News - Innovations in Car Electrical Cables: What’s New in the Market?

With the automotive industry rapidly evolving, electrical cables have become critical components in modern vehicles. Here are some of the latest innovations in car electrical cables:

1.High-Voltage Cables for EVs

High-voltage cables for electric vehicles are key components used in electric vehicles to connect high-voltage batteries, inverters, air-conditioning compressors, three-phase generators and electric motors to realize the transmission of power electrical energy. Compared with the cables used in traditional fuel vehicles, electric vehicle high-voltage cables have the following characteristics and requirements:

High Voltage and High Current: EV high voltage cables are designed to handle voltages up to 600VAC/900VDC (passenger cars) or 1000VAC/1500VDC (commercial vehicles) and currents from 250A to 450A or even higher. This is much higher than the 12V systems typically used in conventional fuel vehicles.

Conductor Material: Conductors are typically constructed of annealed soft copper wire or tinned copper wire for improved conductivity and corrosion resistance. Oxygen-free copper wires (containing less than 0.001% oxygen and more than 99.99% purity) are widely used in EV high-voltage cables due to their high purity and non-brittle characteristics.

Insulation and sheath materials: In order to meet the requirements of high voltage and high current, high-voltage cables are insulated with insulation materials with high wall thickness, such as silicone rubber, cross-linked polyethylene or cross-linked polyolefin, which have good heat resistance and flame retardant effect, and can withstand high temperatures of more than 150℃.

Shielding and protection: High-voltage cables require electromagnetic shielding to reduce electromagnetic field noise and electromagnetic interference, while protective materials (such as heat insulation tubes and compiled tubes) and sealing rings on the outer layer of the cables ensure that the cables are waterproof, dust-proof, and abrasion-resistant in harsh environments.

Design and wiring: The design of high-voltage cables for electric vehicles needs to take into account wiring space constraints, safety requirements (e.g., minimum spacing of 100 millimeters or more between high-voltage and low-voltage conductors), weight and cost. The bending radius of the cable, the distance to the fixing point and the environment in which it is used (e.g. inside or outside the vehicle) will also influence its design and selection.

Standards and specifications: The design and manufacture of high-voltage cables for electric vehicles follow a series of industry standards, such as QC-T1037 Automotive Industry Standard for High-voltage Cables for Road Vehicles and TCAS 356-2019 High-voltage Cables for New Energy Vehicles. These standards put forward specific requirements for the electrical performance, mechanical performance and environmental adaptability of cables.

Applications: high-voltage cables for electric vehicles are not only used for in-vehicle connections, but also for connections between the charging port and the battery, inside the battery, between the battery and the engine and other components, as well as battery energy storage devices and other fields. The cables must be able to withstand harsh conditions such as high and low temperature environments, salt spray, electromagnetic fields, oil and chemicals.

The development and application of high-voltage cables for electric vehicles is one of the key factors in promoting a sustainable and climate-friendly future for electric mobility. As electric vehicle technology continues to advance, the performance and standards of high-voltage cables continue to be optimized to meet the growing demand for power transmission and safety requirements.

2. Lightweight Aluminum Cables

The adoption of lightweight aluminum automotive cables is one of the important trends in the automotive industry, especially in the new energy automotive industry, in the pursuit of lightweight, energy efficiency and range. The following is a detailed analysis of lightweight aluminum automotive cables:

Background and Trend

Automotive lightweight demand: with the rapid development of new energy vehicles, the demand for automotive lightweight design is further enhanced. Wire and cable, as the main components of automotive power transmission, are traditionally designed to use copper as the conductor, but copper core cables are expensive and heavy in quality. Therefore, the development of light-quality, low-priced aluminum conductor wire and cable for automobiles has become a necessary choice for automotive lightweight design.

Aluminum cable advantage: the traditional power industry has a long history of using aluminum cables, aluminum cables, low cost, light weight, long service life, especially suitable for high-voltage long-distance power transmission. China is rich in aluminum resources, material price fluctuations, cost stability and easy to control. In the new energy vehicle industry, the use of aluminum cables instead of copper cables is an ideal solution to reduce weight and cost.

