EV High Voltage Cables

EV High Voltage Cables

Overview:
Swell EV high voltage cables are specially designed for electric vehicle (EV) power systems, ensuring safe and stable transmission of high voltage and high current. Manufactured with advanced insulation materials and precise conductor construction, these cables provide excellent thermal resistance, flexibility, and long-term reliability in demanding automotive environments.

Key Parameters

• Voltage Rating: Up to 600V / 1000V / 1500V (customizable)

• Temperature Rating: -40℃ to +125℃ / +150℃

• Conductor: Stranded bare copper or tinned copper

• Insulation: XLPE / TPE / Silicone (optional)

• Shielding: Aluminum foil / copper braid (optional)

• Flame Retardant: IEC 60332-1-2

• Standards: ISO 19642, LV 216, QC/T 1037

• Compliance: RoHS, REACH

• Color: Orange (standard for EV high voltage), customizable

Description

EV high voltage cables are widely used in electric vehicles, hybrid vehicles, and energy storage systems for connecting battery packs, inverters, motors, and charging systems. These cables are engineered to handle high voltage loads while maintaining flexibility for complex routing inside vehicles.

Swell Cables offers a full range of EV cables with optimized insulation thickness, excellent bending performance, and strong resistance to oil, heat, and abrasion. The cables are suitable for both fixed installation and limited flexible movement in automotive applications.

Product Structure

• Conductor: Fine-stranded copper conductor for high flexibility

• Insulation: High-performance XLPE or TPE insulation

• Shielding: Optional electromagnetic shielding layer

• Outer Sheath: Heat-resistant and abrasion-resistant compound

Designed for high safety, flexibility, and durability in EV power systems.

Applications

• Electric vehicle battery systems

• Motor and inverter connections

• Charging systems

• Energy storage systems (ESS)

• Hybrid and electric commercial vehicles

Advantages

• High voltage resistance up to 1500V, ensuring safe power transmission

• Excellent thermal performance up to 125℃ / 150℃ for demanding environments

• High flexibility for easy routing in compact vehicle structures

• Strong resistance to oil, heat, abrasion, and automotive fluids

• Optional shielding for enhanced electromagnetic interference (EMI) protection

• Compliant with international standards (ISO 19642, LV 216)

• Supports customization for conductor, insulation, and structure

• Stable quality and fast delivery from experienced manufacturer

Certificates

• ISO 9001 Quality Management System

• ISO 14001 Environmental Management System (optional)

• ISO 45001 Occupational Health & Safety (optional)

• ISO 19642 Automotive Cable Standard Compliance

• RoHS Compliance (2011/65/EU)

• REACH Compliance (EC 1907/2006)

• CE Declaration of Conformity (LVD 2014/35/EU)

Specifications

Customer Cases

• Supplied EV high voltage cables for a European electric bus manufacturer, used in battery and inverter systems.

• Provided customized cable solutions for an Asian EV wiring harness supplier, improving installation efficiency and durability.

• Supported energy storage system (ESS) projects with high-performance cables for stable power transmission.

FAQ

Q1: What are EV high voltage cables used for?
A: They are used to connect key components such as batteries, inverters, motors, and charging systems in electric vehicles and energy storage systems.

Q2: What is the typical voltage range of EV cables?
A: EV high voltage cables typically support 600V, 1000V, and up to 1500V depending on system requirements.

Q3: Why are EV cables usually orange?
A: Orange is an international safety color used to identify high voltage circuits in electric vehicles, improving safety during installation and maintenance.

Q4: Can you provide customized EV cables?
A: Yes, Swell Cables offers customization including conductor size, insulation materials, shielding structure, temperature rating, and colors.

Q5: Are your EV cables compliant with international standards?
A: Yes, our products comply with standards such as ISO 19642, LV 216, and meet RoHS and REACH requirements.

Custom Service

Swell Cables provides customized EV cable solutions according to customer requirements, including conductor size, insulation materials, shielding structure, and cable colors.

We support OEM and ODM services for automotive wiring harness manufacturers and EV system integrators.

For more information or technical support, please feel free to contact us.