Black Technology High Power Electric Vehicle Liquid Cooled Charging Cable

New energy vehicle black technology Superfast charging experience One kilometer per second
With the continuous development of charging cable technology, how to improve the charging experience, all major companies have mentioned the concept of full charging in ten minutes. “Charging for 5 minutes, 300 kilometers of endurance” has now become a reality. Huawei’s super charging has proposed a charging experience of one kilometer per second. The emergence of these goals is actually to effectively solve the “slow charging” of new energy vehicles and meet the needs of car owners and the sense of quick experience. This is also the goal pursued by many car companies. Recently, a black technology for electric vehicle charging has appeared on the market, and the emergence of liquid cooled charging cable has provided unlimited possibilities for achieving charging of one kilometer per second.

A stylish red electric car is charging at a wind power charging station, electric vehicle charging cable application.

The core advantage of liquid cooled charging cable

The core advantage of liquid cooled charging gun cables lies in their efficient heat dissipation capabilities. Compared with traditional air-cooled systems, liquid cooled systems quickly absorb and conduct heat through circulating coolant. This direct heat exchange method is more efficient than air-cooled technology that relies on air convection, and can reduce the temperature to a safe range in a shorter time. Therefore, even in the high-load fast charging process, the liquid cooled charging gun can maintain a low temperature rise and ensure the stable operation of the charging facilities. And the rapid heat dissipation characteristics of the liquid cooled charging gun significantly improve the safety of the charging process. Overheating is one of the main factors leading to electric vehicle charging accidents. Especially when charging with high current, components such as cables and connectors are easily damaged due to excessive temperature, and even cause fires. liquid cooled charging gun cables greatly reduce the risk of failure of these components due to overheating through effective temperature control management.

Today, TST cables’ article will take you to understand the technology of liquid cooled supercharging cables and analyze its market status and future trends, hoping to give some inspiration and help to those who are interested

Market status of liquid cooled supercharging
According to the latest data from the China Charging Alliance, the number of public charging piles in February 2023 increased by 31,000 compared with January 2023, a year-on-year increase of 54.1% in February. As of February 2023, member units in the alliance reported a total of 1.869 million public charging piles, including 796,000 DC charging piles and 1.072 million AC charging piles. With the increasing penetration rate of new energy vehicles and the rapid development of supporting facilities such as charging piles, the new technology of liquid cooled supercharging has become the focus of competition in the industry. Many new energy vehicle companies and charging pile companies have also begun to carry out technical research and development and layout for supercharging.

Product features of electric vehicle liquid cooled charging pile cables:

High-power charging: supports hundreds of kilowatts of charging power.
Efficient heat dissipation: accurately control cable temperature and extend service life.
Safety performance: built-in multiple protection measures to prevent overheating and electrical failure.
Environmental adaptability: strong weather resistance, suitable for outdoor use under different climatic conditions.
Improve charging speed: high-power transmission, shorten charging time.
Reduce energy consumption: reduce energy loss through efficient heat dissipation.
Extend cable life: avoid material aging caused by overheating.
Improve safety: low smoke and halogen-free, flame retardant, reduce the risk of fire and electrical failure.

The application of liquid cooled charging guns in the market has also brought improvements in user experience. Due to its low noise and low vibration characteristics, users enjoy a quieter and smoother experience during charging. At the same time, it reduces maintenance requirements and extends the service life of equipment, bringing more convenience and economic savings to operators.
At present, many consumers have a direct concern about the range and charging speed of electric vehicles. Traditional air-cooled charging guns often face the problem of poor heat dissipation when charging at high power, which limits the charging speed and may affect the battery life. liquid cooled charging guns can effectively ensure charging safety with their excellent heat dissipation performance. liquid cooled charging guns bring users a more convenient and fast charging experience with their advantages such as fast charging speed, light weight, thin gun wire, and good charging experience.

As one of the high-power charging devices, the liquid cooled charging gun meets the performance requirements of 800V/600A high-power charging, and also has the advantages of light weight and good charging experience. The main principle is that it is equipped with liquid cooled charging technology. There are cables and water pipes inside the liquid cooled charging gun, which takes away heat through the flow of coolant in the water pipe. There is no need to increase the cross-sectional area to maintain the current. Compared with conventional charging guns, the weight is basically about 30% lighter. Not only is the weight reduced, but the charging efficiency can also be increased.