Aluminum wire product application cases

Bus model: battery pack internal and external ultrasonic welding aluminum wire, large diameter power connecting wire usage, the advantage of using aluminum wire is obvious.

Passenger car: DC busbar adopts 50mm2 aluminum cable, which has been successfully mass-produced. The use of ultrasonic welding effectively improves the electrical contact performance of the joints and effectively reduces the quality of the wiring harness compared to copper wires.

AC charging gun: using high-strength bending-resistant aluminum alloy wire, light weight, stable performance in aging test, has gradually begun mass production; DC charging port wire for passenger cars uses aluminum wire to improve heat dissipation, and ultrasonic welding is used in the round charging port terminal, which significantly improves the electrical contact performance, reduces the amount of heat generated, and improves the service life.

Performance differences between copper and aluminum

Resistivity and conductivity: Due to the different resistivity of aluminum and copper, the conductivity of aluminum conductor is 62% IACS. when the cross-sectional area of aluminum conductor is 1.6 times that of copper, its electrical performance is the same as that of copper.

Mass ratio: the specific gravity of aluminum is 2.7kg/m3, the specific gravity of copper is 8.89kg/m3, so the mass ratio of the two is (2.7×160%)/(8.89×1)≈50%. This means that under the same electrical performance, the mass of aluminum conductor is only 1/2 of that of copper body.

Market Space and Prospect

Annualized growth rate: Based on market analysis, the annualized growth rate of aluminum rolled sheet and extruded material will be about 30% by 2025, showing the huge potential of aluminum in the field of automotive lightweighting.

Uncertainty Analysis

Cost factors: Although aluminum cables have cost advantages, there is a negative factor of increasing cost of aluminum instead of steel in the automotive industry, which may affect the speed of popularization of aluminum cables.

Technical challenges: The application of aluminum cables in automobiles still faces technical challenges, such as the improvement of the electrical contact performance of joints and the optimization of heat dissipation, which need to be solved through technological innovation.

The adoption of lightweight aluminum automotive cables is an inevitable trend for the automotive industry to pursue energy saving and emission reduction, and improve range. With the continuous progress of technology and further optimization of cost, the application of aluminum cables in the automotive industry will be more extensive, making an important contribution to automotive lightweight and energy saving and emission reduction.

3. Shielded Cables for EMI Reduction

Electromagnetic interference (EMI) in automobiles is a complex problem, especially in electric and hybrid vehicles due to the intensive use of high-power electronic devices. As one of the major contributors to EMI, the design and material selection of automotive wiring harnesses is critical to minimizing EMI. Here are some key points on how to reduce EMI in automobiles through the use of shielded cables:

How shielded cables work:Shielded cables work by adding a layer of metal braid or foil around the conductors.This shielding reflects and absorbs electromagnetic waves, thus reducing EMI.The shielding is connected to the ground, which directs captured electromagnetic energy to the ground and prevents it from interfering with other electronic devices.

Types of Shielding: There are two main types of shielding: braided metal shielding and foil shielding. Braided metal shielding provides better mechanical strength and flexibility, while foil shielding provides better shielding at lower frequencies. In automotive applications, it is common to use a combination of these two shielding types for optimal shielding.

Grounding the shield: In order for a shielded cable to be effective, the shield must be properly grounded. If the shield is not properly grounded, it can become an antenna and increase EMI instead.In automobiles, it is common to attach the shield to the metal frame of the vehicle to provide a good path to ground.

Where shielded cables are used: In automobiles, shielded cables are mainly used for critical signal and control lines that are susceptible to EMI or that may become EMI sources themselves. For example, lines used for engine control units (ECUs), sensor signals, in-vehicle networks (e.g., CAN buses), and entertainment systems typically use shielded cables.

Use of shielded cables in conjunction with unshielded cables: In automotive environments where space is limited, high-voltage and low-voltage cables are often placed in close proximity to each other. To minimize EMI, the high voltage cable can be designed as a shielded cable, while the low voltage cable can be unshielded. In this way, the shield of the high voltage cable protects the low voltage cable from EMI.

