EFFICIENT THERMAL MANAGEMENT

Coroflex Active Cooled High Voltage Cables

Lightweight, flexible, and built for high-performance thermal control in demanding EV applications.

As electrical power and current levels continue to climb in modern electric vehicles, thermal management has become mission-critical. Coroflex actively cooled HV cables move heat away from the conductor in real time, keeping temperatures stable and performance consistent. Compared to uncooled cables, they are dramatically smaller and lighter, making them an ideal fit for tightly packaged EV architectures.

QUALITY FROM EXPERIENCE

Liquid-cooled HV cables built for a wide range of applications

From passenger cars and commercial vehicles to buses, construction equipment, and agricultural machinery, Coroflex active cooled HV cables deliver dependable power transmission even in confined spaces and under heavy electrical loads.

Backed by decades of series-production experience with major automotive OEMs, Coroflex active cooled cables can be up to 60% lighter and roughly a third smaller in diameter than conventional uncooled cable systems, saving material, energy, and cost while easing integration into complex vehicle architectures.

AT A GLANCE

Your benefits with our actively cooled High-voltage cables

Greater range and efficiency: Lower cable weight reduces energy consumption, helping deliver more range from the same battery capacity.

Shorter charging times: Active cooling keeps conductor temperatures in check, reducing thermally-induced charging limits regardless of ambient conditions.

More design freedom: Smaller diameters and high flexibility make it easier to route cables through compact vehicle architectures.

Configurable to your requirements: Shielded or unshielded, copper or aluminum, in cross-sections from 35 to 200 mm² for maximum design flexibility.

Cost efficient: Reduced conductor material lowers system costs without compromising performance.

Reliable and protected: Optimized thermal management extends component life; an optional Coroflex ProTect wrap adds extra protection in harsh environments.

REQUIREMENTS IN DETAIL

Complex challenges, concrete solutions

Thermal management as the key to efficiency

As electrical power increases, so does the complexity of balancing current, temperature, and available space. Coroflex active cooled HV cables reliably carry high continuous currents in tight quarters, across a wide range of ambient conditions, and near sensitive electronics, all while maintaining the thermal stability and mechanical robustness that overall system efficiency depends on.

Cooling circuit and temperature resistance

A water-glycol coolant circulates continuously through the cable under pressure, carrying heat away and holding operating temperatures steady even at high current densities or in confined installations. The cables remain pressure- and vibration-resistant and compatible with common cooling media across an ambient range of -40°C to +85°C.

Material selection and design flexibility

Choosing copper or aluminum conductors allows an optimal balance of conductivity, weight, and cost, while shielded and unshielded variants address a wide range of EMC requirements. A modular design and cross-sections from 35 to 200 mm² let the cable be tailored precisely to each vehicle platform, from passenger cars and commercial trucks to marine applications and heavy construction equipment.

Practical advantages of active cooling

Active cooling allows a significant reduction in conductor cross-section. For example, a 35 mm² cooled cable can deliver performance comparable to a 170 mm² uncooled cable. That translates into lower weight, less material use, and room for more compact vehicle designs. For particularly demanding environments, the optional Coroflex ProTect wrapping system adds an extra layer of factory-applied protection, delivered ready to install directly from the spool.

Learn More About Coroflex Active Cooled Cables Today!