TST CABLES Electric Vehicle Liquid Cooling Charging Pile Cable Related Technical Features:

liquid cooled cable

TST CABLES electric vehicle charging cable

Rated voltage: AC 450V/750V, DC 1.0KV.
Cross-sectional area: 0.75mm2, 1.5mm2, 2.5mm2, 4.0mm2, 6.0mm2, 16mm2, 20mm2, 35mm2, 50mm2, 80mm2.
Number of cable cores: signal line + control line + power line.
Conductor: Category 5 and Category 6 flexible conductor.
Bending radius: 5D (special requirements).
Note: “5D” in the cable characteristics means that the bending radius is 5 times the outer diameter of the cable. The above product specifications, dimensions, and structures may change due to the technological progress of TST cables. The cable specifications can be designed and manufactured according to customer requirements.

TST CABLES Electric Vehicle Liquid Cooling Charging Cable Industry Standard:
IEC 62893/EU – 50260/ur62/T33594

What are the key design features of liquid cooled charging guns?
liquid cooled charging guns have several key design features to improve the charging experience. First, the liquid cooled charging gun uses advanced heat dissipation technology to effectively reduce heat accumulation during charging and keep the temperature of the charging gun stable, thereby ensuring charging speed, efficiency and safety. Secondly, the liquid cooled charging gun is light in weight and has a thin gun line, making it more comfortable to hold and easier to operate, thereby reducing the user’s discomfort during use. Through these key design features, the liquid cooled charging gun can not only improve the charging efficiency, but also further enhance the user’s charging experience, making the charging process more convenient, comfortable and enjoyable.

Technical principle of liquid cooled charging pile cable for electric vehicles
liquid cooled charging pile cable is a cable that uses liquid cooling technology and is specially designed for high-power electric vehicle (EV) fast charging systems. This cable effectively manages the heat of the cable during high current transmission through an internal liquid circulation system, avoiding overheating and the resulting safety issues, while also improving charging efficiency.

The liquid cooled charging pile cable contains a closed liquid cooling circulation system, which consists of coolant, circulation pipes, pumps and heat exchangers. When the current passes through the cable, the heat generated is quickly absorbed by the coolant, and then the heat is taken away by the circulation system to keep the cable within a safe operating temperature range.

Classification and materials of liquid cooled charging pile cables for electric vehicles
liquid cooled charging pile cables can be classified according to their internal structure, coolant type, and application environment. Common coolants include water-based coolants and synthetic oil-based coolants, the latter of which generally have better thermal and chemical stability.

The materials of liquid cooled charging cables for electric vehicles mainly include:

Conductor: high-purity copper to ensure low resistance and high conductivity.

Insulation layer: high temperature resistant, oil resistant, and weather resistant materials such as cross-linked polyethylene (XLPE cable) or polyurethane (PU).
Coolant pipeline: usually made of corrosion-resistant and pressure-resistant materials such as stainless steel or reinforced plastic.
Shielding layer and protective layer: used to prevent electromagnetic interference and mechanical damage.

Specific application of liquid cooled charging cables
liquid cooled charging pile cables are mainly used in high-power DC fast charging stations, especially for heavy-duty electric vehicles, buses, trucks and other application scenarios that require high-power charging.

Standards and tests for liquid cooled charging cables
liquid cooled charging pile cables must comply with a series of international and local standards, such as relevant regulations in the UR, UL, IEC, EN and other standard systems. Test items include:

Electrical performance test: such as conductor resistance, insulation resistance, withstand voltage test, etc.

Mechanical performance test: such as tensile strength, bending performance, wear resistance test, etc.

Environmental adaptability test: such as high and low temperature cycle, wet heat test, ultraviolet aging, etc.

Liquid leakage test: ensure that the cooling system is well sealed and there is no liquid leakage.

