Mastering the Materials Behind EV Charging Infrastructure
Imagine pulling off the freeway during a road trip for a much-needed pit stop only to find broken gas pumps at the service station – and no way to fill your tank.
That’s exactly what many EV drivers face when they’re on the road. According to a report by Harvard Business School, only about 78 percent of public electric vehicle chargers are considered reliable. That means nearly one in five could leave drivers stranded.
That lack of reliability is driving what’s called “charging anxiety,” meaning the driver can’t be confident they’ll easily be able to locate one when their battery system needs replenishing.
Charging anxiety gets to the heart of a chicken-egg-scenario in the adoption of EVs. If worries over broken or poorly functioning EV supply equipment (EVSE) linger, it will pump the brakes on EV sales. And if EV sales fail to accelerate, investors will see no need to add to the EV charging infrastructure.
The fate of EVs is tied to reliable EVSEs. Part of the solution is building them with rugged materials that prolong their life and reliability. In the following, we’ll look at some of the causes of physical failure, along with opportunity zones in EVSEs to improve reliability and performance with high-performance foams and pressure-sensitive adhesives.
What Causes EVSE Failures?
To understand how to build better EVSEs, it helps to look at some of the reasons behind their deterioration and failure.
Exposure to the elements: EVSEs kept outdoors can take a beating. Wind, dust, moisture, UV rays, and freeze-thaw cycles can all contribute to the deterioration of their various systems and components.
Less traffic, fewer eyes on the problem: With traditional gas pumps, an out-of-order sign means lost revenue and long lines, which means problems get fixed immediately. EVSEs don’t have the same visibility – yet. There are fewer EV drivers on the road, with most being able to top off their batteries at home. As a result, broken chargers can sit idle longer with less impact. Still, failure can have a big impact on a driver’s day.
Overuse: Conversely, if a charger is the only one for miles around, it may see heavy use. High demand accelerates wear and tear on cables, connectors and enclosures.
Improper maintenance schedules: EVSEs often get installed as a value-add or marketing feature. But without consistent upkeep, they become nothing more than a marker of failed intentions and a source of frustration for drivers.
Building a Robust EVSE with High-Performance Foams and Adhesives
To fight charging anxiety, the antidote is simple: Provide the infrastructure, and protect it.
It starts with high-quality units made from rugged components — high-performance foams and pressure-sensitive adhesives that hold up to the elements. As you engineer resilient EVSE units, use our material finder to identify solutions while focusing on the following zones:
- Exterior sealing: Panels and housings form the armor of the EVSE. But without high-performance gaskets and seals, sensitive electronics inside can be vulnerable. Proper sealing keeps out moisture, dust, and debris while ensuring the unit meets IP ratings.
- Interior sealing: When the exterior housing is damaged by vandalism or an accident, an extra interior barrier against dust and moisture can help protect sensitive components. Interior gaskets seal circuit boards and sub-compartments, adding another layer of protection if the outer shell is compromised.
- Enclosure venting: EVSEs are known to generate heat during operation. Outdoor weather conditions like high temperatures and solar exposure adds to the load. Proper venting and heat dissipation help maintain safe operating temperatures as well as equalize pressure changes that arise from the temperature fluctuations. Heat dissipation protects sensitive components from damage while venting helps alleviate stress on seals during pressure changes.
- EMI shielding: EVSEs rely on constant communication between the vehicle, the grid and the user interface. Conductive foils and absorber materials help block electromagnetic interference that can disrupt performance.
- Wear surface protection: Daily use can cause friction and abrasion inside and outside the EV charging unit. Durable wear-resistant films and coatings protect high-contact areas of the enclosure. This protects surfaces and preserves the unit’s performance and appearance over time.
- Vibration management: Outdoor EVSEs are exposed to constant vibration from passing traffic and user handling. Over time, this can loosen connections or place stress on circuit boards. Resilient cushioning foams help absorb impact and maintain long-term stability for sensitive components.
- Component bonding: Pressure-sensitive adhesives hold your unit and its components together. But many tapes are engineered to enhance protection and functionality, which includes durability under temperature swings, resistance to UV rays, and weathering. They can even add insulating or damping properties.
Moving Forward with a Resilient, Reliable EVSE Infrastructure
Before drivers make the leap to EVs, they need to know that every trip is supported by a reliable network of charging stations. The journey begins with durable materials that are engineered to hold up to heavy use and exposure to the elements. That’s where partnering with Rogers and SRP is a strategic part of your plan.
Rogers Corporation has the proven portfolio of high-performance foam, sponge, solids and film. SRP has the capabilities to convert them into components that fit and enhance functionality. Tap into their expertise, and you can design EVSE solutions that stand up to the elements and deliver reliability when drivers need it most.
As you move forward with the engineering, development and testing of your EVSE, we have solutions. Contact an expert today to talk about sourcing your custom die-cut high-performance components from SRP.