Liquid-cooled cables and connectors
How 500 A flows through something a human can lift.
You'll learn
- Explain liquid-cooled cables and connectors clearly and accurately
- Read the numbers that define the behaviour
- Apply the idea to a real charging session
Overview
Above roughly 200 A, an air-cooled cable would need conductors too heavy to handle. Circulating coolant around the conductors solves it.
In depth
Formula
P_loss = I² × R_cable
Doubling current quadruples cable heating, which is why cooling — not copper — is the practical route to high current.
Example: 500 A through 5 mΩ dissipates 1.25 kW inside the cable.
- Temperature sensors in both DC pins
- Coolant pump and reservoir monitored by the post
- Automatic derating if pin temperature rises
- Regular inspection for cuts and coolant loss
Key takeaways
Remember this
- Cooling enables currents above 200 A.
- Pin temperature sensing triggers derating.
- Careless handling of connectors slows everyone down.
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