Moving to Liquid, Moving to Reliability

Liquid cooling modules are a reliable, efficient and cost-effective alternative to fans at EV charging stations.

Noise pollution is a significant issue affecting both end users’ experience and the surrounding community at electric vehicle (EV) charging stations. Fan cooling modules typically produce up to 65dB of noise, while fan cooling direct-current fast charging (DCFC) systems also reach 65dB. Liquid cooling modules eliminate the need for cooling fans, by utilizing cold plates to dissipate heat without generating any noise. At the system level, liquid cooling power cubes employ passive cooling methods, reducing noise levels to 50dB with adjustable speed AC fans at 45o C ambient temperature.

Efficiency is crucial to determine payback time. While most manufacturers focus on maximum efficiency, Infypower prioritizes core working range efficiency over peak efficiency. Considering the DCFC output voltage range of 150Vdc to 1,000Vdc and the various voltage platforms of passenger EVs, Infypower evaluates real working efficiency based on core working range efficiency. The LRG1K0100G liquid cooling ACDC charger power module, featuring SiC Mosfet and innovative topology, targets at the main charging voltage ranges of 350Vdc to 450Vdc and 700Vdc to 900Vdc. From 40% load to 80% load, and from 300Vdc to 1,000Vdc, the efficiency is higher than 96%. A DC fast charging power cube can control modules’ load ratio above 40%, allowing modules to work in the best efficiency area.

Reliability plays a crucial role in determining service costs, as all charge point operators (CPOs) aim to use highly reliable equipment to minimize service expenses. The LRG1K0100G module incorporates liquid cooling technology and the charging power cube boasts IP65 protection. This setup ensures no air exchange between the interior and exterior, maintaining a clean environment for the modules to operate in. By preventing air from damaging the components and PCB inside the modules, the cold plate offers a more uniform and powerful cooling platform for all components. This facilitates easy temperature control for transformers, conductors, capacitors and power devices. The coolant temperature range spans from -20o C to +60o C at full load, enabling the entire charger to function optimally within this temperature range.

Maintenance stands as a critical aspect of charger station operations, with reduced maintenance translating into lower service costs. Liquid cooling DCFC eliminates the need for a dust filter at the system level, avoiding the periodic replacement of dust filters and saving labor costs associated with routine maintenance. System-level passive cooling, which combines a heat exchanger with electrical commutation (EC) fans, proves to be more reliable than compressor systems.

The primary objective of CPOs is to reduce the total cost of ownership (TCO). The adoption of high-reliability, low-noise pollution, low-maintenance, and high-efficiency liquid cooling DCFC represents the prevailing trend in the charging industry. Infypower’s top priority is to offer mature liquid cooling building blocks for DC charger manufacturers.

Infypower not only supplies liquid cooling modules but also liquid cooling power cubes. The 30kW liquid cooling module has been in field applications for four years, and the 600kW power cube was launched in 2023. The 60kW liquid cooling module is set to enter mass production in Q4, 2025. Infypower has a decade of experience in charging modules and DCFC solutions. We understand the key concerns of charging point operators: noise pollution, efficiency, reliability, and maintenance.

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