EV Charging
Liquid Cooling for EV Charging Cables and Connectors
Tark Thermal Solutions develops liquid cooling systems for high-power EV charging cables and connectors. Solutions can integrate heat exchangers and coolant pumps to manage heat generated during fast charging. Cooling architectures are tailored to the charging current, cable geometry, coolant requirements and installation space, including HPC, heavy-duty charging, and MCS applications.
Our solutions remove heat from charging cables and connectors using closed-loop water-glycol or dielectric-fluid cooling, with cooling capacity, flow, pressure, controls and packaging engineered around the charging platform.
EV Charging Cooling Solutions and Applications We Support
Cable & Connector Liquid Cooling Units for
- Passenger HPC — compact liquid cooling units for 150–350 kW chargers
- Heavy-Duty Charging — higher-capacity units for sustained 350–500 kW operation
- MCS — advanced cooling architectures for 500 kW to 1 MW+ systems
Depending on the charger architecture, the cooling unit may be integrated into the charging dispenser, charge post or charger cabinet.
Cable and Connector Cooling
High charging currents generate resistive heat in the cable conductors and concentrated heat at the cable-to-connector interface.
Liquid cooling removes this heat while allowing the cable to remain thinner and more flexible than an equivalent uncooled conductor. This becomes especially important as charging currents move beyond approximately 400 A.
Best suited for: HPC • Heavy-duty charging • MCS
Connector and Contact Cooling
Electrical contact resistance concentrates heat inside the connector, where available space for heat rejection is extremely limited.
Cooling the connector interface helps control touch temperatures, reduce localized hot spots and maintain charging performance during high-current operation. The connector is therefore one of the most thermally demanding points in the charging path.
Best suited for: High-current CCS • Heavy-duty charging • MCS
Cooling Units for Charging Dispensers
Compact dispensers require significant heat rejection within a restricted installation envelope.
Tark Thermal Solutions can integrate pumps, heat exchangers, fans, reservoirs, sensors and controls into compact cooling units engineered around the available dispenser volume and airflow.
This is particularly relevant for split-cabinet charger architectures, where more power electronics are moved into a central cabinet while the dispenser itself becomes smaller.
Passenger-Vehicle High-Power Charging
150–350 kW | Typically 300–500 A
High-power passenger EV chargers increasingly require liquid-cooled cables to manage heat while keeping the charging cable practical for everyday handling.
Typical systems use a closed-loop water-glycol cooling circuit with a pump, reservoir, heat exchanger and temperature monitoring.
Key cooling priorities include:
- Maintaining safe connector and handle temperatures
- Removing heat from high-current conductors and contacts
- Keeping cables compact and flexible
- Supporting repeated high-power charging sessions
- Fitting within increasingly compact charging dispensers|
For a typical 350 kW charger, a liquid-cooled CCS cable can incorporate temperature, flow and pressure monitoring with control logic that reduces charging current if thermal limits are approached.
Heavy-Duty Truck Charging
350–500 kW | Typically 500–700 A
Heavy-duty charging places greater thermal and mechanical demands on the cable and connector because charging sessions can be longer, more frequent and closer to continuous duty.
Cooling systems therefore need to manage sustained high-current operation while supporting demanding fleet and depot environments.
Key requirements include:
- High continuous cooling capacity
- Connector hot-spot management
- Reliable coolant circulation
- Durable hoses, seals and fittings
- Serviceable cooling architecture
- Resistance to repeated handling and environmental exposure
For most applications in this range, water-glycol liquid cooling provides a strong balance of cooling performance, technical maturity and integration flexibility.
Megawatt Charging System Cooling
500 kW to 1 MW+ | 700 A and Above
Megawatt Charging System applications create a different thermal challenge.
Extreme current density, long charging sessions and high connector heat flux can require higher-capacity or multi-loop liquid cooling architectures.
Depending on the design, suitable approaches can include:
- High-capacity water-glycol cooling
- Multi-loop liquid cooling
- Dielectric-fluid cooling
- Single-phase immersion concepts
- Advanced connector cooling architectures
The MCS specification allows electrical operation up to 1,250 VDC and 3,000 A, although practical cooling architecture depends on the specific operating current, duty cycle and connector design.
Related Content
What We Need to Design Your EV Charging Cooling Solution
To begin sizing an EV charging cable or connector cooling system, provide:
Electrical and thermal requirements
- Continuous and peak cable current
- Cable length
- Conductor cross-section
- Charging duty cycle
- Maximum connector or handle temperature
Cooling system integration
- Available installation volume
- Heat-exchanger airflow
- Coolant-loop location and hose length
- Hose and fitting requirements
- Electrical supply
- Communication interface
Environmental requirements
- Ambient temperature
- Solar loading
- Noise limit
- Required IP and IK ratings
- Coolant specification
- Applicable regional certifications
With current, duty cycle, cable geometry, and available installation volume, Tark Thermal Solutions can perform an initial cooling-capacity and packaging assessment before a formal RFQ.
Why Choose Tark Thermal Solutions for EV Charging Cooling?
Cooling Designed Around the Charging Platform
We engineer the cooling system around the actual current, duty cycle, cable geometry, thermal load and installation envelope rather than forcing the application into a standard configuration.
Multiple Liquid Cooling Technologies
Our engineering approach can incorporate water-glycol, dielectric-fluid and advanced liquid cooling architectures depending on charging current and thermal requirements.
From Thermal Analysis to Prototype Validation
Where packaging is constrained or operating conditions are unusual, thermal simulation and prototype validation can be incorporated into the development program.
Built for Long-Term Reliability
Charging stations can be expected to operate for more than 10 years. Cooling-system design must therefore consider pumps, heat exchangers, seals, hoses, sensors, controls and serviceability as an integrated system rather than isolated components.
Designing a Liquid-Cooled EV Charging System?
Share your charging current, cable geometry and cooling requirements. Our engineers can help assess the cooling architecture, capacity and integration options for your application.