The advancement of vehicle electronics has led to an increase in the use of wires and cables in modern automobiles. Automotive wires are designed to safely and reliably transmit power, data and signals throughout a vehicle under varying operating conditions. Let’s take a look at some of the key materials used in automotive wiring and cabling systems.
PVC Insulation
Polyvinyl chloride Automotive Wire And Cable Materials is one of the most commonly used insulating materials for automotive wiring. PVC is inexpensive to produce, durable and offers good resistance to heat, oils, chemicals and moisture. However, it has low heat distortion temperature of around 70°C, limiting its use in high temperature applications. PVC insulation is suitable for low voltage applications like interior lighting circuits. It is used as insulation for bulk harnessing and general purpose wiring where temperature exposure is moderate.
TPE Insulation
Thermoplastic elastomers or Automotive Wire And Cable Materials offer advantages over PVC like greater flexibility at low temperatures, higher heat resistance and better chemical resistance. TPE insulation allows operation at temperatures between -40°C to 105°C. TPE wires find application in areas near the engine that experience intermittent heat spikes like the engine wiring harness. They are also used for data communication wires inside vehicle doors, seats and other components that experience flexing. Common TPE materials used are styrenic, polyolefin and polyether block amide TPEs.
Silicon Insulation in Automotive Wires and Cables Materials
Silicon rubber insulation provides high heat resistance up to 200°C, making it suitable for use in extreme temperature under-hood applications near the engine. It maintains flexibility even at high temperatures and offers excellent resistance to oil, gasoline and moisture. However, silicon rubber has low tensile strength and is prone to cracking with age. It is used for critical high temperature circuits like electric fan motors, battery cables and engine control units. Reinforced silicon gives it higher strength at the cost of some heat resistance.
Fluoropolymer Insulation
Fluoropolymers like FEP, PFA and ETFE provide the highest rated automotive insulation with heat resistance up to 260°C. They offer unrivaled chemical resistance to oils, fuels, UV exposure, plastics and lubricants. Fluoropolymer insulation allows use in highly corrosive underhood environments and plasma ignition cables. However, their heat resistance comes at the cost of low flexibility and higher cost than other insulations. They are used for critical powertrain applications like glow plugs, injector cables and transmission control units.
Cable Jacketing Automotive Wires and Cables Materials
Along with insulation, the outer protective jacketing of automotive cables is also an important consideration. Common materials used are:
– PVC: Economical and flexible at ambient temperatures butlimited heat resistance. Used for indoor applications.
– TPE: Provides abrasion resistance, oil resistance and flexibility over wide temperature ranges. Used for outdoor applications.
– CSPE: Chlorosulfonated polyethylene offers high chemical resistance and strength. Used in extreme underhood applications near fuels.
– Neoprene: Provides oil resistance, flexibility and tensile strength. Used under hood and for marine applications.
-Polyurethane: Provides high abrasion/cut resistance, flexibility and strength. Used on high wear underhood applications.
– Fluoropolymers: Highest rated jacket with temperature, chemical and abrasion resistance but high cost. Used for critical underhood circuits.
With the proliferation of electronics and precise sensors/actuators in modern vehicles, automotive wires and cables materials reliability has become critical. Selecting the right insulation and jacketing material based on the application operating conditions helps ensure optimal wire performance. Continued material advancements will allow reliable power and data transmission even in most demanding automotive environments.
*Note:
1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it.
About Author - Money Singh
Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemicals and materials, defense and aerospace, consumer goods, etc. LinkedIn Profile