As EV cables in new energy vehicles move from 400V platforms to 800V and even higher voltage levels, the complexity of the vehicle electrical system increases greatly. EV cables are no longer just simple conductors. They directly affect vehicle safety, reliability, and service life.
In real applications, automotive cables in different areas have very different functions. Some carry high current, some handle signal control, and some must work stably for a long time under high temperature or strong vibration.
Automotive high voltage EV cables are mainly used to connect the battery pack, inverter, and drive motor.
In actual use, these EV high voltage cables carry large current for a long time. The working voltage is usually 600V or 800V. Some platforms can reach up to 1500V DC / 1000V AC. The conductor cross-section is usually between 10 mm² and 120 mm². Common sizes include 10/16/25/35/50/70/95/120 mm².
From a structural point of view, the insulation layer usually uses XLPE or XLPO cable material with 125℃ or 150℃ rating. The thickness is generally between 0.6 mm and 1.5 mm. The outer sheath is usually low smoke halogen-free XLPO cable compound, with a thickness of about 0.8 mm to above 2 mm.
The overall cable diameter changes with the conductor size. It is about 6 mm for small sizes and can exceed 30 mm for large sizes.
The key design focus of this automotive cable is: insulation stability, heat aging performance, and no deformation during long-term use.
Common Material:
125℃/150℃ irradiated XLPO cable compound for EV high voltage cable insulation
Automotive low voltage cables are widely used inside the vehicle, such as dashboard wiring, door wiring, seat wiring, and control system wiring. They are mainly used for signal transmission and low power supply.
The working voltage is usually 12V or 24V.
The conductor size is relatively small, usually between 0.13 mm² and 2.5 mm², corresponding to AWG 26 to 14.
Because space is limited, these automotive wiring harness cables usually use thin wall design.
The insulation thickness is usually between 0.2 mm and 0.6 mm.
The overall outer diameter can be controlled between 1 mm and 4 mm.
Although the electrical load is low, these cables bend frequently and are installed in dense wiring systems. Therefore, the materials must have good flexibility, abrasion resistance, and resistance to stress cracking.
Common material:
125℃/150℃ irradiated XLPE cable material for automotive thin wall low voltage wires
TPE for automotive wiring harness cable applications
Engine compartment and battery compartment EV cables face harsh conditions such as high temperature, oil mist, coolant, and continuous vibration.
The typical conductor size is 0.5 mm² to 6 mm².
The insulation thickness is about 0.4 mm to 1 mm.
The overall outer diameter is usually between 2 mm and 8 mm.
For materials, 125℃ or 150℃ XLPE or XLPO cable materials are commonly used. In some high temperature areas, silicone rubber cable material is used.
The key requirements for these automotive cables are: heat resistance, oil resistance, aging resistance, and stable structure under temperature changes.
Common materials:
125℃/ 150℃ irradiated XLPO cable compound for automotive cables
180℃/190℃/200℃ silicone rubber for high temperature automotive cable
EV charging cables are one of the most frequently used external components in new energy vehicles. They include vehicle charging connectors and charging gun cables. The conductor size is usually between 2.5 mm² and 35 mm², and they also include signal wires.
The cable is a multi-core structure with shielding to ensure signal stability.
Because these charging cables bend frequently, the sheath thickness is usually between 1.5 mm and 3.5 mm.
The overall outer diameter is between 10 mm and 30 mm.
TPU cable material is widely used in this field because it has good abrasion resistance, high flexibility, and strong weather resistance. It is suitable for long-term outdoor use and dynamic bending.
Common materials:
90℃ TPU for EV charging cable sheath
XLPE insulation material for EV charging cables
105℃ TPE cable compound (UL standard)
180℃ silicone rubber material for charging cables
Automotive data cables in EV systems are increasing, including CAN wires, Ethernet cables, and cables for cameras and radar.
These cables usually use small conductor sizes of 0.13 mm² to 0.35 mm². They use twisted pair or shielded structures to reduce signal interference.
The insulation layer is thin, usually between 0.2 mm and 0.5 mm.
The overall outer diameter is controlled between 1 mm and 4 mm.
In this field, materials must not only provide basic insulation, but also ensure size stability and signal transmission stability.
Common materials:
105℃ TPU for automotive Ethernet cable sheath
90℃ / 105℃ TPE material for automotive data cables
XLPE and XLPO cable materials are the most important material systems in EV cables. They are mainly used for high voltage insulation.
Their temperature rating is usually 125℃ or 150℃. The crosslinked structure forms a stable three-dimensional network, so the material can keep its shape at high temperature without softening.
These materials are widely used for:
High voltage EV cable insulation
Engine compartment automotive cables
Thin wall low voltage cables
These materials are the foundation of any EV cable system
TPU cable material is mainly used in applications with high mechanical performance requirements.
It can be used for:
EV charging cable sheath
Underbody cable protection
Automotive data cable sheath
Its main advantages are abrasion resistance and flexibility. It can keep stable performance under frequent bending.
TPU is a key material and Angreen is advanced EV cable material suppliers
TPE cable compound is mainly used in low voltage wiring systems.
It has good processing performance and high flexibility, and it is suitable for thin wall design.
