Key performance requirements for battery high voltage cable insulation

China [CN]

Introduction: The selection of insulation materials is mainly based on 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.

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.

Summary: In comparison, current vehicles typically 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℃). If the route inside the electric vehicle is unfavorable, such as near the exhaust pipe, in front of the motor, on the back of the battery, etc., the OEM will even put forward higher high temperature resistance requirements. Such as E grade (175) ℃. The higher heat resistance of the insulation material determines that the cable can carry a higher rated current carrying capacity. For more details, please visit or search ev cables: https://www.omgevcable.com