EXRAD® ERGOFLEX ISO 19642-9 Thin-Wall Shielded HV Battery Cable

    Product features:
  • Ultimate Flexibility
  • Superior Compression Set
  • EV / HEV

EXRAD® ERGOFLEX thin-wall battery cable is a revolutionary highly flexible Irradiation Cross-linked Elastomeric Polyolefin insulation (XLPO) which meets ISO 19642-5 Class D, including all fluid tests such as battery acid, motor oils, power steering and ATF.

These ultra-flexible cables are easier to work with and install especially with regard to tight bend radii.  EXRAD ERGOFLEX is designed to reduce operator ergonomic stress and fatigue while handling cable harnesses.  This state-of-the-art insulation material has excellent compression set characteristics which allows for maintaining proper connector sealing over time and thermal stresses.

The EXRAD ERGOFLEX product is perfectly suited for applications; especially conventional, hybrid and electric vehicles; where a combination of flexibility, long life, thermal robustness and high performance is required.

See the Case Study below for the story of how this next-generation cable technology came to be.

  • High Temperature Rating: 150°C
  • Low Temperature Rating: -55°C
  • Voltage Rating: 1,000V
  • Flame Resistance: FT-2
  • Oil Temperature Rating: 60C°C
  • Ultraviolet Resistance: Black/Orange
  • Flexibility Rating: 5
  • Fluid Resistance Rating: 4
  • Cut-Through Resistance Rating: 3

Specifications

Product

Number

Conductor

Bare Copper

Conductor

Diameter

mm / nom

Primary

Diameter

mm / nom

Shield

Diameter    mm / nom

Shield

Coverage

min

Finished

Diameter  mm / nom

Static

Bend

Radius

mm / min

Finished

Weight

kg/KM, nom

Max Conductor

Resistance

20°C

M  per M

EXRAD-EF/EF-TW-3 3.0m² (44/.29) 2.16 3.2 3.57 95% 4.6 23 49 6.15
EXRAD-EF/EF-TW-5 5.0mm² (70/.29) 2.72 4.05 4.42 95% 5.7 29 74 3.94
EXRAD–EF/EF-TW-6 6.0mm² (84/.30) 3.09 4.15 4.9 95% 5.8 30 90 3.01
EXRAD–EF/EF-TW-10 10mm² (144/.46) 3.99 5.65 6.1 95% 7.8 39 105 1.78
EXRAD–EF/EF-TW-12 12mm² (175/.29) 4.72 6.15 6.7 95% 8.3 42 177 1.47
EXRAD–EF/EF-TW-16 16mm² (224/.30) 5.59 6.8 7.3 95% 9.3 47 226 1.16
EXRAD–EF/EF-TW-20 20mm² (247/.32) 6.02 7.4 8.6 95% 9.9 50 261 0.91
EXRAD–EF/EF-TW-25 25mm² (364/.29) 6.86 8.3 9.5 95% 11 55 321 0.72
EXRAD–EF/EF-TW-35 35mm² (1083/.20) 7.87 9.9 10.4 95% 12.9 77 439 0.53
EXRAD–EF/EF-TW-50 50mm² (1615/.20) 9.91 11.6 12.2 95% 14.9 89 615 0.36
EXRAD-EF/EF-TW-70 70mm²  (2128/.20) 11.94 13.7 15.2 95% 17.0 102 900 0.26
EXRAD-EF/EF-TW-95 95mm²  (2926/.20) 13.97 16.0 17.7 95% 19.5 114 1,081 0.19
ISO 19642 Section Description Requirement Typical Results (35mm2 Sample)
6.1.1 Outside Cable Diameter 13.2mm max. 12.97mm Pass
6.1.2 Ovality of Sheath 10% max 3.4% Pass
5.1.1 Inner Core Diameter 10.4mm max. 9.91mm Pass
5.1.2 Insulation Thickness 0.64mm min. 0.99mm Pass
5.1.3 Conductor Diameter 9.0mm max. 7.87mm Pass
5.2.1 Conductor Resistance 0.527 mΩ/m  max. 0.450 mΩ/m Pass
5.2.2 Withstand Voltage 10kV for 5min No dielectric breakdown Pass
5.2.4 Insulation Faults Sparktest @ 8.0kV No breakdown Pass
5.2.5 Insulation Volume Resistivity 1012 Ω /mm min. 1.25 x 1015 Ω /mm Pass
6.2.3.2 DC Resistance of Screen Per customer agreement 3.95mