Copper Still Reigns as the Top Conductor

As vehicles become more electrically complex with the proliferation of electronic systems, selecting the proper wire and cable materials is vital. While different factors like insulation, shielding and thickness vary based on the application, copper remains the dominant conductor material due to its high electrical conductivity and widespread availability. Capable of transmitting signals and power efficiently, copper serves as the backbone for vehicle wiring harnesses that connect everything from infotainment and driver assist systems to the engine control unit. Its ductility also facilitates easy termination and splicing.

Factors like heat resistance, mechanical strength and cost necessarily come into play for some specialized uses cases. Aluminum alloy is sometimes utilized as an alternative to copper for applications requiring lighter weight or better heat dissipation like battery cables. However, its higher electrical resistance means thicker gauges are generally needed compared to copper.

Plastic and Rubber Insulation for General Wiring

Polyvinyl chloride (PVC) plastic is a commonly used Automotive Wire And Cable Materials  that protects copper conductors from damage, corrosion and short circuits. Inexpensive and durable, PVC insulation can withstand a wide range of temperatures from -25°C to 80°C. This makes it appropriate for general vehicle wiring carrying low voltages below 60 volts. Cross-linked polyethylene (XLPE) is another plastic that provides greater heat resistance up to 105°C, making it preferable for applications closer to the engine.

Elastomer rubber insulation also endures higher heat compared to plastic types. Ethylene propylene diene monomer (EPDM) rubber insulation withstands continuous temperatures ranging from -40°C to 125°C, qualifying it for use with alternator and starter cables. Thermoset rubber like ethylene-propylene rubber (EPR) withstands even higher heat up to 150°C, making it well-suited near exhaust manifolds. The insulating properties of plastic and rubber shield internal conductors from short circuits and potential electrical shocks.

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