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Cable Design & Manufacturing of an EVJE Charging Cable for the Automotive Industry

EVJE Charging Cable
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EVJE Charging Cable
 

EIS Wire & Cable was approached by a key connector assembly supplier of electric charging units, located in Northern California, to partner with them on developing a new system which would require a custom cable to be compatible with residential and commercial charging applications. Working with the customer's connector designs, we developed this 4C composite charging cable from 3/C 14 AWG and 1/C 18 AWG and applied insulation made from thermoplastic elastomer and fibrillated polypropylene fillers. The cable had a diameter of .390" and was manufactured to tolerances of ±.010".


These cables were designed to be extremely flexible, handle 300 V, be lightweight, and withstand temperatures up to 60°C. They were also oil, water, and sunlight resistant and compatible w/ SAE J1772 connectors and NEC 625 charging stations. There were industry requirements for these cables as well, such as ANSI/UL 62 approval, EVE/EVJE level 1 and 2, and UL listing for indoor and outdoor use.

We fulfilled this order within the tight timeline of 2 weeks while delivering on all of the customer's requirements. Additional details on this cable design project can be found in the table below or contact us to learn more.

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Cable Design & Manufacturing Project Highlights

Product Name EVJE Charging Cable
Product Description EIS developed this charging cable for use within electrical car charging units.
Capabilities Applied/Processes Development
  • Designed in conjunction with customers connector designs
Wire Extrusion
Cable Core Twisting
Jacket Extrusion
Equipment Used to Manufacture Part Extruder
Cabler
Part Diameter .390"
Tightest Tolerances +/- .010"
Materials Used 4/C Composite Cable Made Up of:
3/C 14 AWG
1/C 18 AWG

Insulation: Thermoplastic Elastomer, Fibrillated Polypropylene Fillers
Colors Black
In process testing/inspection performed Dimensional
Electrical
Features 300 Volts
Extremely Flexible
Lightweight
Withstands Temperatures Up to 60°C
Resistant to:
  • Oil
  • Water
  • Sunlight
Compatible w/ SAE J1772 Connectors and NEC 625 Charging Stations
Industry for Use Automotive
  • Hybrid and Electric Vehicle Market
Turn Around Time Two weeks ARO
Delivery Location California
Standards Met UL
  • Listed for Indoor and Outdoor Use
EVJE
VW-1
ANSI/UL 62
RoHS Compliant
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