A recent article published in the journal Engineering introduced an innovative liquid metal flexible charging connector (LMFCC) for high-power direct current fast charging (DC-HPC) in electric vehicles (EVs). This approach aims to enhance cooling efficiency and high-current transmission, addressing key challenges in EV technology.
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Advancements in EV Charging Technology
Reducing carbon emissions has become a key priority as global energy structures evolve, particularly transportation.
According to the International Energy Agency, the number of EVs worldwide is expected to increase approximately 10 times by 2030. However, challenges like range anxiety and prolonged charging hinder large-scale adoption compared to conventional fuel vehicles.
HPC technology has emerged as a solution, significantly reducing charging times to levels comparable to traditional refueling.
Recent advancements have increased the peak charging power of DC-HPC systems from 43.5 kW to 450 kW, with new standards aiming for up to 1 MW.
Despite these developments, ultrahigh-current charging exceeding 3000 A remains a significant challenge. The heat generated during high-current charging can lead to equipment failures and safety risks, such as overheating and fire hazards.
Traditional cooling methods, which separate current conduction from heat dissipation, are inadequate for managing the extreme thermal loads of ultrahigh-current applications. This highlights the urgent need for new solutions that enhance thermal management while maintaining charging efficiency and safety.
About this Research: Introducing Gallium-Based LMFCC
Researchers developed a gallium-based LMFCC charging and cooling strategy to address ultrahigh charging currents in DC-HPC systems. They examined its transmission stability under extreme deformation compared to conventional solid metal connectors.
The study employed a compact induction electromagnet-driven system optimized for active cooling to enhance liquid metal flow rates and cooling efficiency. A three-dimensional (3D) multi-physics numerical model was constructed to evaluate the LMFCC's performance across various geometric and hydrodynamic parameters. The experimental setup included a synergetic cooling LMFCC, a direct current (DC) high-power supply, and multi-sensing signal collection systems to monitor temperature, pressure, and flow rate.
The LMFCC system comprises induction electromagnet-driven units, liquid metal flexible cables (LMFCs), liquid metal-enhanced heat dissipation components, and transition connection units. The LMFCs, made of highly elastic silicone tubes filled with liquid metal, enable independent coolant-circulating loops for improved heat dissipation.
The electromagnet-driven unit generated an Ampère force to pump liquid metal through the loops, enhancing cooling performance. Then, a magnetohydrodynamics (MHD)-based numerical model was used to optimize pumping capability and thermal management. The researchers validated the LMFCC's adaptability to superhigh charging currents through experiments, providing insights into its operational reliability and cooling efficiency.
Key Findings of Using New Gallium-based LMFCC
The outcomes indicated that the LMFCC exhibited exceptional cooling efficiency and flexibility, effectively dissipating heat while transmitting high currents. It achieved sudden low temperatures (<16 °C at 1000 A), significantly outperforming traditional cooling methods that struggle to maintain safe levels under similar conditions. Its remarkable bending radius of just 2 cm enhanced adaptability for various applications.
The induction electromagnet-driven system improved liquid metal flow, boosting active cooling capacity and mitigating thermal shocks, extending the charging system lifespan.
Experimental results closely matched the numerical simulations, validating the LMFCC model's accuracy. For example, at a flow rate of 0.2 L·min⁻¹, the experimental pressure head was 47.8 kPa, while the simulation results yielded 44.9 kPa, showing a deviation of 6.5%.
The study highlighted liquid metal's dual role as a coolant and current-carrying conductor, improving reliability while reducing fire hazards associated with copper conductors.
The 3D multi-physics model effectively analyzed MHD generation, optimizing pumping capability and thermal transfer. The results showed that increasing the LMFC's diameter enhanced heat dissipation, ensuring cooling even at high charging currents.
The authors also demonstrated the benefits of integrating an active-rotating magnetic system into the Permanent Magnet Electromagnetic Pump (PM-EMP), which enhances pumping reliability and eliminates common issues like coolant leakage.
Comparative analysis revealed that the LMFCC provides a lightweight, flexible, and highly efficient alternative to conventional copper cables. This makes it a strong candidate for liquid-cooled power lines in electric trucks, aircraft, and ships requiring ultrahigh-current charging.
Potential Applications in the EV Industry
This research has significant implications across multiple industries. In the EV sector, the LMFCC could revolutionize charging infrastructure by enabling rapid recharging and improving the efficiency of the HPC system. Its flexible design allows seamless integration into diverse charging environments, from urban hubs to remote locations.
Beyond EVs, the LMFCC's synergetic cooling strategy could be helpful in renewable energy systems, industrial processes, and thermal management in aerospace and marine transportation.
Its ability to manage heat while transmitting high currents makes it a valuable solution for next-generation power and cooling systems. As demand for high-capacity charging grows, adopting LMFCC technology could enhance the reliability and scalability of future energy infrastructures.
Conclusion and Future Directions
The LMFCC represents a significant advancement in EV charging technology, addressing the challenges of ultrahigh charging with an efficient thermal management solution. It can significantly enhance the performance, safety, and scalability of charging systems, accelerating the adoption of high-power EV infrastructure.
Future work should optimize its design, reduce costs, and integrate it into existing infrastructure. The synergetic cooling and charging strategy marks a breakthrough in thermal management, positioning the LMFCC's potential in high-power applications.
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Source:
Liu, C., & et al. Liquid Metal-Enabled Synergetic Cooling and Charging of Superhigh Current. Engineering, 2025. DOI: 10.1016/j.eng.2024.11.035, https://www.sciencedirect.com/science/article/pii/S2095809924007446