Highly Flexible, Weather-Resistant, and Abrasion-Resistant Charging Pile Cable Jacket

China [CN]

----Protecting the Lifeline of New Energy Charging Safety, OMG Cable Provides Solutions and Services

Electric vehicle charging cables are prone to damage and cracking due to prolonged bending, friction, or exposure to harsh environments. This not only affects appearance but also exposes internal wiring, creating the risk of leakage and short circuits. Extreme weather conditions such as high temperatures and severe cold can also accelerate cable sheath aging. If damage is observed, discontinue use immediately. Minor damage can be temporarily wrapped with insulating tape; in severe cases, replace the cable to ensure safe charging.

Damage and cracking of electric vehicle charging cable sheaths is a frequent safety hazard. The causes and hazards can be analyzed from three perspectives:

1. Causes and Types of Damage

The cable sheath is often made of PVC or TPE. Prolonged exposure to bending (such as repeated winding during charging), dragging (dragging on the ground), and extreme environmental conditions (high temperatures and exposure to sunlight can cause the material to become brittle, while low temperatures can cause the sheath to harden and crack) can lead to thinning, cracking, and even extensive shedding. Fast-charging cables, in particular, carry high currents (up to 200A or more), generating internal heat that accelerates sheath aging. Salt spray in coastal areas and deicing agents in northern China can also accelerate corrosion of the outer insulation layer.

II. Core Safety Risks

Electric Shock Hazard: When the sheath is damaged, the internal high-voltage conductors (DC fast-charging lines can reach voltages over 750V) are directly exposed. Human contact can cause electric shock, especially in rainy conditions where accumulated water can increase the risk of electrical conduction.

Short Circuit Fire: If the damaged conductors come into contact with the metal vehicle body, the charging station casing, or each other, a short circuit can occur instantly. The resulting arcing and high temperatures can ignite surrounding combustible materials and even cause a fire in the battery compartment.

Insulation Failure: The sheath is the cable's primary insulation barrier. Damage reduces insulation resistance, potentially triggering a misjudgment by the vehicle's BMS (Battery Management System), leading to charging interruption or system failure.

III. Scientific Response Plan

Temporary Emergency Treatment: If only minor surface cracks occur (without damaging the internal wiring), immediately wrap the cable with two or more layers of high-voltage insulating tape (such as 3M 130C) extending 5cm from the damaged area to both ends to ensure no exposed wires. Arrange for replacement as soon as possible.

Strictly Prohibit Continued Use: If exposed conductors, multiple strands are broken, or the cable sheath is damaged for more than 10cm, discontinue use immediately! This type of damage has exceeded safety thresholds, and temporary repairs will not eliminate the potential risks.

Professional Replacement Standards: Prioritize original cables or cables certified to national standards such as GB/T 18487.1. Pay attention to the specifications of AC (slow charging) and DC (fast charging) cables. When replacing cables, inspect the integrity of the plug terminal plating to avoid potential problems caused by inferior components.

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