I. Industry Status

The liquid-cooled megawatt flash charging pile industry is one of the directions for the technological upgrade of rapid energy replenishment for new energy vehicles. In 2024, the market size of liquid-cooled supercharging in China is expected to reach 57.8 billion yuan, with a year-on-year growth of 49%. As of January 2025, the number of public charging piles in China has reached 3.76 million units, and the market share growth rate of liquid-cooled supercharging is significant.

（Liquid-Cooled Megawatt Flash Charging Pile）

The liquid-cooled megawatt flash charging technology mainly addresses the following issues:

  ■  Charging Speed: The technology can achieve extremely high charging power. For example, BYD's megawatt flash charging technology can reach a maximum charging power of 1MW, with a peak charging speed of 2km per second, and can charge 407km in just 5 minutes. Zeekr's 1.2-megawatt liquid-cooled charging pile can achieve "charge for 5 minutes, drive for 500km," which significantly reduces charging time and takes a big step towards making the charging speed of electric vehicles comparable to that of traditional fuel vehicles, basically solving the user's range anxiety.

  ■  Heat Dissipation: A large amount of heat is generated during high-power charging, which is difficult to dissipate effectively with traditional air cooling. The liquid-cooled megawatt flash charging technology uses a liquid circulation system to fully cool the charging gun cable and key components inside the charging pile. For example, BYD uses a full liquid-cooled closed-loop cooling system for the cable, terminal, and key components inside the charging pile, which can ensure the stable operation of the equipment at extreme power and avoid equipment failure or reduced charging efficiency due to overheating.

  ■  Grid Load: On the one hand, by integrating bidirectional V2G (Vehicle-to-Grid) functionality to support peak shaving and valley filling, for example, with built-in energy storage modules in the charging pile to relieve instantaneous grid load. On the other hand, by using smart grid interaction technology, such as dynamic load balancing, and using AI to predict grid load and schedule charging power in different time periods, to avoid excessive impact on the grid, thereby improving the stability and reliability of the grid.

  ■  Compatibility: Some liquid-cooled megawatt flash charging technologies have good compatibility design. For example, Teld's liquid-cooled supercharging equipment can be compatible with vehicles on different voltage platforms ranging from 400 to 1000V. BYD uses dual-gun charging technology and intelligent voltage boosting charging technology to upgrade ordinary supercharging piles to flash charging piles, which are compatible with public fast charging piles. Even if the grid voltage is insufficient, rapid charging can be achieved through the voltage boosting module, reducing the dependence on grid transformation and maximizing the use of existing infrastructure to solve the user's pain point of "difficulty in finding charging piles."

  ■  Battery Life and Safety: Through a series of technological innovations, such as BYD's battery using a full-foil design to reduce internal resistance and minimize polarization effects during fast charging, as well as thermal runaway protection technologies, including three-dimensional cooling, self-power-off coating, and dual-loop cooling systems, the technology ensures battery life and charging safety while increasing charging speed.

II. Principles of Liquid-Cooled Megawatt Flash Charging Technology

1. Cooling Mechanism:

The liquid-cooled system uses circulating coolant (such as a mixture of water and ethylene glycol, or fluorinated liquid) to remove heat from the charging pile, charging gun, and cable. The coolant flows through a closed-loop system and transfers heat to the external environment via a heat exchanger (such as a cold plate or radiator), ensuring that the temperature rise of the equipment is controllable even at ultra-high power levels (1000kW+).

Key Components: Liquid-cooled charging gun (with built-in coolant channels), liquid-cooled cable (smaller cross-section but higher current-carrying capacity), and liquid-cooled host (liquid-cooled circulation pump and thermal management system).

Efficiency Comparison: Traditional air-cooled charging piles have a cooling efficiency of about 0.51kW/℃·m², while liquid-cooled systems can achieve 510kW/℃·m², representing a more than fivefold increase in cooling capacity.

