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Tesla’s liquid-cooled charging connector patent paves way for the Semi’s Megachargers

The Tesla Semi visits Yandell Truckaway. (Photo: Arash Malek)

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A recently published patent application from Tesla suggests that the electric car maker is continuing in its efforts to improve its already-stellar Supercharger Network. The design outlined in the document, which features a liquid-cooled charging connector, can potentially pave the way for a more ambitious charging infrastructure, perhaps one that can specifically cater to the all-electric Semi’s Megacharger Network. 

During the all-electric truck’s unveiling, CEO Elon Musk mentioned that the Semi will be able to replenish as much as 400 miles of range in as little as 30 minutes thanks to a network of Megachargers. Neither Musk nor Tesla provided the specs of the Megacharger during the vehicle’s unveiling, though speculations were high that network might provide a power output that is several times more powerful than the company’s Supercharger V2 Network, which had an output of around 120 kW then (Supercharger V2 stations have since been improved to 150 kW).

Being a large vehicle, the Semi requires a lot of power for its charging needs, involving the rapid transfer of mass amounts of electricity in a very short period of time without encountering any heating issues. This is a key concept outlined by Tesla in its recently published patent, titled “Liquid-Cooled Charging Connector,” which involves the use of a liquid cooling system on a charging connector itself. Tesla describes its concept in the discussion below. 

An illustration of Tesla’s liquid-cooled Supercharger design. (Credit: US Patent Office)

To transfer energy faster and decrease charging times, the cable and charging connector must be capable of withstanding high current loads. Current charging connectors are limited in the current loads that they can support as their ability to dissipate heat is limited. Thus, there is a need for a new charging connector to solve the aforementioned problems.

“The present disclosure related to a new charging connector. The charging connector has a first electrical socket and a second electrical socket. A first sleeve is concentrically coupled to the first electrical socket and a second sleeve is concentrically coupled to the second electrical socket. A manifold assembly encloses the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and manifold assembly create a hollow interior space there between. The manifold assembly has an inlet conduit and an outlet conduit such that inlet conduit, interior space, and outlet conduit together create a fluid flow path. 

“Cooling fluid flows through the fluid flow path and cools the charging connector. During operation, the cooling fluid bifurcates into a first fluid stream which flows around the first sleeve, and a second fluid stream which flows around the second sleeve. The first and second fluid streams combine upstream of the outlet conduit. The first sleeve encloses the first electrical socket, and the second sleeve encloses the second electrical socket. The cooling sleeves are made from a thermally conducting material such that heat generated by electrical sockets can be removed by the cooling fluid. In embodiments, this thermally conducting material is a thermally conductive plastic material.” 

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Tesla notes that its liquid-cooled supercharger connector does not only allow faster charging; it also makes the routing of wires in a charging connector much more efficient. This means that Tesla’s Supercharger connectors could eventually be smaller and more compact despite being capable of greater output. An example of this appears to be hinted at by Supercharger V3’s liquid-cooled cables, which are smaller and more compact than those used in Tesla’s V2 Network. 

An illustration of Tesla’s liquid-cooled Supercharger design. (Credit: US Patent Office)

“Cooling fluid absorbs thermal energy from heat in the electrical sockets 404, 406. Sleeves 410, 412 are made of a thermally conducting, electrically insulating material. Heat from the electrical sockets 404, 406 is transferred to cooling fluid through sleeves 410, 412. After flowing around hollow interior space 416, the first fluid stream 804 and the second fluid stream 806 combine together upstream of outlet conduit 514 and flow outside of manifold assembly 414 through outlet conduit 514. Cooling fluid flowing out of manifold assembly 414 through outlet conduit 514 may be received by a reservoir (not shown) which may provide for heat exchanging arrangements. A heat exchanger may be provided to take away heat absorbed by cooling fluid. After rejecting absorbed heat, the cooling fluid may be recirculated back to inlet conduit 512 for further cooling of charging connector 210.

