Infographic: Selecting materials for EV charging stations

25 June 2023

Boyd helps the world's largest EV manufacturers improve the performance, quality, safety and durability of their charging systems. Achieving optimal results starts with using optimal materials. Using their material science expertise, Boyd helps guide materials selection for manufacturers creating the next generation of EV charging systems.

Insulation and shielding

Protecting EV chargers from electromagnetic interference (EMI), radio frequency interference (RFI) and harsh environmental conditions like temperature extremes, weather and ultraviolet (UV) damage is important to achieve optimal performance. Common EMI shielding materials Boyd works with include foil tapes, fabric over foam, and conductive tapes, foams, and elastomers. Thermal and electrical insulators like SOLIMIDE, polyimide, polycarbonate and polypropylene UL 94 rated insulating films, mica and other materials help maintain ideal thermal operating range in temperature extremes and provide flame and spark voltage protection.

EMI/RFI shielding foams
Electrical insulators and isolators
Thermal insulators
Thermal interface materials
SOLIMIDE insulating foam
NVH dampers

Bonding, sealing and protection

Durable gaskets and environmental seals are critical for ingress protection, particularly for outdoor charging stations. Boyd has developed sealing and gasketing solutions using silicone foams, closed cell silicone sponge, polyurethane foam, EVA, vinyl, neoprene and thermoplastics. They work with flexible adhesives such as 3M VHB tape, double-coated tapes, transfer tapes and other materials to efficiently and durably assemble ingress seals into charging stations.

Extruded rubber seals and gaskets
Port seals
Custom molded O-rings
Custom bonding tapes and adhesives
Airflow management
Dust and fluid ingress protection
Injection molded bezel and housing

Display and HMIs

Enhance displays with optically clear adhesives, polarizers, anti-glare films and 3M specialty
materials like light control films, brightness enhancing films, reflective films, and light diffusing
films designed, optimized and fabricated by Boyd for charging stations. Boyd uses carbon,
silver or light transmissive inks to make capacitive switches, and offer durable nameplates and
branding solutions in a range of plastics and metals including aluminum, stainless steel, acrylic,
polyester and polycarbonate.

Display bonding and integration
Display enhancement films
Switch technologies
User-safety labels
Nameplates and branding solutions

Air and conduction cooling

Boyd's in-depth knowledge of air cooling technologies and air flow management combined with design and manufacturing expertise allow them to enhance heat sink technologies from basic aluminum extrusions to complicated zipper fin or die cast geometries. Heat sinks are typically made of copper, aluminum or a combination of materials, depending on project requirements.

Two-phase and liquid cooling

Advanced cooling technologies dissipate heat and prevent thermal runaway without adding significant weight or size. Boyd uses a range of thermal interface materials and advanced two-phase cooling technologies to enhance liquid cooling systems for increased power density and improved performance. Liquid cold plates often feature copper or stainless-steel tubing, aluminum plates and Boyd uses thermal epoxies at the joints to create a gap-free thermal interface.

Liquid cold plates
Liquid cooled chassis
Heat exchangers
Coolant Distribution Unit (CDU)

Boyd engineers have the expertise to help guide materials selection to optimize EV charger performance.
Contact them today.

About Boyd

Boyd is the trusted global innovator of sustainable solutions that make our eMobility customers’ products better, safer, faster, and more reliable. Our innovative engineered materials and thermal solutions advance our customers’ technology to enhance reliability and extend range for electric and autonomous vehicles and accelerate innovation in next-generation electronics and human-machine interface. Core to Boyd’s global manufacturing is a deep commitment to protect the environment with sustainable, scalable, lean, strategically located regional operations that reduce waste and minimize carbon footprint. We empower our employees, develop their potential and inspire them to do the right things with integrity and accountability to champion our customers’ success.

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