High thermal conductivity insulation and sheathing materials for electric vehicle cable application

Polymeric insulated cable with high ampacity and good thermal performance is the core of the new fast charging technology for electric vehicles (EVs). Advanced materials with both good thermal and electrical properties to improve the performance of EVs charging cable are proposed in this paper. Two sample cables were manufactured with ethylene-propylene-diene (EPDM) insulation and a chlorosulfonated polyethylene rubber (CSM) sheath. Both the insulation and sheathing materials were modified by hybrid boron nitride (BN) to improve the thermal conductivity (TC). The test results show that the modified EPDM insulation has good electrical and mechanical properties. For the temperature characteristics of these two cables, the adoption of high TC EPDM insulation and CSM sheath can improve the heat dissipation capability and the temperature distribution in the cable. In addition, the theoretical ampacity of the cable was calculated showing a significant improvement. The employment of high TC insulation and sheath appears to be of great benefit to the reduction of temperature and increase in ampacity of EV charging cables.