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Energy Management

EV Charging Infrastructure

Vehicle charging stations are emerging rapidly — along roadways, in homes and at workplaces. This new infrastructure must be designed and built to be consumer friendly, emphasizing safety, usability and long-term reliability.

Overview


As the electrified future takes shape in real time, major changes are playing out on several levels simultaneously. The rollout of EV charging networks, the proliferation of alternative energy sources, expansion of home EV charging and energy storage capabilities and an emerging variety of on-board battery systems are all converging in a rapidly evolving energy management landscape.

Both commercial and residential EV charging stations demand wider deployment of higher current systems to achieve faster battery replenishment. This shift brings new thermal management and efficiency design challenges while stressing the importance of safety and reliability. EVs are still an emerging market, and the reputations of brands and technologies alike are dependent on safe, easy and fast access to charging stations. Additionally, innovative product development must anticipate emerging regulations alongside international standards.  

The industry’s high level of complexity requires multi-disciplinary perspectives, market insight and extensive engineering and manufacturing knowledge from trusted design experts. Molex is driving this future alongside automakers and product manufacturers to ensure new electric capabilities are safe, compliant and commercially viable. 

Connectivity in Electric Vehicle Charging Stations

The vehicle charging landscape is constantly evolving with new design requirements. Engineers can maximize flexibility while delivering a premium user experience with a range of connector solutions that can accommodate the changes to come.

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EV Charging Infrastructure

EV charging infrastructure must be built on reliability, safety and innovation. Learn how Molex is helping network rollout from the roadside to the home.

Reliability When It’s Needed Most

When EV drivers are on the road and batteries are running low, reliable access to networks of fast-charging stations is mission critical. But as faster vehicle charging speed becomes a primary goal, design engineers must address the effects of higher energy throughputs, such as increased heat and a greater dependence on high-quality power delivery; otherwise, the performance and reliability of both the charging station and the vehicle being charged are at risk. The quality of busbars, connectors and cables is critical to ensuring stations are safe and operational when drivers plug in to recharge.

Charging Cars

Solving Design Challenges

Consumer adoption of EVs is frequently challenged by vehicle range anxiety, charging speed and a perceived lack of available charging infrastructure. The solutions to these challenges lie in higher power products, battery improvements and new business models.

Power System Design Trends

Across various industries, Molex specialists find the systemic balance when designing for power, signal integrity and electromagnetic interference (EMI). We’re bringing this forward-thinking, cross-disciplinary approach to bear on charging stations and vehicles alike. 

High-Power Busbars

Busbars are critical to building reliable and flexible high-current EV charging systems. With input from automotive OEMs and Tier 1 suppliers, we’ve developed a diverse busbar product line of rigid, flexible and laminated solutions. 

Safety is Never Optional

Safety is a must for EV charging stations. In the past, professional technicians were the primary individuals interacting with high-power electric infrastructure. Today, EV charging networks and home energy installations are controlled by consumers without the same level of high-power training or protection.  And low-quality charging can lead to overcharging, introducing risk from thermal runaway and off gassing. These considerations require increased attention to safety concerns and user-centered design issues to assure accessibility, intuitive operation, high-quality power connectivity and reliability in all types of conditions.  

Charging Safety

Shaping the Next-Generation Vehicle

Electric vehicles have presented both an opportunity to reimagine amenities and capabilities and a series of complex engineering challenges. Learn how Molex has worked alongside leaders in the transportation industry to safely introduce innovations from charging infrastructure to in-vehicle entertainment. 

Ensuring Safety at Every Step

Molex is a leader in electrical safety across the entire transportation ecosystem — from the factory floor of an automotive manufacturer to the EV charger mounted on the garage wall. 

EXTreme Power Products

In conjunction with increased current levels, companies must also contend with related issues of thermal management, EMI and power integrity throughout their power systems — all of which impact safety. Molex EXTreme Power products are specifically designed to support high-current applications with optimal power densities and exceptional thermal management capabilities.  

Brad Eissler
"With changes in power comes a re-evaluation of safety, not just for a single connector but for the whole system in context. In EV charging, the problem is even more complex to assure reliable, safe user experiences in extreme conditions over the lifetime of both the vehicle and charging station.”
Brad Eissler
Director, Strategic Markets
Molex

Innovation in a Market of Change

Molex is driving the innovation required for the successful deployment and continued growth of charging infrastructure by proactively addressing design, manufacturing and sourcing challenges. Our scalable portfolio of connectors, cables, busbars and more is built from 80+ years of expertise in engineering solutions for power requirements from the millivolts to the kilovolts. 

A field-tested portfolio is just one benefit of working with Molex. We’ve also assembled a global team of interdisciplinary engineers equipped with the latest technologies and production methods, ready to take on the next industry challenge.

EV Innovation

Volfinity: Battery Cell Contacting System

The Molex Volfinity Cell Contacting System is a lightweight solution for enhanced and reliable battery integration. The system connects battery cells to the control board and communicates cell balancing and temperature metrics.

The New Era of Connected Vehicles

Vehicle-to-everything (V2X) — often referred to as “the IoT on wheels” — has been primarily associated with signal connectivity. But a new era of bidirectional charging is introducing new means of V2X in the form of vehicle-to-home (V2H), vehicle-to-load (V2L) and vehicle-to-grid (V2G) — all dependent on power.  

Emerging Trends from Electrification to Energy Management

Molex is on the forefront of design — not just for EV power challenges but also in the macro trends of power generation and distribution. With the shift to augment conventional fuel with renewable sources, the ability to store, monitor and apportion these energy resources becomes a necessity.  


Busbars

busbar

PowerPlane Busbar Connectors

Sentrality Pin and Socket

Cable Assemblies

cable assemblies

EXTreme Power Products

EXtreme

Micro-Fit Connectors