VOSS Automotive, Amphenol-Tuchel Electronics and the GG Group have introduced a high-voltage EV charging harness designed to support charging power up to 1 megawatt. The new system integrates active liquid cooling throughout the charging cable and socket to reduce thermal losses and enable significantly higher current loads. The companies claim this could reduce charge times to under five minutes.

The charging harness incorporates several key components: the Power2Flow charging cable from GG Group, the CHARGESOK CCS2 socket from Amphenol and a fluid-cooled battery connection and thermal management system developed by VOSS. At the core is a polymer heat exchanger embedded within the cable, which uses a multi-layer plastic tube to circulate a cooling medium—either water-glycol or immersion fluids—between the battery and the charging inlet. The inner layer of the tube is electrically conductive, while the outer layer is thermally conductive and electrically insulating.

By actively cooling the areas of peak thermal load, such as the DC contact chambers in the socket, the system avoids overheating without increasing conductor size. This approach allows a 70 percent increase in current load capacity while reducing cable cross-section, improving flexibility and simplifying installation. In contrast to conventional solutions that use large busbars, this lightweight cable design supports easier integration into compact EV architectures.

The CHARGESOK socket uses direct-contact liquid cooling to dissipate heat at the source. A coolant circulates around the high-current contacts, improving efficiency and enabling continuous high-power charging. The cooling system is designed for compatibility with existing vehicle thermal architectures, offering flexibility for different OEM platforms.

The system is targeted at next-generation EVs requiring rapid charge capabilities and scalable thermal performance. The partners emphasize its applicability across diverse cooling media, lightweight design, and ease of integration into modern vehicle layouts.

Source: VOSS Automotive