Unshielded High Voltage Silicone Rubber Copper Cable (Extreme Temperature Performance)
Overview
Engineered for extreme environments requiring unmatched thermal resilience, this unshielded high-voltage cable combines silicone rubber insulation with high-purity copper conductors. Ideal for electric vehicle powertrains and industrial applications, it delivers reliable power transmission up to 200°C while maintaining flexibility, flame resistance, and long-term durability.
Key Features & Advantages:
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Extreme Temperature Range: Continuous operation from -40°C to +200°C – outperforms standard polymers.
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Superior Flexibility: Maintains pliability in tight spaces (e.g., EV battery/inverter compartments).
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Halogen-Free Safety: Self-extinguishing (≤70s flame duration), low smoke emission (unburned length ≥50mm).
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Environmental Resilience: Resists oils (IRM902/IRM903/gasoline), ozone, UV, and weathering.
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High Dielectric Strength: Rated for AC 1000V/DC 1500V systems with proven reliability (>600,000 km EV validation).
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Global Compliance: Meets ISO 6722, ISO 19642, LV216, DEKRA-179, QC/T 1037, RoHS & REACH.
Product Construction
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Conductor: Bare copper or tinned copper strands (oxygen-free).
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Insulation: High-grade silicone rubber.
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Outer Sheath: Silicone rubber (standard). Color: Orange.
Material Characteristics
| Component | Properties |
|---|---|
| Silicone Rubber | - Exceptional thermal stability (-40°C to +200°C) - High tensile strength & tear resistance (>15N/mm) - Ozone/UV/weather resistant - Halogen-free, flame-retardant |
| Copper Conductor | - Optimal conductivity (tinned variant for corrosion resistance) - Mechanical durability |
Application Scenarios
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Electric Vehicles: Battery pack connections, motor feeds, DC-DC converters, on-board chargers.
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Industrial Machinery: High-temperature ovens, foundries, power generation equipment.
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Renewable Energy: Solar inverter links, wind turbine generators.
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Transportation: Rail traction systems, aerospace power distribution.
Technical Specifications
| Parameter | Value |
|---|---|
| Rated Voltage | AC 1000V / DC 1500V |
| Temperature Range | -40°C to +200°C (peak) / -40°C to +175°C (continuous) |
| Conductor Material | Bare Copper / Tinned Copper |
| Insulation/Sheath | Silicone Rubber |
| Fire Performance | Self-extinguishing (≤70s), Unburned length ≥50mm |
| Min. Bending Radius | 5 × OD (OD ≤ 20mm), 6 × OD (OD > 20mm) |
| Oil Resistance | ≤15% diameter change (IRM902/IRM903/gasoline, 20h each) |
| Tear Resistance | >15 N/mm |
| Voltage Withstand Test | DC 1500V: 1.0kV/30min → 5.0kV/5min → 8.0kV (No breakdown) |
| Standards Compliance | QC/T 1037, ISO 6722, ISO 19642, LV216, DEKRA-179, RoHS, REACH |
Electrical & Dimensional Specifications
| Size (mm²) | Max. Resistance (mΩ/m @20°C) | Ref. Current (A) | Ref. Diameter (mm) | Rated Voltage |
|---|---|---|---|---|
| 2.5 | 7.60 | 30 | 3.70 | AC 1000V/DC 1500V |
| 4 | 4.71 | 40 | 4.50 | |
| 6 | 3.14 | 52 | 5.00 | |
| 10 | 1.82 | 75 | 6.50 | |
| 16 | 1.16 | 100 | 8.30 | |
| 25 | 0.743 | 125 | 10.20 | |
| 35 | 0.527 | 165 | 11.50 | |
| 50 | 0.368 | 215 | 13.50 | |
| 70 | 0.259 | 260 | 15.50 | |
| 95 | 0.196 | 320 | 17.50 | |
| 120 | 0.153 | 370 | 19.50 |
Notes:
Ref. Current: Based on thermal derating at 175°C (actual ampacity varies with installation).
Conductor Resistance: Values shown for bare copper (tinned copper ≈2-5% higher).
Engineering Selection Guide
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Temperature Priority: Ideal for >125°C environments where XLPE/XLPO fails.
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Voltage Rating: Verify system voltage ≤ AC 1000V / DC 1500V.
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Conductor Choice: Use tinned copper in corrosive/humid environments.
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Bending Requirements: Utilize flexibility for complex routing (e.g., around EV components).
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Safety Critical: Ensure flame-retardant properties meet local regulations.
Available Sizes: 2.5mm² to 120mm² (custom lengths/spool packaging).
