COMPONENT WIRING
Component and sub-assembly leads
Leads inside heaters, sensors, motors and other parts supplied to vehicle programmes. Specify the component drawing, local temperature and termination.
Used in the new-energy vehicle industry
APPLICATION / Automotive & EV
Silicone Wire for
Automotive & EV Equipment
Component leads and battery-module wiring.
For component leads and battery-module wiring, we start from AGR silicone single-core wire: fine-stranded tinned copper with silicone rubber insulation, 0.3 mm² to 16 mm², rated −60 °C (−76°F) to +180 °C (356°F) continuous and U0/U 300/500 V from 0.5 mm².
AT A GLANCE
Vehicle wiring at a glance
Each vehicle connection and the silicone wire we start from.
| Connection | Cable construction | Key point |
|---|---|---|
| Component and sub-assembly leads | AGR silicone single-core wire, 0.3 mm² to 16 mm² | −60 °C (−76°F) to +180 °C (356°F) continuous, +200 °C (392°F) short-term |
| Battery-module and sampling leads | AGR silicone single-core wire in colour options | Voltage and current confirmed for vehicle use |
| On-vehicle high-voltage cables | Automotive HV cable requirements | Not covered by our standard range |
CONNECTION TASKS
Automotive & EV equipment wiring
AGR is a single-core lead wire. Automotive HV cable requirements such as ISO 19642 or LV 216 are separate from the AGR specification.
BATTERY WIRING
Battery-module and sampling leads
Power and voltage-sampling leads inside battery modules. Mark the circuit, conductor size and connector on the module drawing.
Used in battery packs; confirm for vehicles
HV SYSTEM BOUNDARY
On-vehicle high-voltage cables
Traction-battery, inverter and charging circuits follow automotive high-voltage cable standards. Send the required standard and test plan for a custom construction review.
Custom project to your standard
SELECTION CHECKS
Operating conditions to specify
Include these conditions with your enquiry so we can select the right cable.
Standard & approval
The automotive or OEM standard, for example ISO 19642 for high-voltage cables, and its required tests define the cable.
Heat & fluids
The local temperature near engines, heaters or power electronics, and any oil, coolant or fuel exposure, set the material requirements.
Vibration & routing
Routing, fixing points, bend locations and vibration decide the mechanical design. Flexible insulation does not replace a fatigue test.
OUR CABLE
Silicone cable construction
Construction and technical data.
AGR / SINGLE-CORE WIRE
AGR silicone-insulated single-core wire
- Temperature range
- −60 °C (−76°F) to +180 °C (356°F) continuous; +200 °C (392°F) short-term (fixed installation)
- Continuous / short-term
- +180 °C (356°F) continuous, +200 °C (392°F) short-term
- Conductor
- Fine-stranded tinned copper, IEC 60228 Class 5
- Insulation
- Silicone rubber; no outer sheath
- Sizes
- 0.3 mm² to 16 mm²
- Outer diameter
- 1.8 mm (0.3 mm²) to 8.0 mm (16 mm²)
- Rated voltage
- U0/U 300/500 V from 0.5 mm²; 300/300 V below 0.5 mm²
- Minimum bend radius
- 6 × cable diameter (fixed installation)
- Ventilation
- Provide appropriate ventilation above +100 °C (212°F)
APPLICATION LIMITS
Automotive component wiring vs. high-voltage cable
Different parts of a vehicle are governed by different cable specifications.
- Component lead
- Wire inside a supplied part: size, insulation, length and termination to the part drawing.
- Battery-module lead
- Power and sampling leads within the module: confirm voltage, current and identification.
- Vehicle HV cable
- Traction and charging circuits: specify the automotive standard, screening and temperature class.
TECHNICAL DOCUMENTS
Datasheet & project checklist
Product datasheet and quotation checklist.
AGR silicone-insulated single-core wire
Construction, applications and size table.
Certification is model-specific; the marks on a datasheet do not replace a certificate.Automotive & EV brief
Send a drawing or existing cable specification with the following information.
What information helps?
- Component or module drawing with the circuit marked
- Required standard, voltage, current and temperature class
- Local heat, fluid exposure and vibration conditions
- Quantity, sample needs and required test documents
BEFORE YOU SPECIFY
Frequently asked questions
Is this an automotive high-voltage cable?
No. Our standard wires are not ISO 19642 or LV 216 cables. A cable to these standards can be reviewed as a custom project, with the required testing.
Why is silicone insulation used in vehicles?
The AGR wire shown uses silicone insulation and is rated up to +180 °C (356°F) continuously, with +200 °C (392°F) short-term exposure. Its datasheet does not list ISO 19642 or LV 216 compliance.
Which AGR sizes are available for component leads?
AGR silicone wire is listed from 0.3 mm² to 16 mm², with outside diameters from 1.8 mm to 8.0 mm. Other sizes and colours are made to order.
CUSTOM SUPPORT & ENQUIRY
Request a silicone cable quote
Need a custom size or construction? Send your drawing, operating conditions and required quantity for a quotation.
ApplicationAutomotive & EVEquipmentNot yet selected
claire@aycables.com