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The Effective Cooling Method for Electric Vehicle Charger Station

With increased worries about the effects of fossil energy on climate warming, the manufacturing of electric vehicles (EV) is soaring in China, Europe, Japan, and the United States. According to the International Energy Agency, the number of electric cars will increase from slightly more than 3 million to 125 million by 2030.

EV Charging

Quick, effective, and easily obtainable fast charging is critical to the widespread application of fast-charging electric vehicles, especially as people drive greater distances. One problem is the extensive distribution of the charging station. Another issue is the charging rate.

Significant power (kW) required to allow quicker charging produces more temperatures, necessitating excellent thermal management to reach peak efficiency. Liquid cooling is the effective cooling method that solves these issues. This article will discuss what liquid cooling is and how it is effective in EV charging stations.

What are Electric Vehicles?

Traditional automobiles run on fossil fuels, and emissions from combustion are a major environmental problem. Because of the negative ecological effect of fossil energy, the usage of electric vehicles is becoming critical.

An electric car generates no electricity from fossil fuels and emits no emissions. Several attempts have been launched to mitigate air pollution through non-traditional power sources.

Electric cars utilize an electric battery and contribute to pollution reduction. Additional electricity is used to charge batteries, which then power the motor. The electric motors move the front and rear wheels.

EV Charging Station

Electric cars have numerous benefits, including greater energy power and effectiveness and being ecologically beneficial and free of pollutants caused by combustion. Temperature control methods for batteries, energy regulators, and electric motors have been designed for use in electric cars.

The popularity of electric cars is growing. However, finding quick charging stations when on the move is a constant struggle.

Charging capacity must be increased to shorten recharge time. As a consequence, the temperature will increase drastically. Regulated thermal management using liquid cooling is required to disperse heat and permit quick charging properly.

The Significance of Cooling Systems

Although improvements in electric vehicle systems have allowed batteries to produce higher energy and need reduced regular charging, the most significant concern for battery safety is building an efficient refrigeration solution.

Releasing the cell charge in electric vehicles produces heat; the quicker you release the batteries, the more temperature it makes. Batteries operate on the power differential concept; at extreme heat, the electrons are stimulated, reducing the difference in electrical potential on both ends of the cell.

Since batteries are only designed to run within particular temperature variations, they will cease to function when there is no refrigeration device to maintain them within a usable range.

A substantial internal temperature differential might result in variable charging and discharging speeds for every cell, lowering battery pack efficiency.

Suppose the battery gets too hot or there is an uneven heat dispersion in the battery system. Possible thermal management concerns like capability deterioration, thermal overrun, and fire eruption may happen in that case. Amid potentially fatal safety hazards, the electric vehicle sector is constantly developing to enhance the cooling unit.

There are some standard cooling methods applied for cooling the battery cell system. The liquid cooling systems are the most efficient, economical, and long-lasting.

What is Liquid Cooling Systems?

Liquid cooling systems provide a better convective heat extraction performance than air, owing to their more significant density and heat capability.

They function extremely fast, with benefits such as minimal construction and simplicity of configuration. Among all the solutions on the market, liquid coolant will provide the best result for keeping a battery system at the proper temperature and consistency.

A fluid cooling system is smaller than an air refrigeration unit. It can save approximately 40% of electrical energy compared to the fans necessary for air cooling.

Furthermore, liquid cooling systems help minimize noise levels. Liquid cooling devices have safety risks, such as leakage and disposal, because glycol may be hazardous to the environment if done poorly.

Tesla, Jaguar, and BMW, to mention a few, are now using such technologies. On the other hand, the intricacy of liquid cooling and its leaking possibilities can be divided into direct and indirect cooling systems.

Direct Liquid Cooling System

Direct cooling, often known as immersion cooling system, cools the whole area of the unit equally. It eliminates hot or cold regions of the batteries and considerably enhances cell efficiency. A dielectric refrigerant with low viscosity, good thermal management, and heat capacity is suitable.

Immersion cooling is commonly utilized for data center systems and high-powered devices. Although due to higher costs and safety issues, the thermal management system for this approach is not suited for most mass-developed EV chargers.

Immersion Cooling

It is beneficial for high-performance EV systems and motorsport. The liquid has a critical temperature of around 60 and 80 degrees Celsius to eliminate overheating and heat instability.

Indirect Liquid Cooling System

Water has been used as an efficient cooling in various industrial settings. The critical problem, however, is the limited possibility for direct refrigeration of batteries.

Indirect approaches that eliminate conductivity with cells while retaining superior temperature dispersion help minimize short-circuiting. The presence of electrical resistance may slow thermal diffusion. However, it has no impact on cooling.

Tesla employed wavy tubing sandwiched among cylindrical cells. A highly conductive and electronically insulating substance covers the spaces between the battery packs and the coolant channels.

Although the wavy tubes are less efficient for cooling due to the lower heat transport contact surface, they are secure mechanically and electrically. All coolant lines are maintained outside the container to prevent coolant leaking. Liquid cooling of cells is seen here, with heat transmission from cells to the liquid cooling methods.

Why is Liquid Cooling System Effective for EV Charging Stations?

Air cooling has previously been the chosen approach. However, with rapid advancement, the water chiller cooling method has proven to be beneficial because air chillers charge relatively slowly.

Water’s heating capacity is also 3,500 times greater than air’s, and it’s around ten times more productive in removing the heat from the origin.

Moreover, liquid cooling allows for pre-filled units, simplifying servicing, expediting potentially critical substitutions, providing rapid initial setup, and speeding up updates. Liquid cooling is used in a variety of applications.

The heated battery system, automobile inverter, automotive e-motor recharging wire, and charging station voltage regulators are among them. Using high-quality parts is critical in a sector where efficiency and dependability are essential to success.

Leaking is an electrical device, like overheating, which is a typical concern in the event of an accident. These hazards are reduced by applying the most advanced liquid cooling system, which is intended for long-term dependability with solid capacity and low-pressure loss.

There are numerous common advantages of liquid cooling systems that set them apart from other refrigeration solutions. They save energy, operate silently, and do not require an open area. It is less dangerous to use and has a higher lifespan.

It can also function in severe environments since the mechanism has a sealed framework. Dust cannot reach the cooler and reduce its refrigeration capability. Liquid cooling systems are essential in various sectors, and their performance has raised their demand on the global market.

However, as there are so many liquid cooling systems of different companies on the market, selecting the ideal one may be challenging. In that circumstance, Coolingstyle’s water chillers are very effective, economical, and long-lasting.

One of their most excellent products is their 5U Rack-mounted Chiller, which has a cooling capability of 1000-1200W. It is perfect for use in an EV charging station.

Coolingstyle 5U Rack-mounted Chiller


Various battery refrigeration technologies have been produced during the last 2 decades to effectively cool battery systems in electric vehicles. From a broader standpoint, the liquid cooling system can assure efficiency in various significant applications such as EV charging stations.

While businesses like Tesla and BMW may utilize typical liquid coolants for their refrigeration mechanisms, further studies and growth on battery cells and cooling systems are required to increase electric car security.


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