The miniature liquid-cooled pump technology is one of the core components of the liquid-cooled megawatt flash charging system. It ensures the stable operation of the system at ultra-high power levels by efficiently circulating coolant to cool key components. The following comprehensive analysis of its application covers technical principles, core advantages, application scenarios, and challenges and breakthroughs:

2. Technical Principles and Core Design

(1) Liquid-Cooled Circulation Mechanism

The miniature liquid-cooled pump drives the coolant (such as an ethylene glycol water solution, silicone oil, or fluorinated liquid) to circulate in a closed-loop system, removing heat generated by key components inside the charging pile (such as charging modules, charging guns, and cables) through a radiator. The flow rate and pressure of the coolant directly affect the cooling efficiency. For example, JONSN's liquid-cooled pump can achieve a flow rate of 50L/min and a pressure of 14bar, which is suitable for liquid-cooled megawatt flash charging pile systems.

(2) Structure of the Miniature Liquid-Cooled Pump

The miniature liquid-cooled pump uses a magnetic coupling design to avoid leakage risks associated with mechanical seals. The gear material is made of high-strength, wear-resistant PEEK (polyether ether ketone) composite material, combined with zirconia nanoceramic shafts to enhance wear resistance and service life. For example, JONSN's precision-grade miniature gear pump, through PEEK modification technology, can achieve a service life of over 20,000 hours, making it suitable for high-pressure difference and lubrication-free environments.

III. Industry Case Analysis — Liquid-Cooled Megawatt Flash Charging System

In liquid-cooled megawatt flash charging technology, the flow rate and pressure parameters of the liquid-cooled pump are the core design indicators to ensure the system's efficient heat dissipation. The following is a detailed analysis based on industry technology trends, parameters of similar systems, and the technical roadmap of a certain brand's liquid-cooled megawatt flash charging system:

1. Core Parameters of Liquid-Cooled Pump Flow and Pressure

(1) Flow Rate (FlowRate)

Typical Range:

30-50L/min (for megawatt-level charging scenarios)

5-15L/min (for low-power charging or standby mode, with intelligent adjustment for energy saving)

Design Basis:

Thermal Load Calculation: Assuming a charging power of 1000kW with a charging efficiency of approximately 95%, the heat dissipation power required is about 50kW (5% loss).

Flow Distribution:

Charging gun and cable: 60%-70% of the total flow (20-35L/min) to address the Joule heat generated by high-current conductors.

Battery pack cooling: 30%-40% (10-15L/min) for balanced heat dissipation of the battery cells.

(2) Pressure (Pressure)

Typical Range:

0.8-1.5MPa (main circulation system, to overcome microchannel resistance)

0.3-0.5MPa (auxiliary circulation, such as external piping of the charging pile)

Design Basis:

Resistance Model:

The pressure drop (ΔP) in the liquid-cooled system mainly comes from:

Microchannels: ΔP ≈ 0.5-1.0MPa (channel diameter 0.2-0.5mm, length > 1m).

Pipe friction: ΔP ≈ 0.1MPa/10m (for stainless steel pipes with an inner diameter of 8-12mm).

Filters/valves: ΔP ≈ 0.05-0.1MPa.

Total Pressure Requirement: The main pump needs to provide an outlet pressure of 1.2-1.8MPa to ensure effective flow at the end of the cold plate.

2. Key Design Considerations

(1) Dynamic Flow Regulation

Smart Control Strategy:

Real-time adjustment of flow rate (using PID algorithm or AI prediction) based on charging power (100kW-1000kW).

Reduce flow to 10-20L/min at low power to decrease pump power consumption (energy saving of 30%-50%).

(2) Materials and Sealing

Pump Body Material:

316L stainless steel: Corrosion-resistant to ethylene glycol, suitable for coolant with pH 6-8.

Magnetic coupling: Leak-free design to prevent high-pressure coolant from seeping into electrical components.

(3) Efficiency and Noise

Pump Efficiency:

Magnetic gear pump efficiency > 80% (compared to traditional mechanical seal pumps at around 60%).

Power consumption controlled within 1000W-2000W during full-power operation.

Noise Control:

Using low-pulsation gear design and vibration isolation brackets, operating noise < 70dB(A).

Comparison: Traditional gear pumps have a noise level of about 80dB(A).

