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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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Miami Beach Mayor considering Elon Musk’s Boring Company tunnels

Miami Beach faces unique constraints, including chronic flooding, porous limestone foundations, and its low elevation near sea level.

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(Credit: The Boring Company

Miami Beach Mayor Steven Meiner has asked city commissioners to consider whether underground transit tunnels could be a feasible solution to the city’s worsening traffic. 

The proposal reflects growing interest in exploring unconventional transit options, especially after city leaders rejected plans to extend the downtown Miami Metromover to South Beach.

New transit alternatives

In a memo, Meiner noted that his request is not tied to a single project but is intended to open a broader discussion on engineering challenges, environmental impacts, potential funding, and integration with existing transit systems. Miami Beach faces unique constraints, including chronic flooding, porous limestone foundations, and its low elevation near sea level, according to Axios.

The tunnel idea is not entirely new. In 2022, Meiner suggested reaching out to Elon Musk’s The Boring Company to discuss potential projects, citing the firm’s work on the Vegas Loop in Las Vegas. At the time, the city passed a resolution to study tunnels further, though it remains unclear whether any formal discussions with the tunneling startup actually took place.

Previous proposals

The Boring Company has shown interest in South Florida before. In 2021 and 2022, it submitted plans for Tesla-powered tunnel systems in Fort Lauderdale and North Miami Beach. While the Fort Lauderdale project was later suspended, reports suggest the North Miami Beach proposal remained active into 2023. Musk also met with Miami Mayor Francis Suarez in 2021 to discuss tunnel systems, though no progress has been reported since.

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The Boring Company has garnered some experience with consumer tunnels over the years, thanks in no small part to the Las Vegas Convention Center and Vegas Loops, which use Tesla vehicles. The greater Vegas Loop is still being expanded today, and efforts are underway to transition the Teslas being used in the tunnels to use Unsupervised FSD.

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Tesla owners are celebrating Model Y L first deliveries

The timing of the Model Y L’s release aligns with growing demand for Tesla vehicles in China.

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Credit: @LuisZhu/X

Tesla customers in China seem to be loving the Model Y L. This was hinted at in posts from the electric vehicle maker on Chinese social media platform Weibo.

The Model Y L is Tesla’s entry into China’s competitive six-seat crossover SUV segment, which has previously been out of reach for the standard Model Y.

Model Y L delivery celebrations

Tesla Model Y L owners in China have been sharing enthusiastic reviews following the delivery of their vehicles. Many cited the SUV’s safety, practicality, and family-friendly design as key reasons for choosing the vehicle. Several noted that they placed orders for the vehicle without seeing the Model Y L in person, while others highlighted that they “only trust Tesla for its safety and technology.”

“For our two kids and two grandparents, the six-seater Model Y L is perfect for our family of six. Because we trust Tesla’s safety and intelligent features, we placed a blind order to be among the first owners to take delivery!” one Model Y L owner stated, as translated by Tesla watcher @tslaming.

Owners praised the six-seater’s handling, spaciousness, and advanced features, with one calling it “perfect” compared to competitors. Families highlighted the Model Y L’s suitability for accommodating children and grandparents, while others described upgrading from previous Teslas as a natural choice. Some even made long trips to pick up their vehicles, eager to take road trips across China in the new model.

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“This is my second Tesla, and I specially took the high-speed train to pick it up! The first thing I’ll do with my new car is take my family and dog on a road trip to Xinjiang, and travel all over China with the Model Y L,” another Model Y L customer wrote. 

Tesla Model Y specs

Unveiled on August 19, the Model Y L joins Tesla’s existing five-seat variants in China, offering a larger footprint and additional seating. Priced from RMB 339,000 ($47,460), the vehicle is positioned above the RWD and long-range AWD five-seat versions. The Model Y L is longer than the standard Model Y, with a wheelbase extended to 3,040 mm.

The timing of the Model Y L’s release aligns with growing demand for Tesla vehicles in China. Recent insurance registration data showed 12,500 Tesla units recorded last week, a 21% increase from the previous week’s 10,300 units. Analysts expect the addition of the six-seat SUV to broaden Tesla’s appeal to families seeking larger electric options, further boosting sales momentum this third quarter.

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Tesla deploys Unsupervised FSD in Europe for the first time—with a twist

Europe has so far been elusive for Tesla’s FSD rollout.

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Credit: Tesla AI/X

Tesla has officially started using Unsupervised FSD in Europe, at least, within the Giga Berlin complex.

Ready for rollout

As per a video from the Tesla AI team, Model Y units that are produced at Giga Berlin now autonomously transport themselves from the end of the production line to their designated holding areas. The video demonstration, which was posted on X, followed a Model Y unit that parked itself autonomously at a charging station, and another that headed straight to Giga Berlin’s outbound area.

Giga Berlin plant manager André Thierig shared his insights on the video, stating that “Every Tesla we built has the ability to drive autonomously and we use this feature 100% for outbound operations, starting from the light tunnel until the car arrives at the outbound yard! Really impressive!” He also stated that he “cannot wait to see this on European roads outside the factory.”

Unsupervised FSD in Europe

Europe has so far been elusive for Tesla’s FSD rollout. While FSD Supervised has been rolled out to consumers in the United States, and to some degree, in China, only tests have so far been implemented in Europe. This has resulted in numerous Tesla owners getting their patience tested, especially those who have purchased FSD in vehicles that are now several years old.

Tesla, for its part, has been demonstrating Unsupervised FSD operating on public European roads across several countries, such as France and Germany. So far, however, the wait is still on for Europe to allow FSD, both Supervised and Unsupervised, to be operated by regular consumers on public roads.

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