Innovations in EV Battery Technology

The 12V power model has been standard in the automotive industry since the 1950s, making it the default in automobile design and components. This standard has enabled automakers to keep costs low and maintain a simple electrical architecture even as features and electrification have expanded over time. 

12V has had a good run, but as modern consumers increase their expectations of performance and in-vehicle experience, the 12V standard must evolve. The emergence of the software-defined vehicle and the move to mild hybrid architecture, as well as more stringent emissions laws, are making 48V design increasingly necessary to meet consumer demands and regulatory requirements. 

Though adoption of 48V faces some challenges, electrical innovators are now readying the path to higher-efficiency systems based on this new standard. Several key factors should be well understood and considered as automotive design ushers us into the electrified future. These include drivers of the 48V standard, advantages for automakers and consumers, and challenges associated with the move to 48V. 

The move to more robust power standards won’t happen overnight, but some key electrical and consumer factors will influence automaker adoption of 48V as the standard for mild hybrid and fully electric vehicles.

Legislative action for reduced emissions

Recent legislation has called for drastic emissions reduction in newly built vehicles, particularly in the U.S. and Europe. These changes fuel the shift to mild hybrid architectures such as integrated starter generators and 48V power networks, as well as an increase in  engine design efficiency. And design engineers are feeling the pressure. A Molex survey of 824 design engineers found that 96% of respondents say it requires effort to comply with power-related regulations.

More stringent fuel economy regulations are similarly pushing the development of advanced technologies such as stop-start systems, advanced driver assistance systems (ADAS) and alternative propulsion solutions like electric vehicles (EVs). These new technologies require higher voltage from power sources, prompting the move to a 48V standard. 

Consumer preference

Carbon-conscious buyers show a strong preference for hybrid, plug-in hybrid electric vehicles (PHEV) and electrically-enhanced cars. OEMs and component providers keen to meet these consumer demands are now building the next generation of components and vehicles in response. It’s no surprise, then, that the same Molex survey mentioned earlier found that 74% of design engineers who work on power list energy efficiency as a main priority.

Electric turbocharging

E-turbo features enhanced engine performance by using an electric motor to spin a turbine and boost air intake into the engine. This kind of turbocharging requires greater power than traditional turbocharging systems powered by either 12V or 24V systems. As more efficient and powerful electric turbocharging systems become standard, 48V power sources will take center stage. 

Space efficiency

The shift to 48V architectures is more than just an increase in the system voltage. The shift also requires a change in the electrical architecture of today’s vehicles. Feature-rich, higher-performance vehicles rely on lighter and smaller components that deliver the same electrical efficiency in a higher-density architecture. 48V standards are vital to delivering consumer-friendly possibilities such as better infotainment and vehicle integration features.

Increased power and efficiency open the door to opportunities for both producers and consumers. The additional efficiency and features made possible by 48V will help producers meet increasing consumer interest in higher-tech, lower-footprint vehicles. 

Engineering benefits of 48V 

• Smaller package size: 48V power allows smaller component production that can deliver the same level of electrical efficiency in a higher-density architecture. This makes it easier to create feature-rich, high-performance vehicles without sacrificing space. Automotive designers can reduce the size of the electrical system while retaining the same features, resulting in improved overall vehicle performance. 
• Production cost savings: Smaller components require fewer materials, reducing production and retail costs while still meeting consumer demand. The improved efficiency of 48V systems can help reduce total energy usage by up to 30%.
• Better feature offerings: Smaller component footprints allow automotive designers to pack more features into a given space. Cars can include more advanced technology such as wireless charging, robust infotainment systems and advanced driver-assistance systems despite their smaller size. These enhancements improve the overall driving experience for customers and also boost a car's value and perceived quality. Additionally, the reduced physical size of these components enables automakers to design sleeker and more aerodynamic vehicles with improved handling and stability.
• Lower emissions: The increased efficiency of 48V systems decreases fuel consumption, carbon dioxide (CO2) and other pollutants that internal combustion vehicles emit. Smaller components lead to lighter vehicles with less drag, further reducing emissions.
• Better fuel economy: Reducing engine load through electric enhancements helps automakers reduce the energy needed to propel the vehicle. The result is lower fuel consumption and better fuel economy. The greater efficiency of 48V systems also allows vehicles to maintain their performance at higher speeds, allowing them to travel farther on a single tank or charge. 

Consumer benefits of 48V

• Improved vehicle performance: Next-generation power solutions enhance existing engine performance, providing more power and torque for improved acceleration. Electric motors deliver smoother torque at lower speeds to increase stability and comfort when cornering or driving on uneven surfaces. 48V systems also help reduce the load on the internal combustion engine, allowing it to work more efficiently and reducing fuel consumption while still delivering high performance. These lighter vehicles enjoy an increased power-to-weight ratio, improving overall performance.
• Lower vehicle costs: With smaller and fewer components, 48V architecture allows a more efficient production process. Manufacturers reduce the materials and labor needed to build a vehicle, reducing their overall costs. For consumers, lighter and more energy-efficient vehicles require less fuel to power and maintain over their lifetime, reducing cost of ownership for drivers.
• Improved handling: Electrically enhanced vehicles respond to inputs with speed and precision, making them more maneuverable than other vehicles. The reduced weight allows vehicles to accelerate faster while maintaining steering stability, giving drivers increased control over their cars. Lighter vehicles also make it easier for manufacturers to fit in advanced active safety systems, like lane-keeping assist, without sacrificing overall performance. This increases the overall safety of the vehicle and gives drivers improved confidence when navigating challenging roads and terrains.

Where 12V design is deeply embedded into auto production, transitioning to 48V will be slower than desired. The transition speed will in part rely on changes in componentry design required to meet the technical requirements of 48V systems, taking into account their own production methods and existing infrastructure. 

Considerations such as cost and the relative novelty of 48V technology can further slow adoption since  strong business cases are required to drive large-scale technology changes. 

Better battery management is integral to the success of 48V architecture. Without the right design, automakers risk inefficient power storage, increased costs and potential safety risks due to system instability. To ensure that they are making the most of their available power storage and battery capacity, automakers must invest in better hardware and software. This can include using predictive algorithms to adjust charging cycles based on usage needs and developing better ways to track battery health over time. 

Advanced energy control systems will be needed to manage the voltage levels within each cell to prevent overcharging or undercharging the battery stack. These measures require a significant investment in research and development, but are necessary for creating reliable 48V systems capable of meeting the demands of modern driving conditions and potentially extreme environments.

As demand for EVs has grown over the past 30 years, Molex has played a critical role in serving the automotive industry. We’re an early developer of solutions that support 48V applications, including connectors and power distribution systems that provide robust power management. Our components facilitate consistent connection and communication across a 48V system, ensuring reliable performance in any environment.