Smaller cables, same current carrying capacity: the RADOX® advantage

As the architectural foundation of every Electric Vehicle (EV), high voltage (HV) cables are expected to deliver critical electrical performance while withstanding the harshest of environments. Historically, this was achieved through the use of corrugated tubes which acted as the solution’s main mechanical protector, shielding materials from abrasion, chemicals, moisture, and demanding operating conditions. 

However, as Original Equipment Manufacturers (OEMs) push for lighter, more compact vehicle architectures, engineers are questioning whether these oversized, archaic tubes have run their course. In fact, advancements in cable materials now make it possible to achieve better mechanical performance without the compromises associated with corrugated tubing.

This has been demonstrated by HUBER+SUHNER across our flagship RADOX® HV cable range. Rather than relying on external corrugated tubing for protection, RADOX® cables integrate exceptional mechanical resistance directly into the cable construction. 

Using an electron-beam cross-linked insulation and jacket material, RADOX® cables offer outstanding resistance to abrasion, UV exposure, weathering, automotive fluids, and continuous high operating temperatures of up to 150°C. This allows the cable itself to provide the durability traditionally achieved through additional protective tubing. 

For example, a 95mm2 high voltage cable enclosed in protective tubing can carry the same current as a 70mm2 RADOX® cable installed in free air, meaning it can dissipate heat more effectively, resulting in lower stead-state temperatures. Current-carrying capacity is improved as a result, while simultaneously reducing electrical losses and slowing thermal ageing to ultimately deliver a longer cable service life. 

Free-air routing is key here, as it allows engineers to make better use of the cable’s inherent performance. Rather than compensating for trapped heat with larger conductors, designers can optimise cable sizing based on the application’s actual thermal conditions – even giving them the freedom to reduce cable dimensions with no concerns over reliability. 

As a leading automotive supplier, HUBER+SUHNER supports customers with adopting and implementing RADOX® cables into EV platforms. Thermal behaviour is tested and modelled by our engineering teams for real installation scenarios such as free air, conduits, bundling, and ambient profiles, fully validating the solution for any scenario. 

Our leading solutions like RADOX® are paving the way for a new era of lightweight, sustainable architectures for EVs, bringing greater vehicle efficiency and lower costs to manufacturers.