Automotive Wire and Cable Materials: Ensuring Safety and Optimum Performance
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| Automotive Wire and Cable Materials |
Copper
vs Aluminum
Automotive Wire And Cable Materials savings over copper but has some drawbacks to consider. Aluminum has about 60% of the conductivity of copper, so larger aluminum cables are needed to carry the same current as a copper cable of the same dimensions. Aluminum is also more susceptible to corrosion, especially in presence of dissimilar metals like copper. This can lead to breakdown of insulation over time. Proper termination techniques help address aluminum's corrosion concerns to some extent.
For low-current applications like lighting and infotainment, aluminum wiring is a viable cheaper alternative to copper. However, for high-current applications involving battery cables, copper remains the safer option due to its better conductivity and corrosion resistance properties. OEMs also opt for copper in applications where failure could lead to safety issues.
Automotive Wire and Cable Materials Coatings and Insulation
To improve corrosion resistance, automotive cables often feature special material coatings. One of the most common is tin plating, which forms a thin, hard layer of tin over copper or aluminum. Tin effectively blocks the underlying metal from oxidation and makes soldering or terminating easier. Other protective coatings include silver, nickel and zinc.
Insulation plays a crucial role in preventing short circuits and ensuring safe, reliable operation of wiring systems. PVC (polyvinyl chloride) has long been the dominant insulation material for automotive wiring due to its toughness, flexibility over a wide temperature range and resistance to fluids like oil, gasoline and brake fluid. However, as vehicles evolve to be more electric, higher temperature insulation materials are needed.
Materials like cross-linked polyethylene, polyphenylene sulfide, fluorinated ethylene propylene and ethylene tetrafluoroethylene can withstand continuous operating temperatures over 105°C. They offer advantages like UV resistance, high dielectric properties and flame retardance. However, higher temperature insulations also increase materials cost. OEMs evaluate performance needs against cost for each specific application.
Wire Shielding and Protection Through Automotive Wire and Cable Materials
Proper shielding helps protect automotive wiring against electric interference, friction and damage from heat, chemicals and moisture. Common shielding materials include tinned copper wire braid, copper foil tape and aluminum Mylar tape. Wire braids effectively screen out electric noise from sources like ignition systems, while retaining flexibility. Copper foil and aluminum Mylar tapes provide additional protection against chafing when bundled with other circuits.
Conduits, raceways and wire looms play an important mechanical protective role. Manufactured from materials like plastic, nylon and stainless steel, they enclose cables and wires neatly while allowing for installation and removal. Conduits safeguard wiring against damages from moving components like suspending, steering and shifting mechanisms throughout the harsh under-hood environment.
High flexibility and fatigue resistance are important conduits material characteristics. Otherwise repeated vibration and flexing cycles could potentially crack casings, exposing wires to elements over the long run. Corrosion resistant plastic and stainless-steel conduits paired with abrasion proof internal sealing offer optimized protection.
Special Application Automotive Wire and Cable Materials
Depending on circuit function and location, automotive wires may require reinforced jacketing or specialized insulation for maximum durability. Battery cables handling high currents need thick copper or aluminum conductors encased in strongly braided fiberglass or polyester jackets. Heat shrinkable split nylon or PVC tubing provide additional mechanical protection and moisture sealing at termination joints.
Engine wiring harnesses located near hot exhaust manifolds use heat resistant silicon rubber compound insulated wires qualified to withstand short intermittent contact temperatures up to 180°C. Temperature sensor wires may use platinum alloy conductors well-suited for resistance applications. Inflammable materials like ethylene propylene are preferred alternatives to PVC in engine compartments.
Fuel lines use semi-rigid plastic or rubber tubes reinforced with resilient braided stainless-steel mesh layer. This construction withstands high pressure pulses while preventing crack propagation. In wiring applications too, combining conductors, insulation, shielding and protective jackets with synergistic material properties help ensure safety, reliability and longevity.
With auto electronics continuously evolving, automotive wire and cable
materials must be selected very carefully based on each application's requirements.
While copper remains the ideal conductor for many safety critical circuits,
aluminum shows potential in less demanding roles to reduce costs. Specialized
insulations, coatings, shielding and reinforcement translate to enhanced
performance reliability under diverse operating conditions. Synergistic
material combinations provide the engineered solutions necessary to efficiently
and safely power tomorrow's automated vehicles.
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