Better EV cables

Over the last few years, standards for electric vehicle (EV) charging have undergone considerable revision. In 2011, the Society of Automotive Engineers (SAE) established the SAE J1772 Electric Vehicle and Plug-In Hybrid Electric Vehicle Conducive Charge Coupler specification. This standard specifies the electrical and physical performance requirements, as well as charger-vehicle communication procedures, for the charge systems of electric vehicles. This charging standard was adopted by both the United States and Japan for Level I (120 V, 6 A, single-phase), and Level II (240 V, 80 A, split phase) electric vehicle charging, and is being implemented by such auto manufacturers as Ford, GM, Honda, Nissan, Tesla, and Toyota.

With the standard comes new forms of rugged, high-power, UL-certified cable. These cables, EVE and EVJE, are made of a thermoplastic elastomer (TPE) that provides higher dielectric strength and improved electrical performance compared to conventional EVT-type cable used previously.

One advantages of the new cables is that they are more flexible in cold conditions. They also have a lower brittle point, which means they are more resistant to tearing in cold weather. And TPE’s high-density polyethylene is also more resistant to moisture and acids than the earlier polyolefin material. So the new cables are more suitable for outdoor environments than EVT cables, and can have a longer operating life in EV charging stations.

Along with the change in cable comes significant changes in connector technology as well. Be sure to see next month’s issue of Electronic Products for a discussion of the new cabling and connector technologies.