The most common conductor material is copper. We all know that copper has bare copper, tinned copper, silver-plated copper wire, etc. These types are still essentially copper, only the surface is coated with other substances.

In recent years, with the rapid development of new energy vehicles, electric vehicles in our lives is also becoming more and more popular, and its accessories market is increasingly developed. Electric car high-voltage wire is also one of the links, high-voltage wire is mainly connected to the car's high-voltage system and battery internal for connecting the charging port and battery, battery internal, battery and engine and other components. Its safety performance is very important. Electric vehicle high-voltage cable is mainly composed of conductor, insulation layer, shielding layer and sheath.


The common electric vehicle high-voltage cable consists of multiple thin copper wires, mainly to increase the conductivity. When there is alternating current or alternating magnetic field in the conductor, there will be a "skin effect", the current will be concentrated in the "skin part" of the wire, the current density on the surface of the conductor is greater than the density in the center. Roughly speaking, it can be understood that the main conductor conducts electricity by the surface. And the higher the frequency of alternating current, the more obvious the "skin effect" will be. The high-voltage platform of new energy vehicles is 300-400V, so the high-voltage wiring harness must reduce the "core" area. As an extreme example, if the wire is infinitely thin, it can be seen as the entire wire is conducting electricity, and the conductivity of the high-voltage harness can be significantly enhanced by the countless thin wires.

If the main high-voltage harness has a cross-sectional area of 50 mm2, the cable is more rigid and difficult to bend if whole copper is used as the conductor. Not only is it difficult to layout in the vehicle, but it may also pierce into the cockpit after a collision, increasing the safety risk. Considering strength and toughness, as well as safety, multi-core conductors are also a better choice.


The same basic principle of using wire anywhere is to choose the right wire according to the current and voltage requirements, not necessarily the thicker the better. Moreover, due to more demanding use conditions, the standard requirements for automotive high-voltage wiring harnesses are higher, and more details are considered in the design to be safer and more durable.

For new energy vehicles, lightweight is very important for range improvement. Then the weight of the wiring harness can start in the selection of materials, conductor materials can be used in new wire conductors, such as new aluminum conductors; insulation materials can be selected from low-density materials, while thin-walled processing.

For more EV HV Cable and electric vehicle High-Voltage cable, please visit OMG official website: https://www.omgevcable.com