As electric vehicles (EVs) evolve toward faster charging speeds, traditional air-cooled cables struggle to handle the growing current and heat. The liquid cooled EV charging cable represents the latest innovation in charging technology, combining high current capacity with active liquid cooling to deliver faster charging with enhanced safety and comfort.
What Is a Liquid Cooled EV Charging Cable?
liquid cooled ev charging cable
A liquid cooled EV charging cable is a specialized DC fast-charging cable designed with integrated cooling channels that circulate a coolant (usually a water-glycol mixture) to dissipate heat from the conductor and connector.
This allows it to support currents exceeding 500A while maintaining optimal temperature and flexibility.
Key Features
⚡ High Power Capacity – Supports up to 500A–600A DC, enabling ultra-fast charging (up to 600 kW).
💧 Liquid Cooling System – Efficiently removes heat from both cable and connector during continuous operation.
🌡️ Temperature Stability – Maintains safe operating temperature, reducing resistance and preventing overheating.
🧰 Lightweight and Flexible Design – Smaller conductor diameter and improved ergonomics for easier handling.
🔋 Compatible Standards – Works with CCS, GB/T, and CHAdeMO high-power DC fast-charging systems.
🛡️ Safe and Reliable – Equipped with sensors to monitor coolant flow, temperature, and pressure in real time.
Technical Specifications (Typical Range)
| Parameter | Typical Value |
|---|---|
| Rated Voltage | 1000V DC / 1500V DC |
| Rated Current | 300A – 600A |
| Cooling Medium | Water-glycol mixture |
| Operating Temperature | -30°C to +90°C |
| Conductor Material | High-flexibility copper |
| Insulation Material | TPE / TPU |
| Cooling Flow Rate | 1.0 – 2.0 L/min |
| Connector Standard | CCS2 / GB/T / CHAdeMO |
| Protection Class | IP67 / IK10 |
Why Choose Liquid Cooled EV Charging Cables?
| Feature | Benefit |
|---|---|
| Higher Power Delivery | Enables ultra-fast DC charging without overheating |
| Improved Efficiency | Lower electrical resistance and energy loss |
| Compact & Lightweight | Easier handling and installation compared to large air-cooled cables |
| Longer Service Life | Reduced thermal stress extends cable and connector lifespan |
| Enhanced User Experience | Keeps the cable cooler and more comfortable to touch during charging |
Applications
Public DC Fast Charging Stations
High-Power EV Fleet Charging Systems
Electric Bus & Truck Charging
Commercial Charging Infrastructure
Next-Generation HPC (High Power Charging) Networks
Conclusion
Liquid cooled EV charging cables are essential for the future of high-power, ultra-fast charging. With advanced cooling technology, they ensure efficient heat dissipation, greater current capacity, and long-term reliability — ideal for modern EV infrastructure.
👉 Contact TOT Wire & Cable today to get detailed specifications or request a quote for custom liquid cooled EV charging cables tailored to your charging system.
