As the architecture of new energy vehicles (NEVs) evolves toward higher voltage, lightweight construction, and greater system integration, the reliability and safety of wiring harnesses have become a critical engineering focus. Acting as the "neural network" of the vehicle, harness systems require comprehensive protection against mechanical, electrical, and thermal challenges.
Within this context, braided sleeving has evolved from a simple harness organizer into a system-level protective component that directly impacts electrical safety, EMC performance, and long-term durability.
1.Key Application Areas — Where & Why
In NEVs, braided sleeving is deployed across multiple key harness zones, each with specific engineering objectives:
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High-Voltage Harness (Battery ↔ Inverter / Motor / DC-DC)
Provides mechanical protection, insulation cut-through resistance, and, when required, electromagnetic shielding. Maintains thermal stability and fire resistance to ensure HV system safety.
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Battery Module and Pack Internal Harnesses
Prevents insulation wear caused by vibration or friction. Expandable or split-sleeve designs allow easy maintenance and module replacement.
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On-Board and External Charging Cables
Must be abrasion-resistant, UV- and oil-resistant, while maintaining flexibility for user handling and storage.
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Power Electronics and Motor Bay (Inverter, PDU, DC-DC)
Requires high-temperature-resistant, flame-retardant, and optional shielding sleeving for reliable performance near heat sources.
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Body Control and Signal Harness (CAN / LIN / Sensor)
Ensures cable organization, EMC separation, and visual identification, supporting efficient vehicle assembly and serviceability.
2. Common Challenges & Engineering Responses
Wiring harnesses in NEVs face unique stresses such as high voltage, EMI interference, thermal aging, vibration, and maintenance complexity. Braided sleeving provides practical engineering countermeasures:
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Challenge
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Engineering Response
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High Voltage / EMI Risk
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Use conductive or tinned copper wire braided shields with proper grounding and terminal treatment.
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Thermal Cycling & High-Temperature Aging
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Select high-temperature materials such as fiberglass, PTFE, or aramid blends; apply thermal insulation where needed.
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Vibration & Mechanical Abrasion
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Employ dense or dual-layer constructions (outer abrasion-resistant layer + inner warning color).
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Assembly & Maintenance Efficiency
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Use side-entry or zipper-style sleeves to reduce disassembly and rework time.
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Compliance & Certification
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Ensure materials meet UL94, IEC 60332, RoHS, and REACH standards.
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3. Material & Structural Trade-offs
Choosing the right material and structure helps balance cost, protection, and assembly efficiency:
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PET (Polyester) Braided Sleeve — Lightweight, abrasion-resistant, cost-effective, recyclable; ideal for low-heat areas.
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Fiberglass Sleeve — Excellent thermal resistance (up to 250°C short-term) and flame retardancy.
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Aramid / Kevlar® Reinforced Sleeve — Exceptional cut and tensile strength; ideal for critical high-protection zones.
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PTFE / Fluoropolymer Sleeve — Superior chemical and thermal resistance, low friction coefficient.
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Metallic / Tinned Copper Braid — Provides EMI shielding; requires proper grounding to ensure effectiveness.
Structural Options:
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Full Braided for continuous protection.
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Split or Side-Entry for easy installation and service.
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Dual-Layer for extreme abrasion zones.
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Self-Closing or Zipper Type for quick assembly and rework.
4. Design & Engineering Checklist
To achieve high reliability in NEV applications, the following parameters should be incorporated into the design phase:
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Functional Segmentation: Classify each harness by function (HV Power, LV Signal, Communication, Sensor).
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Temperature Rating: Define continuous and peak operating temperatures.
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Mechanical Protection: Specify abrasion, cut-through, and bending endurance requirements.
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EMC Requirements: Determine shielding coverage, grounding method, and connection design.
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Assembly Constraints: Evaluate space, process method (manual or automated), and maintenance needs.
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Aesthetics & Identification: Apply colors, stripes, or printing for traceability.
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Regulatory Compliance: Confirm material certification (UL94, IEC 60332, RoHS, REACH, ISO 26262).
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Maintenance Strategy: Consider modular designs for easy section replacement.
5. Validation & Testing Matrix
To ensure real-world reliability, validation testing should be included during prototype and PPAP stages:
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Thermal cycling and aging (LV124 / ISO 16750)
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Vibration and mechanical fatigue testing
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Flexural fatigue and bending endurance
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Abrasion and cut-through resistance
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Flammability and smoke density (UL94, IEC 60332)
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Salt spray and chemical resistance
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EMC shielding effectiveness
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Post-aging insulation integrity
6. Typical Engineering Scenarios
Scenario A: 800V High-Voltage Main Loop
Recommended configuration: outer PET or aramid abrasion-resistant layer + inner fiberglass thermal layer + local tinned copper shield braid with grounded terminals.
Validation focus: grounding continuity, short-circuit tolerance, thermal durability.
Scenario B: Battery Module Interconnect Harness
Recommended configuration: split-type fiberglass or aramid sleeve with visible warning color for maintenance visibility and easy replacement.
7. Actionable Guidelines for OEMs / Tier-1 Suppliers
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Define a "Sleeving Grade Matrix" based on harness function (HV, LV, Signal, Charging).
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Include test items in the supplier specifications (SOQ / PPAP) and require material certificates.
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Validate early during prototype phase to catch assembly or EMC issues.
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Standardize assembly tools and processes, such as crimping and grounding methods.
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Adopt modular maintenance designs for battery and power electronics harness sections.
8. Conclusion: From a "Finishing Part" to a "System Protector"
In NEVs, braided sleeving has evolved far beyond aesthetics or cable organization. It now serves as a critical protection system safeguarding electrical safety, electromagnetic compatibility, thermal stability, and long-term durability.
With advanced material engineering, structural innovation, and strict validation,MJ provides comprehensive braided sleeving solutions that help global OEMs and Tier-1 suppliers achieve higher reliability, easier maintenance, and improved overall system safety.
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