What special materials are used in low voltage wiring harness to improve its durability and reliability?
Publish Time: 2025-03-06
In electric motorcycles and other automotive electrical systems, low voltage wiring harness is a key component for signal and power transmission. Its durability and reliability are crucial to the performance and safety of the entire vehicle. In order to improve the durability and reliability of low voltage wiring harness, manufacturers have adopted a variety of special materials, which show excellent performance in conductivity, heat resistance, corrosion resistance, wear resistance and flexibility.
1. Selection of wire materials
The wires of low voltage wiring harness usually use composite wires, such as copper clad steel wire, copper clad aluminum wire, etc. These materials combine the advantages of different metals, which not only ensure good conductivity, but also improve the strength and durability of the wiring harness.
Copper clad steel wire: Based on steel core wire, the outer layer is coated with a layer of copper. This wire structure has high strength and tension resistance, can withstand large mechanical stress, and is suitable for wiring harnesses that require high-strength support and fixed position. At the same time, the outer copper layer ensures good conductivity, making signal and power transmission more stable.
Copper clad aluminum wire: The aluminum core wire is wrapped in a copper layer, combining the excellent conductivity of copper and the lightweight properties of aluminum. This wire material not only reduces the weight of the wiring harness, but also maintains good conductivity, and is suitable for electric motorcycles with strict weight requirements.
2. Application of insulating materials
The insulation layer of the low voltage wiring harness is an important barrier to protect the wire and prevent current leakage and short circuit. In order to improve the durability and reliability of the wiring harness, manufacturers have adopted a variety of high-performance insulating materials.
Polyurethane rubber: This material has excellent mechanical properties and wear resistance, can withstand large tensile and torsional stress, and has good heat resistance and cold resistance. In low voltage wiring harness, polyurethane rubber is often used to make a tear-resistant outer layer to improve the anti-tear ability of the wiring harness.
Nitrile rubber: This material has good oil resistance, wear resistance and flame retardancy, and is often used to make shock pads and protective sleeves to protect the low voltage wiring harness joints, reduce the transmission of vibration force, reduce the vibration impact on the connection port, and improve the stability of the connection structure.
3. Application of other special materials
In addition to conductor materials and insulation materials, low voltage wiring harness may also use other special materials to improve its durability and reliability.
Corrugated tube: It is made of PA (nylon 6), PE (polyethylene), PP (polypropylene) and other materials by heating and extrusion, and has the characteristics of good wear resistance and flame retardancy. Corrugated tubes are often used for wrapping and protection of wire harnesses, which can effectively prevent wire harnesses from mechanical damage and chemical corrosion.
PVC tape: Although the price is relatively cheap, PVC tape also has certain wear resistance and flame retardancy, and is often used for temporary wrapping or auxiliary fixation of wire harnesses.
Cloth-based tape: This tape has extremely high wear resistance and temperature resistance, and can withstand high temperatures of up to 150°C, but the price is high and the flame retardant effect is not good. In situations where extremely high wear resistance is required, cloth-based tape is a good choice.
4. Comprehensive consideration of material selection
When selecting materials for low voltage wiring harnesses, manufacturers need to consider multiple factors, including conductivity, heat resistance, corrosion resistance, wear resistance, flexibility and cost. Different application scenarios have different requirements for materials, so customized selection is required according to the specific situation. For example, in high temperature and high vibration environments such as the engine compartment, materials with high thermal resistance, high wear resistance and good flexibility need to be selected; while in relatively mild environments such as the passenger compartment, the requirements for material performance can be appropriately reduced to reduce costs.
In summary, the durability and reliability of low voltage wiring harnesses cannot be improved without the application of special materials. By selecting appropriate wire materials, insulating materials and other auxiliary materials, manufacturers can create low voltage wiring harness products with excellent performance, safety and reliability, providing strong guarantees for the normal operation of electric motorcycles and other automotive electrical systems.
