Liquid cooling significantly enhances safety in fast-charging processes through multiple mechanisms:
1. Temperature control and overheating prevention
Fast charging generates extreme heat (exceeding 270°C in 10-minute charges), which liquid cooling effectively dissipates using circulating coolants like ethylene glycol. This maintains stable operating temperatures, reducing fire risks and component degradation.
2. Cable and connector safety
Liquid-cooled cables handle higher currents (up to ~500A) with smaller cross-sections by directly removing heat through coolant flow. This prevents cable overheating, reduces weight for safer handling, and avoids the need for bulky copper wiring required in air-cooled systems.
3. Component longevity and reliability
By maintaining lower operating temperatures, liquid cooling minimizes thermal stress on charging station electronics and vehicle battery systems. This slows insulation breakdown in cables and prevents accelerated aging of power modules.
4. Operational noise reduction
Unlike air-cooled systems requiring loud fans, liquid cooling uses quieter coolant pumps, enhancing user experience while maintaining safety margins during high-power charging sessions.
Comparison of safety factors
| Feature | Liquid Cooling | Air Cooling |
|---|---|---|
| Heat Dissipation | Direct coolant contact >500A | Indirect airflow ≤250A |
| Cable Weight | Lighter (thinner conductors) | Heavy (thick copper) |
| Noise Levels | Low (pump-based) | High (fan-dependent) |
| Thermal Runaway Risk | Actively mitigated | Passively managed |
Original article by NenPower, If reposted, please credit the source: https://nenpower.com/blog/how-does-liquid-cooling-impact-the-overall-safety-of-fast-charging-processes/