“FIG. 9 shows another component included by charging connector 210. A Printed Circuit Board Assembly (PCBA) 902 is thermally coupled to charging connector 210. In embodiments, PCBA 902 is a two-part structure. A first part of PCBA 904 is coupled to charging connector 210 such that the first part of PCBA 904 sits on top of electrical sockets 404, 406. A second part of PCBA 908 is connected to the first part of PCBA 904 through a rigid-flex PCB construction, or other similar interconnects. The two-part structure of PCB A 902 allows for a more efficient routing of electrical wires of charging connector 210, and overall size of charging connector 210 may be conveniently reduced.”

Tesla’s Superchargers are among the fastest and most expansive electric vehicle charging infrastructures in the auto industry. In keeping with its spirit, the company has made it a point to never stop innovating, as exhibited by the company’s debut and ongoing ramp of its Supercharger V3 Network. This could ultimately pay off for Tesla, whose lead in the electric vehicle race might potentially increase even more. 

Such innovations appear to be required of the company, especially with the rollout of ambitious EVs such as the Semi, a vehicle with a different charging infrastructure compared to Tesla’s existing lineup of electric cars. That being said, Tesla nevertheless deserves credit for pushing the envelope and staying on top of its innovations. In the electric vehicle race, after all, a liquid-cooled charging connector could end up making the difference between the fast-charging capabilities of the Tesla Semi and rivals from Daimler and Nikola.

A link to the full text of Tesla’s liquid-cooled charger connector patent could be accessed here.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Cybertruck

Tesla Cybertruck is getting a big security upgrade

“Cybertruck was not 100% carryover in execution like S3XY, so it required work.”

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Credit: Tesla

Tesla confirmed today that a massive Cybertruck security feature is on the way soon, and it is one that owners have been asking about for a long time.

Like all Teslas, Cybertruck has the excellent security feature known as “Sentry Mode.” The feature essentially turns your Tesla into a moving security camera, recording any event that happens nearby.

It has been used to solve crimes such as vandalism and burglary, and even used by police departments to solve other, high-profile crimes.

Tesla quietly added this extra Sentry Mode feature to deter vandals

However, Cybertruck has been missing one key feature of Sentry Mode: the use of the B-Pillar camera has not been enabled, leaving one of the most vandalized and targeted vehicles in the United States with a weakness.

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One person who has been vocal about it is Tesla Cybertruck enthusiast Greggertruck, who has been pushing for answers for months. He finally got his answer from Cybertruck Vehicle Program Manager Siddhant Awasthi:

“It will come soon! Cybertruck was not 100% carryover in execution like SX3Y so it required work. Team has finished work on this and just need to make sure it’s validated and runs reliably (which it should for its feature).”

It sounds as if Tesla’s issue was something they similarly experienced when deploying Full Self-Driving to Cybertruck. The other four Tesla vehicles were able to use FSD because they’re all relatively similar in ride height and overall functionality. They share tons of similarities.

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Cybertruck did not get FSD right away because Tesla still had to work on the differences between it and the other cars in the lineup. As Awasthi said, “Cybertruck was not 100% carryover in execution like S3XY, so it required work.”

Tesla Cybertruck FSD release expected for Sept, Park Assist to come first

It sounds as if Tesla is close to resolving some of the more intricate details of adding the functionality, and it was just a matter of time before it figured out the issue.

The release of the B-Pillar camera being active during Sentry Mode events on Cybertruck will likely come in a software update in the coming weeks.

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Investor's Corner

Tesla investors may be in for a big surprise

All signs point toward a strong quarter for Tesla in terms of deliveries. Investors could be in for a surprise.

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(Credit: Tesla)

Tesla investors have plenty of things to be ecstatic about, considering the company’s confidence in autonomy, AI, robotics, cars, and energy. However, many of them may be in for a big surprise as the end of the $7,500 EV tax credit nears. On September 30, it will be gone for good.

This has put some skepticism in the minds of some investors: the lack of a $7,500 discount for buying a clean energy vehicle may deter many people from affording Tesla’s industry-leading EVs.

