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Introduction of high-voltage wire sheath and insulating material materials for electric vehicles

Date:2019/9/6 10:09:29

The cable is the life of the power system, and the outer sheath of the cable is the outermost layer of the cable. The following is a brief introduction to the role of the cable outer jacket, the provisions of the cable outer jacket, and the common materials of the cable outer jacket.


1. The role of cable outer sheath

The main function of the outer sheath of the cable is to strengthen the insulation performance while protecting the cable from mechanical damage.


2. Common materials of cable outer sheath

Sheath materials can be divided into metallic materials and non-metallic materials. The metal materials include a copper sheath, aluminum sheath, and lead sheath. Non-metallic sheaths include polyvinyl chloride, polyethylene, polypropylene, nylon, fluoroplastics, silicone rubber, neoprene, chlorosulfonated polyethylene, nitrile rubber, low-smoke halogen-free polyolefin, polyurethane, type, etc.


3. Provisions for cable outer sheath

The first characteristic of product quality is its quality, which is reflected in the appearance quality of the product. Regardless of the type of product or semi-finished product, the quality of appearance must be emphasized in production, and strict control and inspection should be carried out.

The jacket is the appearance of the cable. The appearance requirements are smooth and round, uniform gloss, no deviation from the core (no more than the specified deviation), no mechanical damage, flattening, no visible debris, bubbles, trachoma, obvious particles, bamboo Section shape, twist shape, etc.

In addition to complying with the above quality requirements, the thickness of the sheath also has a certain effect on the quality of the cable.


4. Standard of cable outer sheath

The thickness of the sheath is calculated and controlled according to the standard, and the calculation formula is D (outer diameter before extrusion)×0.035+1

The thinnest point of single-core sheath: nominal value×85%-0.1;

The thinnest point of multi-core sheath: nominal value×80%-0.2;


Fifth, the difference between the cable outer sheath and the cable insulation material

The sheath material is mainly used to protect the cable. It is used to select the sheath material according to external conditions, temperature, humidity, chemical environment, and special requirements.

Insulation materials mainly protect conductor insulation. Non-insulating materials and temperature grades are selected according to conductor heating conditions, service life, and special requirements.


Ogilvy, as a self-developed cable manufacturer that entered the field of new energy from 2006, chose XLPE as the insulation and sheath. It is characterized by low toxicity, moisture resistance, good UV resistance, processability, good, good coloring, halogen-free, smoke release, low flame retardant properties.

XLPE is the abbreviation of the English name for cross-linked polyethylene. Polyethylene is a linear molecular structure that is easily deformed at high temperatures. The process of cross-linking polyethylene makes it a network structure. This structure has a strong resistance to deformation even at high temperatures. XLPE cable material is a polyethylene containing organic peroxides such as DCP (dicumyl peroxide). This peroxide reacts with polyethylene under high temperature, high pressure, and inert gas environment, making thermoplastic polyethylene into thermosetting (elastomer) polyethylene, namely XLPE.

The excellent anti-aging characteristics and super heat-resistant deformation determine that the cross-linked polyethylene cable can allow a large current to pass under the conditions of normal operating temperature (90℃), short-term failure (130℃) and short circuit (250℃).

XLPE insulated cables significantly improve the performance of PVC insulated cables. The long-term working temperature of PVC insulated cables is only 70℃, while the long-term allowable working temperature of XLPE insulated cables can reach 90℃. At 130 ℃ temperature to maintain the elastic state, relative to the same cross-section of PVC insulated cable, its flow rate can be increased by about 25%. Therefore, in practical applications, PVC insulated cables can be replaced with cross-linked polyethylene insulated cables with a lower cross-section.

OMG always adheres to the principle of "only for safety", uses high-quality and safe raw materials, implements the standards, produces efficient and high-quality cables, and provides customers with safe products.

Recommended link for internal (high-voltage) cable products for OMG electric vehicles: https://www.omgevcable.com/ev-charging-cables/ev-charging-cables.html