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To mitigate energy risks and achieve carbon neutrality, the electrification and digitization of automobiles have emerged as pivotal developmental trajectories for the global automotive sector. Governments around the world have introduced various plans and initiatives. In 2022, the global penetration rate of electric vehicles exceeded 10% for the first time.
During this period of rapid expansion in the market share of new energy vehicles, ‘driving range’ has consistently been one of the decisive factors influencing consumers’ decisions to purchase EVs. As a result, various automotive brands are continuously enhancing their product offerings. The American automotive website Edmunds conducted a comparative analysis of driving range test data for 61 electric vehicle models, including Mercedes-Benz, BMW, and Ford, and the vast majority of electric car brands have exceeded the range stated in the publicity.
On the other hand, beyond the inherent driving range capability of vehicles, the accessibility and strength of ‘refueling’ options on roads also significantly impact the ‘driving range.’ Without conveniently located and efficient charging stations, the driving range of new energy vehicles remains constrained
In 2006, BYD constructed China’s first electric vehicle charging station. By April 2023, China had more than 2 million public charging stations, with alternating current (AC) charging stations slightly higher than direct current (DC) charging stations. The distribution of these two major types has remained relatively stable. In 2022, the United States pre-planning to allocate a budget of $7.5 billion for the establishment of 500,000 public charging piles. Considering this growth trajectory, it is projected that the demand for public charging stations across the entire United States will exceed 1 million by 2030. A similar trend is evident in the European market. According to a report by Euractiv on July 25, 2023, the European Council passed a new regulation mandating that all European Union member states must provide a charging station every 60 kilometers along major roads starting from 2025.
Consequently, within the context of burgeoning market demand and evolving national policies, high-powered liquid-cooled charging stations are poised to become the next frontier in alleviating ‘range anxiety’ for new energy vehicles.
From the trend point of view, there are four key directions in the development of charging stations: ①DC instead of AC, ② the high-powered and standardized design of charging modules, ③ the substitution of liquid-cooled heat dissipation for air cooling, and ④ the elimination of onboard chargers (OBC). These four trends influence each other. Direct current charging reduces the charging time for new energy vehicles, significantly enhancing charging efficiency (AC charging stations require 8-10 hours for a full charge, whereas DC charging stations only need 20-90 minutes). Concurrently, the trend toward high-powered charging modules will drive further increases in energy density within a certain volume of battery packs. Additionally, the high voltage circuit in charging generates substantial heat, leading to significant heat loss. Therefore, effective battery thermal management becomes crucial. Traditional air cooling gradually becomes inadequate to meet the demands of such high power and rapid heat exchange, hence the promising market prospects for high-powered liquid-cooled charging stations.
From a perspective rooted in technological security, traditional charging stations or semi-liquid-cooled charging stations employ air cooling mechanisms. These systems utilize radiators or fans to draw air into the structure from one side, directly expelling the heat generated by electrical components and the entire module. The expelled air carries away the heat from the structure. However, this cooling method demands a stringent air quality standard, as the air can carry impurities such as dust and moisture. When the impurities are drawn into the charging station, they adhere to the internal components, deteriorating insulation and heat dissipation quality, resulting in reduced charging efficiency and equipment lifespan.
While the liquid-cooled heat dissipation utilizes the liquid-cooled plate/water cooling plate/serpentine tube, without any air duct outside the module. The heat dissipation principle is that the circulation of cooling liquid(coolant) within the chamber of the liquid-cooled plate, transferring heat to the radiator, which can be directly blown away by the air surface heat. As a result, the liquid-cooled charging module and electrical components inside the charging station remain isolated from the external environment, allowing for an IP65 protection rating. This design enhances reliability, heat exchange efficiency, and overall lifespan.
As experts in the field of battery thermal management, XD Thermal places a strong emphasis on the water cooling method: how to optimize the efficient and secure performance of charging stations through liquid-cooling. To understand how your project can benefit from liquid-cooling for heat exchange, feel free to consult our specialized technical team. We hold a significant advantage in technical support, experience sharing, and cost control.
