High Voltage DC Silicone Rubber Cable – Shielded, Halogen-Free, Copper Conductor for EVs

Shielded High Voltage Silicone Rubber Copper Cable (For EV & Industrial Applications)

Overview

This shielded high voltage silicone rubber insulated copper cable is engineered for demanding power transmission applications requiring exceptional electrical performance, environmental resilience, and electromagnetic compatibility (EMC). Its advanced construction ensures safe and reliable operation of high-voltage systems, particularly within the rigorous environment of electric vehicles (EVs) and other critical industrial settings.

Key Features & Advantages:

• Superior EMC Performance: Integrated aluminum foil shield effectively minimizes electromagnetic interference (EMI) emission and protects internal conductors from external EMI, enabling safe parallel operation of power lines.

• Halogen-Free & Flame Retardant: The silicone rubber insulation and sheath are inherently halogen-free, offering enhanced safety by being flame retardant and self-extinguishing (flames extinguish within 70s, unburned length ≥50mm).

• Extreme Temperature Resilience: Outstanding performance across a wide temperature range from -40°C to +200°C.

• High Voltage Rating: Designed for AC 1000V / DC 1500V systems.

• High Reliability Insulation: Silicone rubber insulation provides excellent high-frequency characteristics, oxidation resistance, non-volatility, and long-term aging resistance.

• Robust Construction: Bare copper or tinned copper conductor ensures optimal conductivity and corrosion resistance.

• Flexibility & Durability: Maintains flexibility even at low temperatures, with a controlled minimum bending radius for ease of installation.

• Long-Term Aging Compliance: Meets stringent long-term (3000h) and short-term (240h) aging requirements per QC/T 1037 standard.

• Easy Installation: Compatible with molded EV connectors, eliminating the need for soldering.

Product Construction

This cable features a robust layered design:

1. Conductor: High-purity Bare Copper or Tinned Copper strands.

2. Insulation: Premium Grade Silicone Rubber.

3. Shielding: Aluminum Foil layer for EMI/EMC protection.

4. Outer Sheath: Silicone Rubber (Standard) or alternative material as specified by customer requirements. Color: Standard Orange.

Material Characteristics

• Insulation/Sheath: Silicone Rubber

  • Exceptional thermal stability (-40°C to +200°C)

  • Excellent electrical insulation properties at high voltages

  • High resistance to ozone, weathering, and aging

  • Halogen-free, low smoke emission

  • Flame retardant and self-extinguishing

  • Good flexibility over a wide temperature range

• Conductor: Copper (Bare or Tinned)

  • High electrical conductivity

  • Excellent corrosion resistance (especially tinned)

• Shield: Aluminum Foil

  • Effective electromagnetic shielding

  • Lightweight

Application Scenarios

• Electric Vehicles (EVs): High-voltage interconnects for Battery Packs, Electric Motors, DC-DC Converters, On-board Chargers (OBC), Power Distribution Units (PDUs).

• Charging Infrastructure: EV Charging Stations (AC and DC).

• Industrial Automation: Power supply lines for machinery requiring high voltage, flexibility, and EMC shielding in harsh environments.

• Renewable Energy: Connections within solar inverters and wind turbine power systems.

• Transportation: Rail, marine, and aerospace applications requiring high-temperature and high-voltage cabling.

• Any application demanding: High Voltage DC/AC power transfer, exceptional temperature range, halogen-free safety, EMI/EMC protection, and long-term reliability in harsh conditions.

Technical Specifications & Performance

Electrical & Dimensional Reference (Conductor: Bare Copper):

(Note: Reference Current values are indicative for thermal conditions; final ampacity depends on installation environment, bundling, and ambient temperature.)

Engineering Selection Notes

• Select conductor size based on required current carrying capacity (Ampacity) and voltage drop limitations.

• Ensure the selected voltage rating (AC 1000V / DC 1500V) meets or exceeds system requirements.

• Adhere strictly to the Minimum Bending Radius during installation to prevent damage to the cable and shield.

• Consider the extreme temperature range (-40°C to +200°C) suitability for the application environment.

• The aluminum foil shield requires proper termination (e.g., 360-degree contact) for effective EMC performance.

• Confirm fire safety performance (self-extinguishing) meets local regulations and application needs.

Available in shielded configuration as described. Unshielded variants also available upon request.