Cable Layout and Design: In addition to using shielded cables, proper cable layout is also very important. The formation of loops in cables should be avoided, as loops increase EMI. in addition, cables should be located as far away as possible from EMI sources, such as motors and power converters.

Use of filters: In addition to shielded cables, EMI filters can be added at both ends of the cable to further minimize EMI. filters can be capacitors or inductors, which filter out noise in a specific frequency range.

In summary, by using shielded cables and combining them with the right cable layout and filtering techniques, EMI in automobiles can be significantly reduced, thereby improving the reliability and performance of electronic equipment.

4. High-Temperature Resistant Cables

High-temperature resistant automotive cables are cables designed for the automotive industry to maintain stable performance in high-temperature environments. They are mainly made of several special materials to ensure reliability and safety in high-temperature areas such as engine compartments. Here are a few common materials used for high temperature resistant automotive cables:

TPE materials: thermoplastic elastomers (Thermoplastic Elastomers), including styrenes, olefins, dienes, vinyl chloride, polyesters, esters, amides, organofluorines, silicones and vinyls. Currently, SEBS (styrene-ethylene-butylene-styrene block copolymer) based elastomers are the most widely used TPE materials.

TPU materials: thermoplastic polyurethane (Thermoplastic Polyurethane), the molecular structure is divided into polyester-type and polyether-type, by the rigid block and flexible chain segments.TPU materials in the processing process of injection molding accounted for more than 40% of the extrusion molding is about 35% or so, with good elasticity and wear resistance.

PVC material: Polyvinyl Chloride (Polyvinyl Chloride), through the addition of different amounts of plasticizers to regulate its softness, reduce its “glass transition” temperature, so as to have good flexibility and plasticity, easy to process molding.

Silicone material: a highly active adsorbent material, amorphous substance, thermosetting rubber. Silicone has excellent heat and cold resistance and a wide range of operating temperatures, from -60°C to +180°C and beyond.

XLPE cross-linked polyethylene: through chemical cross-linking into thermosetting elastomers, improved insulation properties, the cable temperature resistance range is expanded, the performance has been improved. XLPE cable once combustion occurs, the production of carbon dioxide and water, relatively environmentally friendly.

The selection and use of these materials enable high temperature resistant automotive cables to work stably for long periods of time in high temperature environments such as engine compartments and near exhaust systems, ensuring the normal operation of automotive electrical systems. In addition, high-temperature resistant cables also have the advantages of oil resistance, water resistance, acid and alkali resistance, corrosive gas resistance, aging resistance, etc. They are suitable for metallurgy, electric power, petrochemicals, rolling stock, energy, iron and steel, electrical machinery and other fields. When choosing high-temperature resistant cables, you need to choose the right model according to the actual application scenario, temperature environment, voltage level and other factors to ensure that the cable has good performance and safety under high temperature conditions.

5. Smart Cables with Integrated Sensors

Smart car cables with integrated sensors are an integral part of modern smart cars, and they play a key role in the vehicle's electrical and electronic architecture. Smart car cables are not only responsible for the transmission of power, but more importantly, they carry data and control signals, connecting microcontroller units (MCUs), sensors, actuators, and other electronic control units (ECUs) in the car, forming the car's “neural network”.

The function and importance of smart car cables

Data Transmission: Smart car cables are responsible for transmitting data from sensors to the MCU and commands from the MCU to actuators. This data includes, but is not limited to, speed, temperature, pressure, position, etc., and is critical to achieving precise control of the vehicle.
Power Distribution: The cable not only transmits data, but is also responsible for distributing power to the various electronic devices in the car to ensure that they work properly.
Safety and security: The cable is designed with safety in mind, such as the use of fireproof materials and the setting of overcurrent protection, to ensure that the circuit can be cut off in time in the event of a malfunction, avoiding potential safety hazards.