Tesla warns consumers of huge, time-sensitive change coming soon

The focus on quarterly deliveries, while potentially waning in terms of importance to the future, is still a big indicator of demand, at least as of now. Of course, there are other factors, most of them economic.

The big push to make the most of the final quarter of the EV tax credit is evident, as Tesla is reminding consumers on social media platforms and through email communications that the $7,500 discount will not be here forever. It will be gone sooner rather than later.

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It appears the push to maximize sales this quarter before having to assess how much they will be impacted by the tax credit’s removal is working.

Delivery Wait Time Increases

Wait times for Tesla vehicles are increasing due to what appears to be increased demand for the company’s vehicles. Recently, Model Y delivery wait times were increased from 1-3 weeks to 4-6 weeks.

This puts extra pressure on consumers to pull the trigger on an order, as delivery must be completed by the cutoff date of September 30.

Delivery wait times may have gone up due to an increase in demand as consumers push to make a purchase before losing that $7,500 discount.

More People are Ordering

A post on X by notable Tesla influencer Sawyer Merritt anecdotally shows he has been receiving more DMs than normal from people stating that they’re ordering vehicles before the end of the tax credit:

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It’s not necessarily a confirmation of more orders, but it could be an indication that things are certainly looking that way.

Why Investors Could Be Surprised

Tesla investors could see some positive movement in stock price following the release of the Q3 delivery report, especially if all signs point to increased demand this quarter.

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We reported previously that this could end up being a very strong rebounding quarter for Tesla, with so many people taking advantage of the tax credit.

Whether the delivery figures will be higher than normal remains to be seen. But all indications seem to point to Q3 being a very strong quarter for Tesla.

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Elon Musk

Tesla bear Guggenheim sees nearly 50% drop off in stock price in new note

Tesla bear Guggenheim does not see any upside in Robotaxi.

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tesla showroom
Credit: Tesla

Tesla bear Guggenheim is still among the biggest non-believers in the company’s overall mission and its devotion to solving self-driving.

In a new note to investors on Thursday, analyst Ronald Jewsikow reiterated his price target of $175, a nearly 50 percent drop off, with a ‘Sell’ rating, all based on skepticism regarding Tesla’s execution of the Robotaxi platform.

A few days ago, Tesla CEO Elon Musk said the company’s Robotaxi platform would open to the public in September, offering driverless rides to anyone in the Austin area within its geofence, which is roughly 90 square miles large.

Tesla CEO Elon Musk confirms Robotaxi is opening to the public: here’s when

However, Jewsikow’s skepticism regarding this timeline has to do with what’s going on inside of the vehicles. The analyst was willing to give props to Robotaxi, saying that Musk’s estimation of a September public launch would be a “key step” in offering the service to a broader population.

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Where Jewsikow’s real issue lies is with Tesla’s lack of transparency on the Safety Monitors, and how bulls are willing to overlook their importance.

Much of this bullish mentality comes from the fact that the Monitors are not sitting in the driver’s seat, and they don’t have anything to do with the overall operation of the vehicle.

Musk also said last month that reducing Safety Monitors could come “in a month or two.”

Instead, they’re just there to make sure everything runs smoothly.

Jewsikow said:

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“While safety drivers will remain, and no timeline has been provided for their removal, bulls have been willing to overlook the optics of safety drivers in TSLA vehicles, and we see no reason why that would change now.”

He also commented on Musk’s recent indication that Tesla was working on a 10x parameter count that could help make Full Self-Driving even more accurate. It could be one of the pieces to Tesla solving autonomy.

Jewsikow added:

“Perhaps most importantly for investors bullish on TSLA for the fleet of potential FSD-enabled vehicles today, the 10x higher parameter count will be able to run on the current generation of FSD hardware and inference compute.”

Elon Musk teases crazy new Tesla FSD model: here’s when it’s coming

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Tesla shares are down just about 2 percent today, trading at $332.47.

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