Technical Challenge: Heat Management in High-Power EV Charging

Fast charging offers tremendous convenience—imagine fully charging your EV in just five minutes. But behind this promise lies a serious technical hurdle: excessive heat. As charging power increases, heat becomes the primary bottleneck for many automakers.

Why Fast Charging Causes Heat

According to the formula P = U × I, power increases by raising voltage or current. However, increasing current in the limited space of a charging pile generates significant heat. This rise in temperature can damage internal components and compromise system safety. As a result, efficient thermal management is essential for the reliability and safety of ultra-fast charging stations.

Two Cooling Strategies: Thick Cables vs. Liquid Cooling

To manage heat in fast charging, two main solutions are used:

1. Increase cable thickness to carry higher current

2. Adopt liquid cooling for active heat dissipation

Some manufacturers have chosen thicker cables, but these result in bulky, heavy charging guns (often 3–4 kg), making them difficult to handle—especially for female users. This compromises the charging experience.

The more advanced solution is liquid cooling, which delivers superior performance with lighter, more manageable cables.

Liquid Cooling: Industry Trend and Adoption

Liquid cooling has gained rapid traction across the EV industry:

• March 2019 – T Company launched the world’s first liquid-cooled Supercharger (V3), reducing cable diameter by 44% compared to V2.

• August 2021 – GAC Aion released the A480 supercharging pile with full liquid cooling.

• April 2022 – TELD introduced a 600 kW liquid-cooled charging pile.

• August 2022 – Xpeng Motors launched the S4 pile, delivering up to 480 kW and 670A, using liquid cooling.

Advantages of liquid-cooled systems:

• Faster charging

• Lower noise and heat

• Enhanced safety and stability

• Lightweight cable for better usability

Why Choose TOPSFLO Liquid-Cooled Pumps?

Liquid cooling works by circulating coolant in a closed loop to absorb and dissipate heat—and the core of this system is the circulation pump.

TOPSFLO, a global expert in micro pump solutions, provides brushless DC pumps specially designed for high-power EV charging applications, including:

• High-power DC fast charger cooling modules

• Liquid-cooled charging gun lines

• Ultra-fast charging systems up to 600 kW

TOPSFLO EV Fast Charging cooling pumps feature:

• Compact design with low temperature rise

• Intelligent speed control (5V/PWM, FG signal feedback)

• Six safety protection mechanisms

• Long lifespan up to 30,000 hours

• High and low temperature resistance

• Full customization to meet unique client needs

With broad compatibility and proven reliability, TOPSFLO liquid cooling pumps ensure stable thermal management in today’s most advanced EV charging systems.

Conclusion

As fast charging becomes the norm, liquid cooling will be key to ensuring safety, performance, and user comfort. TOPSFLO’s cutting-edge circulation pumps are ready to meet the evolving demands of the EV charging revolution.