The first 600KW liquid cooled supercharging station in the country’s high-speed service area
Tesla is the first car company in the industry to deploy liquid cooled supercharging piles in batches. It has currently deployed more than 1,500 supercharging stations in China with a total of 10,000 supercharging piles. Tesla’s V3 supercharger adopts a full liquid cooling design, liquid cooling charging module and liquid cooling charging gun. The maximum charging power of a single gun is 250kW/600A, which can increase the range of 250 kilometers in 15 minutes. The V4 charging piles that will be deployed in batches will increase the charging power to 350kW per gun.
Subsequently, Porsche Taycan launched the 800V high-voltage electrical architecture for the first time in the world, and supports 350kW high-power fast charging;
Great Wall Salon Mecha Dragon 2022 Global Limited Edition, the current can reach 600A, the voltage can reach 800V, and the peak charging power is 480kW;
GAC Aion AION V, the peak voltage can reach 1000V, the current can reach 600A, and the peak charging power is also 480kW;
Xiaopeng G9, 800V silicon carbide voltage platform mass production car, suitable for 480kW ultra-fast charging;

liquid cooled charging pile cable provides a safe, efficient and durable solution for high-power charging scenarios through its unique liquid cooling technology and the application of high-performance materials. It is one of the important technologies to promote the development of electric vehicle charging infrastructure to a higher level.

How to choose a reliable and high-quality liquid cooled charging cable supplier?

The quality of charging cable on the market varies greatly, which requires consumers, operators and even automakers to be extra careful when choosing charging gun cables. TST cables provides several core aspects that you need to know when choosing a suitable charging gun cable, so that you can choose a suitable charging cable.

  1. Safety performance: A high-quality charging gun should pass safety performance tests such as insulation, flame retardancy and high temperature resistance to ensure that it can protect personal and property safety during the charging process. This can be understood by looking at the test report of the charging gun. Companies with strong guarantees will definitely have qualified test reports, so that customers can choose them with confidence.
  2. Material quality requirements: The material design of the charging gun cable must ensure safety and waterproofness, and must have a high degree of durability so that it can adapt to a variety of environmental conditions. TST cables is well aware that the charging gun will inevitably face the test of wind, frost, rain and dew during outdoor use. Therefore, in the design of the charging gun cable, special attention is paid to the improvement of its waterproof and dustproof performance, so that the product reaches the IP67 waterproof standard to ensure its reliability and long-term stability under severe weather conditions.
  3. Current carrying capacity: An excellent charging gun cable should have a high current carrying capacity to meet the needs of fast charging and reduce the waiting time of users.
  4. Temperature rise control: The temperature rise problem is common during the charging process, especially the crimping resistance at the power terminal crimping is prone to sudden changes. Therefore, the charging gun cable needs to have an excellent heat dissipation design to ensure a stable charging temperature and ensure charging safety.

With the rapid development of the electric vehicle industry, the role of charging guns has become increasingly prominent, and its safety cannot be ignored. Choosing a good charging gun is crucial to improving the charging experience and ensuring charging safety. The charging gun cable series developed and produced by TST cables, including AC/DC/EV and high-power liquid cooled charging gun cables, are strictly tested before leaving the factory. At the same time, they follow the IATF 16949 automotive standard and ISO 9001 standard during the production and development process, and have passed a number of safety tests such as temperature resistance and corrosion resistance to ensure the reliability and safety of the product. And the product line is rich, which can meet the diverse needs of different customers. Cooperating with TST cables, a world-leading cable provider, with CQC certification, double quality assurance. The advantages of TST cables charging cable are not only reflected in their excellent product performance, but also in their deep insight into market demand and continuous pursuit of technological innovation.

TST cables has rich experience in the automotive charging cable industry. The liquid cooled charging gun cable product technology covers oil-cooled and water-cooled charging gun cables, which can meet the requirements of automotive customers. In addition, TST cables’ liquid cooled charging gun products have passed multiple tests such as high temperature resistance, explosion resistance, and corrosion resistance, which can solve the charging problem for customers. liquid cooled charging gun cables effectively control the temperature rise during the charging process, reduce the safety hazards caused by overheating, and enhance the stability and reliability of the charging process. As one of the suppliers of liquid cooled charging gun cables, TST cables aims to provide users with more excellent charging solutions and promote the healthy development of the electric vehicle industry. If you have any needs for new energy vehicle charging cables and liquid cooled charging pile cables or want to apply for a free sample order, please contact us by email, phone, or WhatsApp. Choosing TST cables’ liquid cooled charging cable is not only choosing a high-quality product, but also choosing a reliable partner. For more information about charging cable, high temp cable and automotive cable, please visit TST cables’ official website.

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