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What is Liquid Cooled Ultra Fast Charging?

Liquid Cooled Ultra Fast Charging is  is achieved by setting up a dedicated liquid circulation channel between the cable and the charging gun, and adding cooling liquid with heat dissipation function to the channel. The cooling liquid is circulated through a power pump to remove the heat generated during the charging process and reduce the temperature of the cable.

Compared to traditional air cooling charging systems, liquid cooling systems have better cooling effects, faster charging speeds, and safer charging, greatly improving the efficiency and lifespan of charging systems.

Advantages of Liquid Cooled Ultra Fast Charging

With the popularization of electric vehicles, the demand for fast charging is increasing day by day. Liquid cooled supercharging technology has emerged, which mainly has the following key advantages:

A. Higher current and faster charging speed

The liquid cooled charging gun utilizes internal liquid pipes and coolant to take away the heat generated by the cable, thereby achieving greater current transmission. The liquid cooled charging gun also requires a matching cooling unit, which is composed of a liquid tank, liquid pump, radiator, and fan. The liquid pump drives the refrigerant to circulate in the gun line, bringing heat to the radiator and blowing it away by the fan, achieving a larger carrying capacity.

B. The EV charging plug and cable is lighter, and the charging equipment is lighter in weight.

The output current of traditional charging stations is limited by the charging connector cable, as the heating of the cable is proportional to the square value of the current. Excessive current can cause the cable to overheat. To reduce the heat generation of the cable and prevent overheating, it is necessary to increase the cross-sectional area of the wire, thereby increasing the weight of the connector cable. For example:

125A CCS2 EV charging connector DC+/DC- Cable are 35mm²

150A CCS2 EV charging connector DC+/DC- Cable are 50mm²

200A CCS2 EV charging connector DC+/DC- Cable are 70mm²

There are cables and liquid pipes inside the liquid cooled charging connectors. For example:

The cable of a 500A liquid cooled charging connector DC+/DC- Cable are 50mm²only

which can take away heat through the flow of coolant inside the liquid pipe. Due to the thinner cables, liquid cooled charging connectors are much lighter

C. Low heat generation, fast heat dissipation, high safety

The body of ordinary air cooling charging stations and semi-liquid cooling charging stations are air-cooled for heat dissipation. Air enters the charging station body from one side, blowing away the heat from electrical components and rectifier modules, and then disperses from the EV Charger body on the other side. However, the air can be mixed with dust, salt mist, and water vapor, which can adsorb on the surface of internal devices, leading to poor system insulation, poor heat dissipation, degraded charging efficiency, and reduced equipment lifespan.

The fully liquid cooled charging station adopts a liquid cooled charging module. The front and back of this module are designed with no air ducts, but with heat exchange between the coolant inside the liquid cooling plate and the outside. This allows for a fully enclosed design of the power section of the charging station, with the radiator located externally. The coolant carries heat to the external radiator, and the external air blows away the heat from the surface of the radiator. Due to the lack of contact between the liquid cooling charging module and electrical accessories and the external environment, the fully liquid cooling charging station can achieve an IP65 protection level and higher reliability. In addition, due to the better thermal conductivity and faster heat dissipation speed of liquid circulation cooling, the heat dissipation effect of fully liquid cooled charging stations is better.

Application of Ultrasonic Welding in Liquid Cooled Supercharging

Ultrasonic welding is a welding method that utilizes the heat energy generated by high-frequency vibration to apply pressure between two workpieces, causing them to experience friction and thermal fusion.

Ultrasonic metal welding has advantages such as fast speed, energy saving, high fusion strength, good conductivity, no spark, and close to cold processing.

Contact resistance is an important indicator of the quality of cable and terminal termination, which directly affects the heat generation of the termination area. Using ultrasonic welding to connect cables and contacts on high-power charging lines can reduce heat generation and improve current carrying capacity. This welding method can effectively reduce contact resistance

Ultrasonic EV Charging Plug Conductor and Cable Welding Video

Tags: #Liquid Cooled Ultra Fast Charging #charging station #CCS2 ev charging connector