Brugg Cables to launch 850-amp liquid-cooled charging cable

Swiss cable maker Brugg Cables has announced a new high-performance charging cable, the Alligator-HPC, that can deliver DC electricity at 1,000 volts and up to 850 amps. The company plans to launch the cable in early 2020.

Today’s conventional cables typically max out at 550 amps, but thanks to an in-wire cooling system, the Alligator-HPC was able to manage currents of up to 1,000 amps under laboratory conditions at an ambient temperature of 40° C.

The cable’s core is a strand arrangement in which finely-layered hollow structures allow the flow of coolant. The water-based cooling fluid is non-toxic and largely biodegradable. Utilizing a newly-developed CCS2 connector, the coolant can be routed directly to the contacts. The cooling system allows cable lengths of up to 7 meters.

Brugg says that employing this active cooling in both the charging cable and at the contacts permits a massive reduction in charging time. The fast-charging capability opens up the opportunity to charge next-gen high-capacity EVs within 8 minutes or less. In comparison, conventional 125-amp fast-charging stations can take up to an hour to charge 80% of the same battery.

Brugg Cables Product Manager Albert Martinez said, “Thanks to the innovative cooling technology, our charging system delivers twice as much power as previous high-performance cables – with higher flexibility at extremely low weight. The Alligator-HPC is ready for the powerful new generation of e-vehicles.”

Source: Brugg Cables

  • Mack Knife

    And how much will these cost?

    • bobdvb

      There will be relatively little need for these connectors because domestically we don’t need high capacity chargers. In the USA 95% of trips are shorter than 30 miles, and 99% is below 70 miles. The weighted average trip distance is 9.4 miles. Vehicles owned by urban households averaged 8.5 miles and rural vehicles averaged 12.1 miles. So most users can charge at home with a regular charger or just go weekly to a supercharger.

      Those high capacity chargers are more suited to commercial vehicles or at fast charge stops as a replacement for petrol stations. But petrol stations will become more rare in future as most people slow charge at home.

      With relatively few of these stations they should get more maintenance, like a fuel pump pipe which this is akin to. Petrol stations are very polluting and need special environmental clean-up when they are refurbished or removed. Also fuel pumps drip a little regularly, look at the floor around them, it will be nice when that is no longer necessary.

      • jamcl3

        The target market might be trucks with 1 MWh batteries.