Crack Electric Aviation Charging Anxiety: Breakthrough In 3000V Liquid-cooled Fast-charging Cable

With the acceleration of the transformation of the global aviation industry to electrification, the endurance and charging efficiency of electric aircraft (eVTOL, etc.) have become the core bottleneck restricting the development of the industry. In this context, liquid-cooled fast-charging cable technology, with its efficient heat dissipation and high-voltage carrying capacity, has become a key breakthrough to crack the "charging anxiety" of electric aviation. This paper will focus on the technical progress, industry impact and future challenges of 3000V liquid cooled fast charge cable analysis.

1. The technical principle and advantages of liquid cooled fast charging cable

Efficient heat dissipation mechanism

Liquid cooling technology through the design of coolant circulation channels inside the cable, the use of electronic pumps to drive the coolant flow, quickly carry away the heat generated during the charging process. Compared with traditional air cooling technology, the cooling efficiency of liquid cooling is improved by several times, so that the cable can run stably at higher current. For example, the liquid-cooled charging gun from Faye Technology reduces the weight of the gun line by 50% through this technology, while supporting high-power charging above 350kW.

High voltage and high current carrying capacity

Liquid cooling technology significantly reduces cable cross-sectional area, reducing weight and volume while supporting higher voltages and currents. Taking the liquid-cooled high-power charging cable developed by Far East Cable as an example, its current carrying capacity is increased by more than 3 times through coolant heat dissipation, achieving a charge of 3-5 minutes of 100km, and can be adapted to 3000V high-voltage systems. Ford and Purdue University's research further shows that liquid cooling technology combined with phase change cooling methods can support ultra-fast charging above 450kW, laying the foundation for the high-voltage needs of electric aviation.

2. Breakthrough progress of 3000V liquid cooled fast charge cable

Technical standards and certification breakthrough

Domestic companies such as Far East Cable have passed the TuV Rheinland certification, and its liquid-cooled charging cable has become the first product in the world to obtain this certification, marking the international recognition of technology maturity and safety. In addition, the China electric Vehicle high-power charging Technology and Standards Pre-research working group is promoting the standardization of liquid-cooled charging interfaces, paving the way for the commercialization of 3000V high-voltage systems.

Material and process innovation

The liquid-cooled cable must meet the requirements of electrical conductivity, heat dissipation, and resistance to extreme environments. For example, the Far East cable uses high-strength materials, has been tested for corrosion resistance to high-temperature refrigerants, and has characteristics such as blasting resistance and UV resistance, which significantly improves reliability in aviation scenarios. Foreign companies such as Ionity promote the extension of liquid cooling technology to higher voltage levels by optimizing conductor materials, reducing resistance and achieving cable weight reduction design.

Ultra-fast charging efficiency

The liquid cooling technology combined with the 3000V high voltage platform can increase the charging power to the megawatt level. Taking Huawei ChaoJi charging technology as an example, it supports 1000-1500V voltage and 500-600A current, and can recharge more than 300km in 10 minutes. If upgraded to the 3000V system, the charging time of electric aircraft is expected to be shortened to the same level as refueling of fuel aircraft, completely eliminating "charging anxiety".

3. Industry impact and future challenges

Promote the commercialization of electric aviation

Liquid cooled fast charging technology can significantly reduce the ground charging time and improve the efficiency of aircraft operation. For example, the 540kW supercharged pile of the power King fast charge has been applied to the field of heavy trucks, and if it is adapted to the aviation scenario, it will accelerate the large-scale application of eVTOL and other models.

Industrial chain coordination demand

Liquid cooled fast charging requires full link coordination of charging pile, cable, battery and thermal management system. At present, the cost of the liquid-cooled charging gun accounts for 20% of the total cost of the charging pile, and the material and mass production scale are still the key to cost reduction. In addition, the aviation field needs to develop more stringent safety standards, such as explosion-proof, low temperature resistance (-40 ° C), etc., to further test the maturity of technology.

Policy and infrastructure support

The national level is accelerating the revision of charging standards, such as the new national standard for "Connecting devices for conductive charging of electric vehicles" will support higher voltage and current. Electric aviation needs to synchronously plan the charging network, combine the layout of liquid-cooled supercharging stations in airports and urban air transportation hubs, and form an "air-space integration" recharge system.

4. Conclusion

The technological breakthrough of 3000V liquid-cooled fast-charging cable marks a new stage of electric aviation from "endurance priority" to "efficiency priority". Although cost, standards and industrial chain coordination are still challenges, with the advancement of material innovation, policy support and large-scale application, liquid cooling technology is expected to become the core engine of electric aviation popularization, opening a new era of green aviation.