SUNON Cooling Solutions Make Automotive Charging Stations Prosper


Eager to achieve carbon reduction, global leaders are now heavily encouraging electric vehicle (EV) use and heavily investing in establishing EV charging stations. The effectiveness of EV charging equipment helps drive EV purchases and greatly improves EV users’ recharging convenience, which are just two benefits to the advancement of the charging technology. EV charging stations consist of multiple battery modules and their structure is highly complex; a well-designed thermal solution with a spoiling function is required to enhance the charging efficiency and the safety of the fast charging operation.

The SUNON team is a thermal expert when it comes to custom designing a total solution for EV charging station systems, including uniformly conducting concentrated heat and rapidly decreasing system temperature, by which the charging system works in an appropriate operating environment that assures the equipment’s safety.

Two-Phase Cooling Solution for Charging Station(Wall-Mounted)
A wall-mounted charging station is classified as small-scale but highly effective charging equipment, and its internal system is often installed in a limited space where heat dissipation is the primary problem. When the operating temperature reaches over 100℃, its charging effectiveness and safety are both at risk of failure.

The SUNON R&D team designed a two-phase cooling module solution (188*181*41 mm) for a client’s charging system based on the type of structure mentioned above. The module is light, slim in shape, and covered firmly upon the system’s heat sources, quickly and uniformly conducting heat. This design causes the system temperature to quickly decrease to its optimal operating condition (below 70℃).

Aside from the system’s overheating issue, the charging station is built semi-indoors where the system’s effectiveness is gradually degraded in the long run due to exposure to poor environmental conditions such as rain, humidity, and dust. SUNON’s thermal module can be customized, providing nickel plating technics to enhance the module’s anti-oxidation. By applying this custom-created solution, the charging station system can continue to perform well in a variety of working conditions and the efficacy of its charging and safety to use are assured.

Thermal Performance of the Two-Phase Cooling Solution for Charging Station (Wall-Mounted)

Fan Cooling Solution for Charging Stations (Stand-Alone)
A stand-alone charging station operates with efficiency; however, degradation and system malfunctions can occur when the system temperature rises and is constantly stored inside of the station because of its high-performance charging process (2.5kW) and extended operation (6-8 hrs). SUNON provides a highly effective thermal solution that quickly and stably dissipates a large amount of heat and thus extends the charging station’s lifespan. By utilizing this solution, the station’s long-lasting operation efficiency and safety will be sustained.

In addition, our client’s system operating environment is outdoors, where the charging process is affected by windy and dusty conditions. SUNON’s thermal solution with our IP21-IP68 design can meet various IP requirements for charging stations. For instance, we designed a thermal solution with higher anti-water spray and anti-dust protections for our client’s system. Long-lasting heat dissipation, an assurance of effective charging-discharging operations, and the equipment’s continued reliability are the secured outcomes of applying SUNON’s thermal solution.

Specification of the Fan Cooling Solution to Charging Stations (Stand-Alone)

Ingress Protection for Environmental Applications

SUNON constantly focuses on ESG practices. Firstly, we manage our business with the purpose of proactively developing energy-saving technologies and products, aiming to provide total thermal solutions and services to industries that are related to environmental sustainability. Besides, we are eager to go green internally, putting green supply chain management and smart manufacturing into practice, and we also build our workplaces with diversity, inclusion, and talent cultivation. Our staff is encouraged to participate in social events, such as advocating for environmental protection and caring for people with disadvantages. We are constantly taking actions to achieve our goal of long-term sustainability.

More Thermal Solutions for Automotive

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