liquid cooled EV charging cable

In the previous article, we discussed the importance of liquid cooling technology for DC Fast Charging, which enables electric vehicles to achieve excellent charging experiences. This includes enhancing the charging power limit of High-power charger (HPC), achieving more efficient, energy-saving, and reliable charging.     Why Liquid Cooling Matters in DC Fast Charging   As EV adoption accelerates, the demand for ultra-fast, efficient, and safe charging solutions grows rapidly. Liquid cooling technology has become a critical enabler in High Power Charging (HPC), allowing systems to safely deliver 500A and beyond without overheating.   Previously, we explored the role of liquid cooling in enhancing thermal management. In this article, we'll take a closer look at the core components of liquid-cooled EV charging systems, and how Workersbee's 500A liquid-cooled CCS2 charging cables offer a competitive edge for your EV charging infrastructure.   What Is a Liquid-Cooled EV Charging Plug?   A liquid-cooled EV charging plug is engineered to manage the extreme heat generated during high-current DC charging. It consists of several essential components:   ·Coupling Part ·Enclosure ·Liquid Cooling Assembly ·Terminal Pin ·Sealing System ·Cable Clip   Spotlight: The Liquid Cooling Assembly   The core of the plug’s thermal regulation lies in the liquid cooling module, which actively disperses heat from critical contact points during high-power charging. During high-current charging, the terminal pins heat up more than the cable conductors, due to contact resistance. To mitigate this, a cooling structure is built around the pins, enabling forced liquid cooling using a circulating coolant.   The assembly is designed for:   ·Simple and efficient structure ·Easy manufacturing ·Excellent temperature rise control   Its structure typically includes:   ·Dual-sided coolant inlets/outlets (using smooth “pagoda-style” joints) ·Thermal conductive material (for heat transfer without direct coolant-metal contact) ·Fixing nuts, seals, and mounting screws   This design ensures effective cooling while maintaining electrical insulation and operational safety.     Inside the Liquid-Cooled Cable: Structure & Design Highlights   Unlike standard DC charging cables, liquid-cooled EV charging cables integrate a coolant channel within the cable itself. Here's how it works:   ·A liquid cooling tube runs through the center, carrying coolant ·The conductor wraps around the tube ·An insulated outer layer protects the system   This integrated design determines the internal layout of the plug and the cooling performance of the system.   Key Design Requirements for Public Charging Infrastructure    To ensure long-term performance, the following are essential in cable design:   1. High flexibility – Prevents cable stiffness and enhances usability. 2. Proper outer diameter – Avoids weak thin jackets while staying compact. 3. Low sheath temperature rise – Improves safety and comfort for users. 4. Strong welding – Guarantees a stable electrical connection for the pin-conductor joint.       The Role of the Liquid Cooling Tube   The cooling tube is a critical component, affecting both thermal transfer and coolant flow efficiency. Here's what matters:   ·A narrower internal channel within the cooling tube increases resistance to coolant flow, which can significantly hinder the system’s ability to remove heat effectively.     ·Outer diameter: Must balance strength, flexibility, and lightness. ·Material: Requires good chemical resistance, elasticity, and toughness.   Longer cables may generate more heat and higher resistance, so it's essential to balance cable length vs cooling efficiency.       Liquid Cooling System: How It All Circulates   Beyond the cable and plug, a complete liquid-cooled EV charging system includes:   ·Coolant pump ·Radiator/heat exchanger ·Coolant reservoir (oil tank) ·Connecting pipes     Working Principle   1. Heat generated during charging is absorbed by the coolant. 2. Once the coolant absorbs excess heat from the charging components, it flows into a heat exchanger, where thermal energy is transferred out before the liquid recirculates. 3. The coolant is returned to the reservoir and pumped back into the plug.   Advanced systems include temperature, pressure, and level sensors, enabling automatic operation with smart controls. Chargers typically only need to supply power and start signals.       Why Choose Workersbee's 500A Liquid-Cooled Charging Cable?   Workersbee's 500A CCS2 Liquid-Cooled Charging Cable is designed to deliver reliable high-power charging for demanding public and fleet applications. It has passed CE certification and uses TPU-insulated, user-friendly cables.     Core Advantages   1. Outstanding Performance Tailored cooling tube and cable designs with excellent thermal, chemical, and mechanical properties.   2. Superior User Experience Flexible and easy-to-handle cable enhances usability in public environments.   3. Maximum Safety Temperature rise of the outer jacket is strictly controlled to avoid overheating.   4. Robust Manufacturing High-quality welding of pins and rigorous production control ensure durability and long-term performance.   5. Lower Maintenance Cost Modular terminal quick-change design eliminates full plug replacement, reducing service costs.   6. Flexible Customization Options for cable length, connector type, current rating, and branded logos.   7. Global Compatibility Complies with CCS2 and international standards, ensuring wide interoperability across charging networks.     Ready for the Future of Fast Charging   As the EV market shifts toward ultra-fast public charging, liquid-cooled technology will be the foundation of safe, stable, and scalable infrastructure.   Workersbee's liquid-cooled EV charging solutions are built for the future—with innovation, flexibility, and safety in mind.   Whether you're building a highway supercharging station or upgrading your fleet depot, our 500A liquid-cooled CCS2 cables deliver the power and performance your business needs.     Reach out to the Workersbee team today for product specs, samples, or custom solutions.