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Tesla’s liquid-cooled charging connector patent paves way for the Semi’s Megachargers
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.
“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.”
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.
“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.
A plant manager at a Tesla factory just tipped off the fact that the company will begin production of an affordable model in the coming weeks, all but confirming that a new car will be unveiled tomorrow.
Tesla has been teasing some kind of product unveiling for October 7 on its social media accounts. It has now dropped two separate indications that a new product is coming on its X account.
Fans have been anticipating two things: either the company’s planned affordable model, which has been codenamed “E41,” or the Roadster, a long-awaited vehicle that Tesla has kept under wraps for much longer than it would likely care to admit.
Tesla all but confirms that affordable Model Y is coming Tuesday
André Thierig, Tesla’s plant manager at the German production plant Gigafactory Berlin, tipped off what is likely coming tomorrow at the product unveiling as he revealed during an internal event today that a light version of the Model Y will begin series production and deliveries “in a few weeks.”
Thierig’s revealing of plans was reported by Handelsblatt, a German media outlet.
The description of a “light version of the Model Y” aligns with what CEO Elon Musk said earlier this year, as well as what we have seen on public roads, both covered and uncovered.
Last week, we finally saw an uncovered version of what the affordable model likely is, as it was cruising around near Gigafactory Texas, just outside of Austin.
Tesla coding shows affordable model details, including potential price
Musk said earlier this year, candidly during an Earnings Call, that the affordable model Tesla planned to release was a Model Y.
“It’s just a Model Y. Let the cat out of the bag there,” Musk said.
The images of what we assumed to be the affordable model lined up with Musk’s candid statement:
🚨 It looks like the new affordable Tesla Model Y was spotted near Giga Texas
Model Y body with the Model 3 fascia, no glass roof, and looks as if there is a front bumper camera!
Should be coming soon! https://t.co/UAXQMHjM23 pic.twitter.com/9lC5te9GnW
— TESLARATI (@Teslarati) October 3, 2025
Tesla is expected to unveil its affordable model tomorrow during the planned event, which has been teased twice. Pricing and other details are still pending, but the company is expected to reveal this information tomorrow.
News
Three things Tesla needs to improve with Full Self-Driving v14 release
These are the three things I’d like to see Tesla Full Self-Driving v14 improve.
As Tesla plans to release Full Self-Driving version 14 this week after CEO Elon Musk detailed a short delay in its rollout, there are several things that continue to plague what are extremely well-done drives by the suite.
Tesla Full Self-Driving has truly revolutionized the way I travel, and I use it for the majority of my driving. However, it does a few things really poorly, and these issues are consistent across many drives, not just one.
Tesla Full Self-Driving impressions after three weeks of ownership
Musk has called FSD v14 “sentient” and hinted that it would demonstrate drastic improvements from v13. The current version is very good, and it commonly performs some of the more difficult driving tasks well. I have found that it does simple, yet crucial things, somewhat poorly.
These are the three things I’d like to see Tesla Full Self-Driving v14 improve.
Navigation, Routing, and Logical Departure
My biggest complaint is how poorly the navigation system chooses its route of departure. I’ve noticed this specifically from where I Supercharge. The car routinely takes the most illogical route to leave the Supercharger, a path that would require an illegal U-turn to get on the correct route.
I managed to capture this yesterday when leaving the Supercharger to go on a lengthy ride using Full Self-Driving:
You’ll see I overrode the attempt to turn right out of the lot by pushing the turn signal to turn left instead. If you go right, you’ll go around the entire convenience store and end up approaching a traffic light with a “No U-Turn” sign. The car has tried to initiate a U-turn at this light before.
If you’re attempting to get on the highway, you simply have to leave the convenience store on a different route (the one I made the vehicle go in).
It then attempted to enter the right lane when the car needed to remain in the left lane to turn left and access the highway. I manually took over and then reactivated Full Self-Driving when it was in the correct lane.
To achieve Unsupervised Full Self-Driving, such as navigating out of a parking lot and taking the logical route, while also avoiding illegal maneuvers, is incredibly crucial.
