The conductor is usually copper. Some use aluminum. There are also elastomeric insulation and sheaths, usually steel or alloy cable cores and / or braided shields, for strength and EMI protection. Some cables flow coolant in their internal pipes. There is usually some inert plastic filler. Most fast DC charging cables also contain communication or signal lines, so cars and chargers can "talk". The cable must be flexible enough to be easily used at all ambient temperatures and have a long service life. They should be environmentally friendly, recyclable and non-toxic to the environment. Usually, conductors are twisted for flexibility.

Details:

The key of electric vehicle charging cable is to conduct large current, usually at very high voltage, and keep the cable intact, safe and cool. There are many different ways to achieve this. But most have the same elements.

In addition to the above basic elements, the charging cable must also be able to resist:

Water, oil, automotive chemicals and other solvents

Sun and weather - especially ultraviolet radiation, heat and cold, rain or ice damage

Cuts and abrasions

Electromagnetic interference or hacker attack

Abuse and sabotage

Fire and flame

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