- Conductor: 2.5 – 120 mm²
- Jacket: TPU · TPE
- Construction: Straight · coiled · liquid-cooled
- Standards: IEC 62196 · GB/T 20234
- Shielding: Shielded or unshielded
- Ingress rating: IP55 with fitted coupler
Key benefits
Cooling designed with the coupler
The thermal path runs continuously from contact to cable, so the derating curve is a property of the assembly rather than two independently rated parts.
Cold-flex behaviour specified
Jacket compounds are chosen for low-temperature flexibility, which is where cheap cables fail first in northern European and North American winters.
Shielding where the vehicle needs it
Shielded and unshielded constructions are both available, selected against the EMC concept of the platform rather than by default.
Description
The cable is the part of a charging system that takes the most physical abuse and is the most visible to the end user. Jacket material, bend radius and cold-flex behaviour matter more to real-world durability than the conductor rating does.
Liquid-cooled DC cables carry the coolant alongside the conductors, which is what allows 500 A through a cable an operator can lift. Cooling loop integration is designed together with the coupler so the thermal path is continuous.
Technical specifications
| Parameter | Value / Condition |
|---|---|
| Conductor cross-section | 2.5 mm² – 120 mm² |
| Jacket material | TPU or TPE |
| Construction | Straight, coiled, or liquid-cooled |
| Shielding | Shielded or unshielded |
| Rated voltage | Up to 1,000 V DC |
| Rated current | Up to 500 A liquid-cooled |
| Lengths | Standard 3 m / 5 m / 7 m, custom on request |
Configuration options
| Type | Cross-section | Max current | Cooling | Typical use |
|---|---|---|---|---|
| AC, straight | 2.5 – 6 mm² | 32 A | Natural | Portable AC |
| AC, coiled | 2.5 – 6 mm² | 32 A | Natural | On-board stowage |
| DC, natural | 25 – 70 mm² | 200 A | Natural | Public DC |
| DC, liquid-cooled | 35 – 120 mm² | 500 A | Liquid | High-power DC |
| Parameter | Value / Condition |
|---|---|
| Operating temperature | -30 °C to +50 °C (mobile), -40 °C to +85 °C (fixed) |
| Parameter | Value / Condition |
|---|---|
| Standards | IEC 62196 · GB/T 20234 |
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Applications
- Public charging
- Workplace charging
- Fleet depots
- Portable emergency chargers
- Wallbox
FAQ
TPU or TPE?
TPU has better abrasion and cut resistance; TPE is lighter and more flexible in the cold. For public duty we normally recommend TPU.
When is liquid cooling worth it?
Above roughly 300 A. Below that the weight and cost of the cooling loop is not justified by the conductor saving.
Downloads
Related resources
- How to select an on-board charger: a 7-step checklist for OEM and Tier-1 buyers
- 400 V vs 800 V architectures: what it changes for the on-board charger
- IEC 62196 compared: Type 2, CCS1, CCS2, GB/T, NACS and CHAdeMO