Automotive Wire

High voltage wire is a specialized insulated conductor designed to handle voltages above 600V, essential for high-power and energy-intensive environments. It is widely used in EV systems, industrial equipment, battery packs, solar energy infrastructure, and energy storage systems (ESS), where electrical and thermal reliability is critical.
 
These wires feature heat, oil, and abrasion-resistant insulation such as silicone, XLPE, or ETFE, tailored to system needs. They comply with global standards like UL 758, and ISO 6722, ensuring both electrical safety and mechanical durability.
 
Selecting the right high voltage wire requires evaluating voltage class, temperature rating, conductor type, and insulation thickness. Trusted by manufacturers, OEMs, and engineers, these cables support safe, efficient, and long-lasting systems across transportation, energy, ESS, and automation sectors.

SAE J1128 is a key U.S. automotive wire standard developed by the Society of Automotive Engineers (SAE) for low-voltage electrical systems in passenger vehicles, trucks, and off-road equipment. This American specification defines the construction, performance, and testing requirements for primary wires used in 12V or 24V systems.
 
SAE J1128 covers multiple wire types including GPT, GXL, SXL, and TXL, which differ in insulation thickness and temperature resistance. These wires are commonly used for vehicle control circuits, lighting, dashboard electronics, engine compartments, and power distribution.
 
Designed for harsh automotive environments, J1128-compliant wires offer excellent abrasion resistance, chemical resistance, flexibility, and thermal stability, with operating temperatures typically ranging from -40°C to +125°C, depending on insulation type.
 
As a widely recognized U.S. specification, SAE J1128 wire is trusted by OEMs, wire harness manufacturers, and aftermarket installers for its consistent quality and durability. It plays a critical role in designing reliable automotive electrical systems and meets both performance and safety requirements across the global automotive industry.

JASO D611 is a Japanese automotive standard established by the Society of Automotive Engineers of Japan (JASO). It defines the performance, construction, and testing requirements for low-voltage automotive wires, especially in 12V and 24V systems commonly used in Japanese and Asian vehicles.
 
This standard applies to single-core electrical wires used in a variety of automotive applications such as engine compartments, chassis wiring, interior electronics, and lighting systems. It evaluates wire characteristics such as insulation thickness, conductor resistance, heat resistance, cold flexibility, and chemical performance, ensuring durability in demanding vehicle environments.
 
Wire types classified under JASO D611 include common designations like AV, AVS, AVSS, and CAVUS, which differ in wall thickness and current capacity. These wires are widely used in Japanese OEMs and have become a benchmark for automotive harness manufacturers throughout Asia.
 
JASO D611 plays a vital role in ensuring electrical reliability, lightweight wire design, and space-saving installation in modern vehicle electrical systems. It is often referenced alongside ISO 6722 and SAE J1128 in global automotive wire development.

ISO 6722 is an international standard that defines the requirements for single-core low-voltage cables used in automotive electrical systems, particularly in 12V and 24V vehicles. Developed by the International Organization for Standardization (ISO), this specification ensures consistent global benchmarks for performance, durability, and safety in automotive wiring.

The standard applies to cables made with copper or tinned copper conductors, rated up to 60V DC, and suitable for temperature classes from -40°C to +150°C. It includes a range of insulation materials, such as PVC, XLPE, TPE, and ETFE, to meet various automotive application needs.

ISO 6722 defines essential criteria for wire construction, insulation properties, and overall mechanical and electrical performance, including resistance to heat, abrasion, and aging. It is widely adopted by OEMs, wire harness manufacturers, and automotive cable suppliers. Common wire types like FLRY, AVSS, and TXL are designed to meet or exceed ISO 6722 standards, making it a critical reference for wire selection in engine compartments, vehicle bodies, and interior electronics.

Electric vehicle cables (EV cables) are specially designed for electric vehicle applications, including external charging connections and internal high-voltage power distribution. These cables play a vital role in both residential/public EV charging systems and the internal power architecture of electric cars.

In charging applications, Electric vehicle cables (EV cables) are used to connect vehicles to AC or DC charging stations, with insulation engineered for UV resistance, flexibility, and mechanical strength. They are commonly found in portable EV chargers, charging stations (AC/DC fast chargers), and wall-mounted units, complying with standards such as SAE J1772, IEC 62196, and CHAdeMO.

Inside the vehicle, high-voltage EV cables link battery packs, inverters, motors, and BMS systems, supporting voltages up to 1000V and operating in high-temperature environments. These cables are often insulated with silicone, XLPE, or TPE to ensure excellent heat resistance, oil resistance, and EMI shielding.

Compliant with UL, SAE, ISO, and IEC standards, EV cables are essential components in building safe, energy-efficient, and reliable electric mobility systems for OEMs, EV infrastructure providers, and automotive harness manufacturers.