Characteristics and material selection requirements of new energy cables

Author: EVCOME-EV Chargers Manufacturers

New energy cables are the abbreviation for wires and cables used in new energy vehicles, which are divided into two types: vehicle-mounted (internal) and non-charging (charging). With the development of new energy vehicles, cables for the transmission of electric energy will also usher in explosive growth. By 2020, China plans to add more than 12,000 centralized charging and replacement stations and more than 4.8 million decentralized charging piles. At the same time, the government will also increase subsidies for charging infrastructure. There are some differences between the new car cables and ordinary car cables: 1. The use environment has changed 1. High voltage and high current (vehicle) can reach 600/300A, while the battery voltage of traditional fuel vehicles is usually 12V, corresponding The wire withstand voltage rating is less than 60V. 2. High wire diameter and large number of cables (vehicle) high-voltage battery inverter transformer / low-voltage battery / air-conditioning compressor / electric heating / power distribution device…Many power-consuming structures are connected by cables, and a large number of cables are discharged in a limited space. 3. The cable in the exposed space (non-vehicle) charging gun is exposed for a long time, and its weather resistance, abrasion resistance, bending resistance, and tear resistance are strictly required. 2. Due to the characteristics of large voltage/high current and large number of large-diameter wires, the design of the high-voltage wiring harness in the car faces challenges such as wiring, safety, shielding, weight and cost. New energy cable material selection and requirements Because of the high voltage and high current in the new energy vehicle and the limited space, the charging pile cables are exposed outdoors for a long time, and the particularity of the use environment puts forward very strict requirements on the performance of the cable materials. Cables for new energy vehicles need to have high and low temperature resistance, oil and water resistance, flame retardancy, tear resistance, insulation, and UV aging resistance. Commonly used materials are TPE, TPU, XLPO, NBR+PVC, neoprene, silicone rubber, etc. 1. TPU used in charging pile cable polyurethane sheath material advantages: flexibility, rolling resistance, voltage resistance, high temperature pressure resistance, aging resistance, acid and alkali resistance, salt spray resistance, waterproof. It has excellent high tension, high tensile strength, toughness and aging resistance, and the material is environmentally friendly. Disadvantages: At present, domestic processing is difficult and the cost is high. Working temperature: cold resistance -40 degrees; temperature resistance within 150 degrees. 2. TPE is currently mainly used to refer to the elastomer with SEBS as the substrate, which is used for charging gun cables. Advantages: simple processing technology, low density, moderate price, the overall cable is very soft, and can meet the requirements of existing standards. Disadvantages: most of them contain unsaturated bonds, poor temperature stability; low oil resistance, especially gasoline; poor weather resistance. 3. Working temperature: cold resistance -50 degrees; temperature resistance within 120 degrees. 3. Polyvinyl chloride elastomer Advantages: flame retardant and insulation, acid resistance, oil resistance, easy processing and modification, and cheap. Disadvantages: There will be black smoke and HCl gas when burning. Working temperature: cold resistance -40 degrees; temperature resistance within 105 degrees. 4. Silicone rubber Advantages: heat-resistant, cold-resistant, weather-resistant, waterproof, soft, and easy to install. Disadvantages: not oil resistant, poor tear resistance, more expensive. Working temperature: cold resistance -40 degrees; temperature resistance within 200 degrees. 5. XLPE advantages: strong cross-linking ability, good elasticity, good insulation, light structure, easy installation and low cost. Disadvantages: poor heat resistance, difficult to control the color difference between batches. Working temperature: cold resistance -50 degrees; temperature resistance within 100 degrees. .


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