Too Much Time in the Left Lane on the Highway
It is illegal to cruise in the left lane on highways in all 50 U.S. states, although certain states enforce it more than others. Colorado, for example, has a law that makes it illegal to drive in the left lane on highways with a speed limit of 65 MPH or greater unless you are passing.
In Florida, it is generally prohibited to use the left lane unless you are passing a slower vehicle.
In Pennsylvania, where I live, cruising in the left lane is illegal on limited-access highways with two or more lanes. Left lanes are designed for passing, while right lanes are intended for cruising.
Full Self-Driving, especially on the “Hurry” drive mode, which drives most realistically, cruises in the left lane, making it in violation of these cruising laws. There are many instances when it has a drastic amount of space between cars in the right lane, and it simply chooses to stay in the left lane:
The clip above is nearly 12 minutes in length without being sped up. In real-time, it had plenty of opportunities to get over and cruise in the left lane. It did not do this until the end of the video.
Tesla should implement a “Preferred Highway Cruising Lane” option for two and three-lane highways, allowing drivers to choose the lane that FSD cruises in.
It also tends to pass vehicles in the slow lane at a speed that is only a mile an hour or two higher than that other car.
This holds up traffic in the left lane; if it is going to overtake a vehicle in the right lane, it needs to do it faster and with more assertiveness. It should not take more than 5-10 seconds to pass a car. Anything longer is disrupting the flow of highway traffic.
Parking
Full Self-Driving does a great job of getting you to your destination, but parking automatically once you’re there has been a pain point.
As I was arriving at my destination, it pulled in directly on top of the line separating two parking spots. It does this frequently when I arrive at my house as well.
Here’s what it looked like yesterday:
Parking is one of the easier tasks Full Self-Driving performs, and Autopark does extremely well when the driver manually chooses the spot. I use Autopark on an almost daily basis.
However, if I do not assist the vehicle in choosing a spot, its performance pulling into spaces is pretty lackluster.
With a lot of hype surrounding v14, Tesla has built up considerable anticipation among owners who want to see FSD perform the easy tasks well. As of now, I believe it does the harder things better than the easy things.
Elon Musk
Elon Musk teases previously unknown Tesla Optimus capability
Elon Musk revealed over the weekend that the humanoid robot should be able to utilize Tesla’s dataset for Full Self-Driving (FSD) to operate cars not manufactured by Tesla.
Elon Musk revealed a new capability that Tesla Optimus should have, and it is one that will surely surprise many people, as it falls outside the CEO’s scope of his several companies.
Tesla Optimus is likely going to be the biggest product the company ever develops, and Musk has even predicted that it could make up about 80 percent of the company’s value in the coming years.
Teasing the potential to eliminate any trivial and monotonous tasks from human life, Optimus surely has its appeal.
However, Musk revealed over the weekend that the humanoid robot should be able to utilize Tesla’s dataset for Full Self-Driving (FSD) to operate cars not manufactured by Tesla:
Probably
— Elon Musk (@elonmusk) October 5, 2025
FSD would essentially translate from operation in Tesla vehicles from a driverless perspective to Optimus, allowing FSD to basically be present in any vehicle ever made. Optimus could be similar to a personal chauffeur, as well as an assistant.
Optimus has significant hype behind it, as Tesla has been meticulously refining its capabilities. Along with Musk’s and other executives’ comments about its potential, it’s clear that there is genuine excitement internally.
This past weekend, the company continued to stoke hype behind Optimus by showing a new video of the humanoid robot learning Kung Fu and training with a teacher:
🚨 Some have wondered if this is ‘staged’ or if Optimus is teleoperated here
Elon Musk said this is completely AI https://t.co/N69uDD6OVM
— TESLARATI (@Teslarati) October 4, 2025
Tesla plans to launch its Gen 3 version of Optimus in the coming months, and although we saw a new-look robot just last month, thanks to a video from Salesforce CEO and Musk’s friend Marc Benioff, we have been told that this was not a look at the company’s new iteration.
Instead, Gen 3’s true design remains a mystery for the general public, but with the improvements between the first two iterations already displayed, we are sure the newest version will be something special.
Tesla plant manager tips off affordable model production
Three things Tesla needs to improve with Full Self-Driving v14 release
Elon Musk teases previously unknown Tesla Optimus capability
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