According to the data, the cables laid by innovative hybrid/electric vehicles are different from the general cables sold in the market, and need to meet various high requirements. The complex electronic system of the vehicle needs to shield the electrical interference generated by the high power/high voltage current passing through the power cable. Weight reduction is also paramount for electric and hybrid vehicles. The life expectancy of the complete vehicle including electrical components should be no less than 10 years. The environment surrounding the vehicle is particularly hazardous. General insulation will be damaged by gasoline, oil and other fluids. The temperature around the cable can reach 125°C or higher, or -40°C or lower in northern climates.

Specially designed: High voltage cables specially designed for hybrid and electric vehicles are made of irradiated cross-linked elastomer (XLE). This type of cable belongs to the category of battery and power transmission cables, and has long been maturely used in ordinary cars, large trucks, construction and agricultural machinery.

Dimensional optimization: specially designed high voltage cables are made of very tough, flexible and thin insulation materials. This thin insulation outperforms conventional thick insulation in abrasion and cut through resistance. Thinner insulation allows tighter bend radii and takes up less space.

Lifetime Optimization: Vehicles typically have a lifespan of more than ten years. The life of a commercial vehicle is given a fairly long number of hours of operation. A typical bus is expected to have a service life of over 50,000 hours.

High-voltage cables require insulation materials that retard the aging process even at very high temperatures. Compared with ordinary cables, the life of XLE products is 100-­‐1000 times longer.

Unlike normal battery cables, HEVs and EVs conduct current almost all of the time. The current generates heat due to the resistance of the conductor. The heat generated by the electric current heats the cable from the inside out. If the cable is heated from the exposed outside, it will age as quickly as if the cable is heated inside.

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