Key performance requirements for battery high voltage cable insulation

Product Introduction: The selection of insulation materials mainly considers heat resistance requirements and mechanical strength. The specially designed stranded conductors can be rationally chosen to be softer than standard battery cables, allowing the specially designed stranded conductors to remain flexible.

The basic difference from conventional automotive cables is that the structure needs to be designed for a rated voltage of 600 V, and if used on commercial vehicles and buses, the rated voltage can be as high as 1,000 V or more. The cables currently used in cars powered by internal combustion engines are designed for a rated voltage of 60 V.

Function: As with all insulating materials, such high voltages are never a challenge. For industrial and domestic electrical systems, this is still low voltage. For high-voltage cables used in automobiles, the challenge should be thermal and mechanical properties.

Because high voltage brings increased application risks, according to standard requirements, high-voltage cables must be visually distinguished from ordinary automotive cables, and the designated surface must be bright orange.

High voltage cables need to carry high currents as they connect batteries, inverters and electric motors. Depending on the power requirements of the system components, the current can reach 250A to 450A. Such high current is difficult to find on conventionally driven vehicles. The result of high current transfer is high power consumption and heating of components. High voltage cables are therefore designed to withstand higher temperatures. A trend towards further increase in temperature requirements can now be seen.

To sum up: In comparison, current vehicles usually use cables rated to 105°C which is sufficient, as long as the cable is not used in the engine compartment or other areas that are resistant to higher temperatures. Electric vehicle high-voltage cables usually have a temperature higher than this, such as Class C (125℃) or Class D (150℃). A challenge in the development of electric vehicles in many cases is the space to incorporate more electrical components. Cables and connectors also require space to be routed through. Often results in tight bend radii. Due to the inherent design of conventional cables, high bending forces are difficult to overcome. To solve this problem, high flexibility of high-voltage cables is crucial. Welcome to visit: https://www.omgevcable.com