New energy cables (e.g., electric vehicle charging cables, in-vehicle high-voltage cables, and renewable energy system cables) must meet the following specialized technical requirements:
1. Electrical Performance
High Voltage Capacity
Rated voltage range: 600V–1000V DC or 450/750V AC, with higher requirements for commercial applications16.
Insulation must comply with GB/T 33594-2017 and other standards for voltage endurance testing12.
High Current Transmission
Continuous current: 250–450A, with transient peaks requiring low-resistance conductors (e.g., copper cores) and optimized cross-sectional design68.
EMI Shielding
Copper braided shielding or multi-layer composite shielding to suppress high-frequency harmonics (e.g., EMI from motors)36.
2. Environmental Adaptability
Temperature Resistance
Operating temperature range: -40°C to 125°C; localized high-temperature zones (e.g., near motors) require tolerance up to 175–200°C46.
Materials: Silicone rubber or cross-linked polyolefin insulation for thermal stability38.
Weather and Chemical Resistance
UV, ozone, oil, acid/alkali resistance for outdoor durability57.
Microbe-resistant coatings for nuclear or marine environments7.
Mechanical Durability
Dynamic bending radius ≥ 8× cable diameter (e.g., charging gun connectors)37.
Tensile strength, crush resistance, and abrasion protection for vehicle vibrations and complex routing58.
3. Safety and Lifespan
Flame Retardancy and Eco-Friendliness
Compliance with IEC 60332-1-2 flame-retardant standards; halogen-free materials (low smoke, non-toxic)8.
RoHS & REACH compliance for environmental safety8.
Service Life
Design lifespan: ≥ 3,000 hours (standard) or 12,000 hours (high-voltage systems), validated via accelerated aging tests6.
4. Installation and Structural Design
Routing Standards
Separation distance between high/low-voltage cables: ≥ 100 mm; prioritize underbody placement for high-voltage lines3.
Fixation intervals ≤ 200 mm to prevent wear and loosening3.
Sealing and Protection
Heat-shrink tubing or rubber seals for IP67/IP69K ratings (dust/waterproofing)38.
5. Standards and Certifications
Compliance with GB/T 18487 (charging systems), ISO 6722 (automotive cables), and other standards13.
ATEX/IECEx certification required for explosive atmospheres
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