. It will also allow them to try new ways to safely speed up the charging process and extend battery life.

Expanding charging infrastructure

Even with these constraints, driving range has improved dramatically, with many electric vehicles now offering a range of 400 to 500 kilometers.

However, drivers' range anxiety has not been fundamentally resolved. There are few charging stations and they are far apart. This is indeed a problem for drivers. According to Deloitte's 2022 Global Automotive Consumer Study, 14% of consumers decided not to consider buying an electric car due to concerns about the lack of available charging stations.

To change this, we need to invest in expanding the charging infrastructure. Tesla's investment and pilot program for the Supercharger network across the United States mentioned above is just the beginning. In order for the electric vehicle market to survive and grow, we need a more adequate charging network.

New business models

The introduction of new charging stations may also be accelerated by the strengthening of economic forces. For example, the implementation opinions on "Further Improving Electric Vehicle Charging Infrastructure" issued by the National Development and Reform Commission proposed to give full play to the energy storage characteristics of power batteries, explore and promote orderly charging, V2G and other forms, and realize the coordinated interaction between electric vehicles and power grids. In mining sites, ports, urban transportation and other scenarios, the battery replacement model should be promoted according to local conditions.

Operators are also looking for new ways to make money from charging stations. For example, some operators have added digital screens on charging points that can provide customers with promotions if they shop at nearby restaurants, shopping malls and theaters while waiting to charge. Other companies are developing visual chargers that can collect customer data, including demographic data and the make and model of the charging car. However, others may broadcast local televised sports events or other entertainment content that can bring in revenue.

For any business, charging kiosks are a branding opportunity, with unique designs that can be used to put a corporate message on them. For example, automakers are beginning to deploy charging kiosks at their dealerships, with designs chosen to portray values ​​such as “effortless luxury” or “forward-looking technology.”

While exterior design is largely dictated by interior components, flexibility is increasing. For example, Molex can build busbars in a variety of shapes, sizes and coatings, giving the company the flexibility to meet EV design needs while maintaining manufacturability.

There are still many obstacles to electric vehicle battery charging and infrastructure construction, but the momentum is clear, which is inspiring manufacturers, suppliers and companies to let their ideas run wild.

Software plays a starring role in vehicles, and the rapidly growing number of data connections requires engineers to look at traditional systems differently. From the engine and brakes to the seats and car radio, no part of the car operates in isolation anymore. Designers are now working with top technology partners to bring seamless, connected in-car experiences to market.