Coroplast cable is high-performance electrical wiring, designed for demanding environments and often used with electrical vehicles. These cables are engineered with precision to handle electrical energy transmission in vehicles, ensuring safety, efficiency, and reliability.
These cables have evolved a lot over the years. Initially developed for industrial and automotive use, their design keeps improving and progressing to keep up with advancements in electric mobility, continually adapting to the rising demands for higher voltages, improved flexibility, and robust insulation systems.
Today, Coroplast cables are indispensable in modern EV architectures. Their ability to withstand extreme temperatures, resist electromagnetic interference, and endure continuous mechanical stress makes them ideal for various electrical applications in EVs and beyond.
Material Composition and Construction
The core of Coroplast typically comprises high-conductivity materials like copper or aluminium alloys; Copper offers excellent electrical performance, while aluminium alloys provide a lighter alternative for weight-sensitive applications.
Insulation materials include cross-linked polyethylene (XLPE), thermoplastic elastomers (TPE), and silicone rubber. These materials are chosen for their thermal stability, chemical resistance, and flexibility.
To ensure electromagnetic compatibility (EMC), many Coroplast cables incorporate a screening braid made from tinned copper wires and/or aluminium-polyester tapes. This shielding effectively minimises electromagnetic interference.
The cable strands are often constructed using fine-wired, multi-strand techniques, which enhance flexibility and reduce the minimum bending radius.
Manufacturing Process
Coroplast cables are produced through precision-controlled extrusion and lamination processes. These methods ensure uniform insulation thickness and concentricity.
Throughout production, rigorous quality control checks are performed, including high- voltage testing, dimensional inspections, and conductor resistance tests.
The cables conform to various industry standards such as ISO 6722, LV 216, and SAE J1127/8, ensuring their compatibility and safety in automotive systems.
Technical Specifications
Coroplast cables are available in a range of conductor cross-sections, catering to diverse current-carrying requirements. Their diameters vary according to insulation and shielding needs, allowing customisation for space-restricted environments.
They are designed with high flexibility ratings, enabling tight bends with a small radius without compromising performance.
Temperature resistance can range from -40°C to +200°C, depending on insulation and sheath materials.
Voltage ratings typically range from 60V for low-voltage applications to 600V or more for high-voltage systems. Current capacity is determined by conductor size and installation conditions.
Applications and Use Cases
Automotive Applications
Coroplast cables are a cornerstone of electric vehicle design, used in high-voltage (HV) connector assemblies for powertrains, transmitting power between the battery and motor systems. In regenerative braking systems, they facilitate energy recovery by efficiently carrying electrical signals and power.
Battery management systems (BMS) rely on these cables for accurate voltage sensing, current transmission, and thermal monitoring.
They’re also compatible with a range of existing EV charging infrastructures, including AC and DC fast charging systems, making Coroplast the cabling of choice for car charging.
Industrial Applications
In industrial settings, Coroplast cables support the operation of heavy machinery, providing reliable electrical connections under harsh conditions. They are increasingly found in renewable energy setups, such as wind turbines and solar farms, where durability and resistance to UV and moisture are crucial.
Factory automation systems use these cables for interconnecting sensors, actuators, and control units. Their modularity and customisation options make them ideal for complex component interconnection needs.
Specialised Applications
Coroplast cables are built with heat-resistant insulation materials so they’re ideal for high-temperature zones like engine compartments.
In environments with exposure to moisture, oils, or chemicals, specialised jacketing ensures longevity and safe operation, and they’re also suited for outdoor and underground installations, where weatherproofing and mechanical robustness are essential.
Where space is tight, Coroplast's thin-wall designs offer excellent performance in compact formats.
Performance Advantages
Electrical Performance
Coroplast cables are engineered for high conductivity, ensuring minimal energy loss.
Their low voltage drop characteristics maintain stable power delivery over long distances and advanced shielding provides excellent EMC protection, minimising interference with sensitive electronics.
They maintain signal integrity even in high-noise environments, ensuring accurate data and control signal transmission.
Mechanical Advantages
Compared to traditional wiring, Coroplast cables offer significant weight reductions, aiding overall vehicle efficiency and, as noted earlier, their compact dimensions and flexibility make installation easier in difficult spaces.
But this flexibility also enables easier routing during assembly, reducing labour time and cost.
Designed for extended service life, these cables resist abrasion, vibration, and mechanical fatigue.
Environmental Benefits
Coroplast cables operate reliably across a broad temperature range, making them suitable for use all over the world.
They are built to resist UV radiation and harsh weather conditions for outdoor use and chemical-resistant sheathing ensures durability in corrosive environments.
In their manufacturing, recyclable materials are integrated and Coroplast incorporate sustainable practices into their processes.
Technological and Industry Advancements
As we speak there is ongoing research and development into how Coroplast can become lighter and use more conductive materials and compact cable structures.
New formulations enhance insulation performance and thermal tolerance and smart cables can now be manufactured with embedded sensors for monitoring. Although this is still in its early days, cables are increasingly integrated into digital vehicle architectures, supporting diagnostics and data communication.
There is ongoing global standardisation, simplifying integration and certification and new regulations are pushing for low-emission and recyclable cable components.
Hilltop: Your Quality Coroplast Supplier
For further information, check out our video guide to Coroplast or contact our sales support team. We’re here to help you power your EV applications safely and sustainably.
