Temperature resistance of different wire harness materials
Jul 14, 2025
The temperature resistance of automotive wiring harnesses varies significantly due to different materials. The following is a comprehensive analysis of the main materials and their temperature resistance characteristics:
1. Polyvinyl chloride (PVC)
Temperature resistance range: -40℃~105℃, but long-term exposure to above 100℃ will accelerate decomposition and rapid aging at 130℃.
Features: Low cost and good flame retardancy, but poor high temperature stability, and stabilizers need to be added to improve performance. Commonly used in low temperature areas such as passenger compartments.
Limitations: Releases hydrogen chloride gas at high temperatures, which may corrode equipment.
2. Cross-linked polyethylene (XLPE)
Temperature resistance range: -40℃~125/150℃, long-term working temperature can reach 90℃, short-term tolerance 130℃.
Features: Lighter and thinner than PVC, better heat resistance, 25% higher interception rate, and halogen-free and more environmentally friendly. Mostly used in engine compartments or high-voltage wiring harnesses.
Advantages: Maintains elasticity at high temperatures, stable insulation performance
3. Silicone material
Temperature range: -60℃~200℃, stable performance under extreme temperature differences, flexible and anti-bending.
Application: High-voltage wiring harnesses or parts that require frequent bending (such as door wiring harnesses), protection level can reach IP68, suitable for electric vehicle high-voltage systems.
Case: Pacoray silicone wiring harnesses are resistant to 200℃ high temperatures and are used for high-power motor connections.
4. Cross-linked polyolefin (XLPO)
Temperature range: Similar to XLPE, but more resistant to chemical corrosion, suitable for oily environments2.
Comparison: Halogen-free, high-temperature safety is better than PVC.
5. Special materials (such as PPS, PA66)
Temperature range: 180℃ (such as PPS), used for high-temperature components such as engine compartment terminals.
Design: With glass fiber reinforcement, thermal deformation rate <1% (at 150°C), such as TE Connectivity's sheath.
Summary and selection recommendations
Low temperature area (passenger compartment): PVC (-40°C~105°C)23.
High temperature/high pressure area: XLPE (125/150°C) or silicone (200°C).
Extreme environment: Silicone or PPS materials are preferred, taking into account flexibility and temperature resistance.
Different materials need to be selected comprehensively according to the working environment (temperature, vibration, corrosion), and refer to international standards such as GB/T 19666, ISO 8092, etc.
