In an automotive wire/cable harness system, cables used in different areas have very different requirements. Working voltage, temperature, wire size, and mechanical conditions all vary by location.
For this reason, there is no “one-size-fits-all” material for automotive cables. Material selection is based on application location, wire size, and temperature rating.
Cross-linked polyethylene and related materials are widely used because they meet these specific and well-defined requirements in automotive wire harness systems.
Typical applications include cables from the battery to the inverter, from the inverter to the drive motor, and high-voltage power distribution cables.
Typical working voltage: 600V/800V/1000V DC
Common conductor cross-section areas: 10mm²/16mm²/ 25mm²/ 35mm²/ 50mm²/ 70mm²
Common insulation and sheath materials: 125℃/ 150℃ XLPE or XLPO for insulation, Low-smoke halogen-free cross-linked polyolefin (LSZH-XLPO) for the outer sheath, 180℃/200℃ vapor-phase silicone rubber materials for high-temperature designs.
High-voltage cables in new energy vehicles are exposed to high current, continuous heat buildup, and strong electromagnetic fields.
Cross-linked materials greatly reduce the risk of thermal deformation. They help maintain insulation performance and lower the risk of long-term cable failure.
Typical applications include dashboard wiring, door harnesses, roof and seat harnesses, control signals, and low-power circuits.
Typical working voltage: 12V/24V.
Common conductor cross-section areas: 0.13 mm²/ 0.22 mm²/ 0.35 mm²/ 0.5 mm²/ 0.75 mm²，Equivalent to AWG 26–18。
Common materials: 105℃/125℃ XLPE , meeting ISO 6722 Class B / Class C。
Interior vehicle areas have relatively stable temperatures, but wiring is dense and bending is frequent.
Electron-beam cross-linked polyethylene maintains good mechanical strength, stable insulation thickness, and strong resistance to stress cracking, even in thin-wall designs.
For this reason, it has become the main material for low-voltage automotive wire harnesses.
Typical applications include engine control units (ECU), sensor and actuator connections, starting systems, and charging systems.
Common wire size range: 0.5mm²–6.0mm²，Mainly AWG 20–10。
Common materials: 125℃XLPE，125℃XLPO，150℃XLPO materials for premium models or high-temperature zones。
The engine compartment is exposed to long-term high temperatures, oil mist, fuel contact, and strong vibration.
The three-dimensional network structure of cross-linked polyethylene prevents softening at high temperatures. It also improves oil resistance and aging resistance, helping the cable maintain stable dimensions.
Typical applications include CAN, LIN, FlexRay networks, camera and radar wiring, and in-vehicle communication systems.
Common wire size range: 0.13 mm²–0.35 mm², Usually twisted pair or shielded structures。
Common materials: 105℃/ 125℃ thin-wall XLPE，125℃ TPE materials
Angreen Automotive Wire Harness Materials Comply With The Following Standards:
International standards: ISO 6722-1, ISO 6722-2, ISO 14572, LV 216, ISO 19642, DEKRA K179
Chinese standards: GB/T 25085, GB/T 25087, QC/T 1037
Product Features: Easy processing, good flexibility, no precipitation, and strong abrasion resistance
Product Categories Include:
Temperature ratings: 125℃/ 150℃
Suitable for new energy vehicle high-voltage cables with conductor sizes above 25 mm²and below 120 mm²
Temperature ratings: 125℃/ 150℃
Suitable for low-voltage cables up to 25 mm², especially thin-wall cables from 0.1 mm² to 10 mm²
Temperature ratings: 180℃/ 200℃
| Application positioning | Common Specifications (mm^2) | Common Material |
| Drive Motor-MCU | 25P、35P、50/70/95 | 180℃ Silicone\150℃XLPO |
| Air Conditioning System-PDU | 4P、6P、10P | 125℃XLPO |
| Battery(Small)-DC | 10、16 | 125℃XLPO |
| DC-PDU | 16P | 125℃XLPO |
| MCU-PDU | 25P、35P、50P | 125℃XLPO |
| On-Board Charger - Battery | 6P、10P | 125℃XLPO |
| Battery-DC | 35、50、70、95 | 125℃/150℃XLPO、Silicone |
