60kW liquid-cooled power module connection system: A highly reliable and highly efficient next-generation fast-charging core supporting solution

With the number of new energy vehicles exceeding 10 million and the 800V high-voltage platform accelerating its popularization, public fast-charging infrastructure is moving from "usable" to "user-friendly" and "long-lasting". In this process, the 60kW liquid-cooled charging module has become the mainstream power unit for DC fast chargers, split-type charging piles, and energy storage linkage systems due to its high power density, stable temperature control, and strong adaptability.

However, the key to the long-term reliable operation of the entire system often does not lie in the main power components themselves, but in those high-reliability connectors that silently support high current and signal transmission, as well as their accessories. A well-designed connection solution can not only ensure a system efficiency of over 96%, but also significantly improve the service life of equipment in harsh environments such as high temperature, high humidity, and strong vibration.

This article will, from an engineering practice perspective, disassemble a complete connection solution for a 60kW DC/DC liquid-cooled module - a series of high-performance components provided by a leading connector manufacturer in China, and explain how it, with a contact resistance of milliohms, over 200 times of plug-in and pull-out life, and military-grade environmental adaptability, provides the underlying support for various high-power energy scenarios.

I. Core Challenges of the Connection System for 60kW Liquid-Cooled Modules

The current mainstream 60kW liquid-cooled power modules generally have the following technical characteristics:

Wide input voltage range: usually supports 300V–1000V DC (some compatible with AC rectification input)

High output current capacity: up to 115A at 1000V output, even under rated 60kW conditions, it needs to bear continuous high current

Strict deployment environment: outdoor installation, relative humidity ≥ 90%, salt fog corrosion, mechanical vibration (acceleration up to 147m/s²)

High energy efficiency requirements: the overall efficiency is often nominally ≥ 96%, and the connection loss is extremely sensitive

Under this background, traditional connectors are prone to become the "weak link" of system reliability due to issues such as increased contact resistance, overheating, plug-in and pull-out failure, or poor sealing. And a set of connectors specifically optimized for liquid-cooled modules is the key to breaking through this problem.

II. Core Components Details: Full Chain High-Reliability Design

Socket end:

Model: MPC60-14G12ZKY-2 (Part Number: 50-913-50111)

Model: MPC60-4ZKY-2 (Part Number: 50-913-50050)

Plug end:

Model: MPC60-14G12TJW-2 (Part Number: 50-903-50032)

Model: MPC60-4TJW-2 (Part Number: 50-903-50031)

Key performance highlights:

Power terminals Rated current 115A, initial contact resistance ≤ 0.5mΩ, effectively suppressing Joule heat;

Voltage withstand capability 3000V AC/DC, insulation resistance ≥ 5000MΩ, meeting high-voltage safety isolation standards;

Operating temperature range -55℃ ～ +125℃, passing 48-hour neutral salt spray test (NSS);

Mechanical plug-in and pull-out life ≥ 200 times, suitable for modular maintenance or frequent replacement scenarios;

Insulation housing uses PA66 (UL94 V-0 flame retardant grade), V2.0 version optimizes the structure between terminals, improving creepage distance and anti-fouling ability.

Note: 14-core version integrates signal channels (3A/24V), supports CAN communication, status feedback, etc.; 4-core version is dedicated to large current input/output bus connection.

2. φ6 Plug-in Component: Crown spring structure ensures dynamic contact reliability

Model: 8.571.50083 (Part Number: 60-571-50083) This component adopts a high elasticity crown spring contact structure (Crown Spring Contact), which is the core for achieving low impedance and long lifespan:

The separation force of the socket is controlled within 8N to 20N, balancing the stability of insertion and the operation feel;

It supports 25mm² / 3AWG / 4AWG large cross-section cable crimping, with tensile strength ≥ 1350N;

The contact material is gold-plated copper or beryllium copper alloy, with excellent conductivity and oxidation resistance;

It also passes the 48-hour salt spray test, suitable for high-corrosion environments such as coastal areas and industrial zones.

This component is widely used in key nodes such as internal busbars of modules and external cable termination, ensuring the stability and reliability of the "last one centimeter" electrical path.

3. M4 fixing screw: A tiny component with a crucial role

Model: 8.222.1034 (Part Number: 80-222-01034)

This seemingly ordinary M4×0.7 screw actually relates to the overall structural safety:

Material: Carbon steel base + zinc-nickel alloy coating, balancing mechanical strength and corrosion resistance;

Recommended locking torque 1.5 N·m, minimum destructive torque 3 N·m, avoiding over-tightening that causes the plastic shell to crack;

Operating temperature range is consistent with the module (-55℃ to +125℃);

Complies with RoHS and REACH environmental directives.

In high-frequency vibration scenarios (such as highway service areas, charging stations, port charging piles), a reliable fastening solution can effectively prevent connectors from loosening, shifting, or even falling off.

III. Typical application scenarios: From fast charging to energy storage, comprehensive coverage

This connection solution has been successfully applied to various cutting-edge energy infrastructure:

Integrated/Flexible DC fast charging piles: As the standard interface for a 60kW liquid-cooled module, supporting multi-module parallel expansion to 360kW or even higher;

Battery replacement station charging system: High insertion and removal life, matching over 100 daily battery pack charge and discharge cycles;

Industrial energy storage (BESS) linkage charging: In peak-valley arbitrage, emergency backup power supply, etc., achieving energy coordination scheduling between the power grid, energy storage, and electric vehicles;

Photovoltaic storage charging integrated microgrid: Seamless connection of photovoltaic inverters, energy storage battery clusters, and charging terminals, building a local zero-carbon energy closed loop.

These scenarios collectively point to a trend: High-power, high-density, and highly reliable modular design, has become the core competitiveness of the next generation charging and energy storage equipment - and all of this is based on the high-reliability connection accessories described in this article.

IV. Conclusion: Efficiency begins with reliable connection

In the era of "charging 200 kilometers in 5 minutes", we should not overlook those "invisible heroes" hidden behind the power modules. A fully verified connection system not only can enhance the MTBF (Mean Time Between Failures) of the entire device, but also can reduce the full life cycle operation costs and enhance the trust of end users in the charging network.

If you are developing or purchasing 60kW liquid-cooled charging modules, DC/DC converters, energy storage PCS or related systems, it is recommended to focus on such connection accessory solutions that have been verified through batch application. True efficiency is not the victory of a single component, but the coordinated reliability of every link in the system.