It can be used for:
Low voltage cable insulation
Flexible automotive wiring harness
Automotive Ethernet cables
Silicone rubber cable material is required in areas where the temperature is above 150℃.
Its temperature rating can reach 180℃ or even 200℃.
It can be used for:
High temperature automotive cables
Engine and battery system cables
In real applications, EV cable materials are usually used in combination:
High voltage insulation: XLPE / XLPO
Sheath: low smoke halogen-free XLPO
High temperature areas: silicone rubber
Low voltage systems: TPE or thin wall XLPE
Automotive Ethernet cables: TPE or TPU
This combination helps balance performance, cost, and processing.
Conclusion: Choosing the Right EV Cable Material Supplier
EV cable systems are continuously evolving with higher voltage levels and more integrated vehicle design. Different cable types have clear roles in size, structure, and material selection.
XLPE / XLPO, TPU, TPE, and silicone rubber cable materials all play key roles in their suitable applications.
For cable manufacturers and wiring harness companies, choosing a reliable EV cable material supplier or automotive cable compound manufacturer is critical.
With proper material selection and structure design, it is possible to improve the safety, stability, and long-term performance of EV cable systems.
Q: Which manufacturers in China are recommended for EV cable materials?
A: Most manufacturers that produce crosslinked polyolefin materials for cables can also produce materials for automotive cables. For example, Angreen New Materials Technology Co., Ltd., a professional EV cable material supplier.
Q: What standards do these modified plastic manufacturers meet for automotive cable materials?
A: Taking Angreen as an example, their EV cable materials meet international standards such as ISO6722, ISO19642, QC/T1037, and JASO D611. These are also the main standards currently used in the automotive cable field.
Q: What types and specifications are available for automotive cable materials?
A: Taking Angreen as an example, their automotive cable materials are divided into the following types and specifications. Multiple colors are available (high voltage automotive cables are usually orange).
| 125°XLPE For Automotive LV-Thin-Wall Cable | PFXBS61D5084 | Suitable For 0.35-0.75mm^2 |
| 125°XLPE For Automotive LV-Thin-Wall Cable | PFXBS59D5137 | Suitable For 1-4mm^2 |
| 125°XLPE For Automotive LV-Thin-Wall Cable | PFXBS9050138 | Suitable For 10-25mm^2 |
| 125°XLPE For Automotive HV Cable | PFXBS875053 | for ≥25 mm² up to 120 mm² |
| 125°XLPE For Automotive HV Cable | PFXBS92530 | for ≤25 mm² |
| 125°XLPE For Automotive HV Cable | PFXBS95529 | Suitable For 8-35mm^2 |
| 150°XLPE For Automotive LV-Thin-Wall Cable | PFXBS55D6017 | Suitable For 0.35-1mm^2 |
| 150°XLPE For Automotive LV-Thin-Wall Cable | PFXBS57D692 | Suitable For 1-6mm^2 |
| 150°XLPE For Automotive LV-Thin-Wall Cable | PFXBS906019 | Suitable For 10-25mm^2 |
| 150°XLPE For Automotive HV Cable | PFXBS886008 | For ≥25 mm² up to 120 mm² |
| 150°XLPE For Automotive HV Cable | PFXBS92660 | For ≤25 mm² |
| 125°XLPE Insulation Material for NEV HV/Energy Storage Cable | PFXOR805057 | For ≥25 mm² up to 120 mm² |
| 125°XLPE Sheath Material for NEV HV/Energy Storage Cable | PFXOR805058 | For ≥25 mm² up to 120 mm² |
| 180°Silicone For Automotive HV Cable | PHQNC70-1E | Fumed Silicone Compound |
| 125°XLPE For Automotive HV Cable | PFXBS46D5101 | For ≥6mm^ |
| TPU For Automotive Ethernet Cable | PFUBK901078 | UL94 V-0 |
| 125°XLPE For Energy Storage Cable | PFXOR85542 | Suitable For≤10mm^2 |
| 125°XLPE For Energy Storage Cable | PFXOR85543 | Suitable For＞10mm^2 |
| 90°TPU Charging Pile Cable sheath Material | PFUBK85518 | Meet EN50629，CQC33594 |
| Charging Pile Cable XLPE Insulation Material | PFXBS92431 | Meet EN50620/IEC62893 |
| Charging Pile Cable XLPE Insulation Material | PFXBS85471 | Meet GB/T33594, EN50620 |
| 105°TPE Sheath Material For Charging Pile Cable | PFEBS92170 | Meet GB/T33594 |
| 105°TPE Sheath Material For Charging Pile Cable | PFEBK801010 | Meet UL62、UL1581 |
| 180°Silicone For Charging Pile Cable | PHQNC70-1C | Fumed Silicone Compound |
Q: Can the thermal aging performance of automotive high-voltage cable materials pass the test at 175℃x 240 H?
A：Yes, they can pass the thermal aging performance test at 175℃x240 H. They can also pass the thermal aging performance test at 150℃x3000H.
Q: What standards must automotive cable materials meet?
A：Generally speaking, automotive cable materials that meet ISO 6722, ISO 19642, QC/T 1037, and JASOD 611 are generally safe for use.
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