3. Technical Challenges and Solutions

(1) Leakage Risk under High Pressure

Solution:

Replace traditional mechanical seals (dynamic seals) with magnetic coupling shielded structures (static seals) for shaft seals, with a pressure resistance > 2.0MPa.

(2) Low-Temperature Environment Adaptability

Challenge: At -30℃, the viscosity of ethylene glycol increases to 50mPa·s (compared to about 3mPa·s at room temperature), causing a surge in startup pressure.

Solution:

Preheat the pump motor (using PTC heaters) to raise the coolant temperature above 10℃.

Add viscosity reducers (such as poly-α-olefins) to lower the low-temperature viscosity to 20mPa·s.

(3) Long-Life Requirement

Design Life: >50,000 hours (approximately 5 years of continuous operation).

Life Assurance:

- Bearing Material: Use bearing-grade modified PEEK composite ceramic technology to enhance wear resistance by three times.

- Brushless DC Motor: Reduce brush wear, with a Mean Time Between Failures (MTBF) > 50,000 hours.

IV. Advantages of JONSN Liquid-Cooled Pumps in Fully Liquid-Cooled Megawatt Flash Charging Systems

JONSN is one of the pioneering domestic companies in the field of liquid-cooled supercharging piles, specializing in miniature gear pumps. It holds a significant market share in the liquid-cooled supercharging pile industry and offers professional and mature solutions. The following are the advantages of JONSN liquid-cooled pumps in fully liquid-cooled megawatt flash charging systems:

■ Efficient Thermal Management

In fully liquid-cooled megawatt flash charging systems, high-power charging generates a significant amount of heat, making temperature control of batteries and charging equipment crucial. JONSN's miniature liquid-cooled pumps precisely control the flow of coolant to rapidly conduct heat away, preventing battery overheating and thereby ensuring charging efficiency and equipment longevity. These pumps are utilized in liquid-cooled systems, where their highly integrated and energy-efficient design achieves stable coolant circulation and optimizes the system's energy efficiency ratio.

■ Leak-Free Sealing

JONSN's miniature liquid-cooled pumps employ magnetic drive technology, eliminating the need for mechanical seals and fundamentally solving the leakage issues associated with traditional pumps. This feature is particularly vital in liquid-cooled systems, as coolant leakage could lead to electrical short circuits or equipment corrosion. Through the design of isolation sleeves and magnetic couplings, JONSN's pumps significantly enhance sealing, ensuring safe coolant transfer in high-pressure and high-temperature environments.

■ High Load and Harsh Environment Adaptability

Fully liquid-cooled megawatt charging systems typically require prolonged high-load operation, imposing stringent demands on the pumps' heat resistance and corrosion resistance. The miniature magnetic gear pumps are manufactured from high-strength materials such as stainless steel and alloys, enabling them to withstand high-temperature and high-pressure conditions. In a megawatt flash charging system that adopts a full liquid-cooling solution, the accompanying pumps must operate continuously in high-voltage and high-current environments, and JONSN's magnetic gear pumps provide the necessary heat resistance.

■ Compact Design and High Integration

Liquid-cooled systems demand high space utilization. JONSN's miniature liquid-cooled pumps, with their small size and compact structure, are well-suited for integration into charging piles or battery packs. The company's products, through their highly integrated design, reduce space occupation and simplify the installation process, making them especially appropriate for space-limited scenarios such as charging stations. Additionally, the linear flow control and low-pulsation characteristics of JONSN's miniature liquid-cooled pumps can be utilized in the precise temperature control segments of liquid-cooled systems.

Overall, JONSN's miniature liquid-cooled pump technology, through its efficient heat dissipation, compact design, and intelligent control, has become the “heart” of the liquid-cooled megawatt flash charging system. Its technological advantages have been proven in liquid-cooled supercharging solutions, meeting the heat dissipation requirements for 1000kW-level fast charging. The application of JONSN-MR miniature liquid-cooled pumps in megawatt flash charging systems has distinct advantages. Their reliable quality and performance ensure stable and efficient operation. High-precision control guarantees the liquid cooling effect, and the corrosion resistance enhances the reliability of the equipment. It is an ideal solution for fully liquid-cooled megawatt flash charging systems!