Voltage Cable Compound For Automotive Manufacturers

What factors affect the wear resistance and mechanical strength of automotive cable composites?

The wear resistance and mechanical strength of automotive cable composites are affected by many factors. Here are some key factors:

Selection of raw materials:
Substrate: The type of polymer or resin used directly affects the wear resistance and mechanical strength of the composite. For example, polyurethane and silicone generally have better abrasion resistance than other plastic materials.
Fillers and reinforcements: Added fillers (such as glass fibers, carbon fibers or mineral fillers) can significantly increase the mechanical strength and wear resistance of the material.

Composite material formula:
Ratio: The ratio of raw materials (such as the ratio of resin to filler) affects the strength and wear resistance of the final product.
Additives: Antioxidants, UV inhibitors and other additives can improve the material's long-term stability and wear resistance.

Processing technology:
Molding process: Processes such as extrusion, injection molding or pressing can affect the density and structural strength of the material.
Temperature and Pressure: The temperature and pressure conditions used during processing can affect the final properties of the material.

Usage environment:
Temperature: Extreme high or low temperature environments may affect the mechanical properties and wear resistance of materials.
Humidity: High humidity environments may cause the material to absorb water, reducing its mechanical strength.
Chemical Exposure: Chemicals (such as oils, fuels or acids) can affect a material's resistance to chemical attack, which in turn affects its mechanical properties and wear resistance.

Mechanical loads and stresses:
Working conditions: The mechanical stress, bending and vibration that the cable is subjected to during use will affect the wear resistance and strength of the composite material.
Vibration: Prolonged vibration can cause material fatigue, affecting its performance.

Aging and Degradation:
Oxidation: Exposure to oxygen or ozone may cause aging of the material, reducing its strength and wear resistance.
UV radiation: Materials exposed to sunlight over time may undergo degradation that affects their performance.

When selecting composite materials for automotive cables, how to consider voltage level, environment and cable use?

When selecting composite materials for automotive cables, it is crucial to consider voltage level, environment and cable use. Here is a guide on how to consider these factors:

1. Voltage level
a. Electrical insulation performance of materials
Insulating materials: Select composite materials with appropriate electrical insulation strength to ensure that they can withstand the electrical load of the cable at a specific voltage level. Commonly used high electrical insulation materials include cross-linked polyethylene (XLPE) and fluoroplastics (such as PTFE).
Voltage resistance: Composite materials need to have good voltage resistance to prevent electrical breakdown or breakdown. Usually, these materials are tested to ensure that they can operate safely within the specified voltage range.

b. Electrical conductivity
Conductor materials: Ensure the compatibility of the conductor material and the composite material to maintain the electrical conductivity of the cable and reduce power loss.

2. Environmental factors
a. Temperature range
High/low temperature resistance: Select composite materials that can maintain performance within the operating temperature range of the vehicle (including high and low temperatures). For example, silicone and polyurethane perform well in high temperature environments.
Thermal stability: Ensure that the material does not degrade at high temperatures to avoid cable performance degradation or failure.

b. Humidity and moisture
Waterproofness: Select composite materials with waterproof or moisture-resistant properties to prevent the material from absorbing moisture or shorting. Materials such as polyethylene (PE) and polyvinyl fluoride (PTFE) have good water resistance.
Corrosion resistance: For humid or corrosive environments, choose corrosion-resistant materials such as fluoroplastics to provide long-term protection.

c. Chemical exposure
Chemical resistance: Ensure that the composite material can resist the attack of chemicals (such as oils, fuels and detergents) in the automotive environment to avoid material degradation. Rubber and certain plastics can provide good chemical resistance.

d. Ultraviolet radiation
UV resistance: If the cable is exposed to sunlight, select materials that are resistant to UV radiation, such as materials with anti-UV additives, to prevent material aging and degradation.

3. Cable use
a. Dynamic and static applications
Dynamic applications: For cables that need to be bent and moved frequently (such as cables in the engine compartment), choose materials with excellent flexibility and abrasion resistance, such as thermoplastic elastomers (TPE) or reinforced polyurethane.
Static applications: For cables that move less frequently, common materials such as polyvinyl chloride (PVC) and cross-linked polyethylene (XLPE) can meet the needs.

b. High current density
Heat dissipation: For cables that need to carry high currents, choose composite materials with good heat dissipation properties to prevent overheating and damage. Materials such as polyurethane have good thermal conductivity.

c. Safety requirements
Flame retardancy: For applications that require high safety (such as cables in passenger compartments), choose flame retardant or self-extinguishing materials to reduce the risk of fire. Materials such as high temperature resistant polymers (such as fluoroplastics) generally have good flame retardancy.