Design Requirements

The design of smart car cables must meet the following requirements:

Reliability: Cables need to be able to work reliably in a variety of harsh environments in the car, including high temperature, low temperature, vibration and humidity.
Durability: Cables must be durable enough to withstand long periods of use without failure.
Safety: Cables should be well insulated to reduce the risk of short circuits and have the necessary protection mechanisms.
Lightweight: With the trend towards lightweight vehicles, cables also need to be as light and thin as possible to reduce the overall weight of the vehicle.
Electromagnetic compatibility: Cables should have good shielding performance to reduce signal interference.

Application Scenario

Smart car cables are widely used in various systems of automobiles, including but not limited to:

Engine control system: connecting engine ECU with sensors and actuators to realize precise control of the engine.
Body control system: connecting body control module (BCM) with windows, door locks, lighting and other systems.
Driver Assistance System: connects the ADAS (Advanced Driver Assistance Systems) controller with sensors such as camera and radar.
Infotainment system: connects the multimedia center with audio speakers, navigation system, etc.

Future Trends

As automotive electronic and electrical architectures evolve, so do smart car cables. Future trends include:

Centralized architecture: As automotive electronic architectures shift from distributed to centralized, cable complexity and length are likely to decrease, helping to reduce vehicle weight and improve the efficiency of information flow.
Intelligent management: Cables will integrate more intelligent components, such as built-in sensors and smart connectors, enabling self-diagnostics and status reporting.
Application of new materials: To further reduce weight and improve performance, cables may be made of new lightweight materials.

Smart car cables are key components connecting automotive electronic systems, and their design and performance are critical to ensuring the safety and reliability of automobiles. As technology advances and automotive electronics accelerate, smart car cables will continue to evolve to meet the need for higher performance.

6. Biodegradable and Eco-Friendly Cables

Against the backdrop of the pursuit of environmental protection and sustainable development, biodegradable and environmentally friendly automotive cables are becoming a hot topic in the automotive manufacturing industry. These cables not only meet the needs of the automotive industry in terms of performance, but also show significant advantages in terms of environmental protection.

Biodegradable Insulated Cables

Biodegradable insulated cables are made of biodegradable insulating materials, which, under certain environmental conditions, can be gradually decomposed through the metabolism of microorganisms and ultimately converted into environmentally friendly small molecules, such as carbon dioxide and water. This process usually requires a certain amount of time and suitable environmental conditions. The use of biodegradable cables is in line with the principles of green and sustainable development. It ensures the performance of cables while minimizing the impact on the environment and promotes the development of the green cable industry.

Cables with non-polluting insulating varnish

Non-polluting insulating varnish for cables uses non-hazardous insulating varnish to replace the insulating materials that contain hazardous ingredients in traditional cables. This innovation not only reduces environmental pollution, but also improves the safety and reliability of cables.

Bio-based materials in automotive cables

Bio-based materials, especially polylactic acid (PLA) fibers, composites and nylon, have great potential for application in the automotive industry due to their biodegradability, environmentally friendly production and processing, wide range of raw material sources, low odor, and low volatile organic compounds (VOC) content. With the substantial increase in production capacity, PLA polylactic acid (PLA), as a bio-based polymer derived from natural resources, has also seen its tremendous development. PLA is chemically synthesized from natural corn. This material can be decomposed into CO2 and H2O by microorganisms after being discarded, without causing pollution to the environment, and is recognized as a new eco-material that is green and sustainable in the 21st century.

Application of TPU materials in automotive cables

Thermoplastic polyurethane (TPU) materials not only offer excellent performance, but also are biodegradable (3-5 years) and recyclable.The sustainable and environmentally friendly properties of TPU materials offer a new option for automotive cables, which helps to reduce the impact on the environment.

Challenges and Outlook

Although biodegradable and eco-friendly automotive cables exhibit many advantages, their application faces some challenges and limitations. For example, the speed and effectiveness of degradation are affected by environmental conditions, requiring careful evaluation and selection of application scenarios. At the same time, the performance and stability of degradable insulation materials need to be continuously improved and tested to ensure their reliability and safety. In the future, as technology continues to advance and environmental awareness increases, biodegradable and eco-friendly automotive cables are expected to play a greater role in the automotive industry, driving the entire industry in a more environmentally friendly and sustainable direction.