Huber+Suhner RADOX Cables Aim to Cut EV Weight and Improve Thermal Management
Testing shows a 70mm2 RADOX cable can replace a 95mm2 corrugated tube cable while reducing weight by 25% to 30%.
HUBER+SUHNER is promoting its RADOX® high-voltage cable technology as a solution for next-generation electric vehicle architectures, targeting weight reduction and improved thermal management by eliminating the need for traditional corrugated tubing.
What Happened
The company’s RADOX® technology, which utilizes electron-beam radiation crosslinking of thermoplastic polymers, creates cables that serve as their own mechanical shields. According to the source, this design allows the cables to operate at continuous temperatures up to 150°C and be routed in free air rather than tight bundles. This approach contrasts with traditional setups that rely on corrugated tubes to protect high-voltage cables from environmental hazards. HUBER+SUHNER states that the RADOX® cables possess better abrasion and cut resistance and greater flexibility compared to conventional alternatives, even with thinner insulation.
Why It Matters
For EV manufacturers, the shift away from corrugated tubes addresses critical bottlenecks in vehicle design. The source notes that corrugated tubes trap heat and reduce airflow, which increases electrical resistance and forces engineers to derate cables to maintain safety. This thermal buildup can significantly reduce insulation lifetime, with the Arrhenius rule suggesting that every 10°C increase in operating temperature can cut insulation life by 50%. By enabling free-air installation, RADOX® cables maintain a derating factor near 1.0. Testing cited by HUBER+SUHNER indicates that a 70mm2 RADOX® cable can replace a 95mm2 cable enclosed in a corrugated tube while carrying the same 500 A current load, resulting in a weight reduction of 25% to 30%. This weight savings contributes to the industry’s goal of maximizing driving range and enabling faster charging through better thermal control.
The Bottom Line
HUBER+SUHNER’s RADOX® technology offers a method to downsize EV high-voltage architectures by removing corrugated tubing, thereby reducing vehicle weight and improving heat dissipation. The source presents this as a proven approach already demonstrated in other sectors like rail and offshore energy, now being applied to meet OEM demands for lighter, more efficient electric vehicles.
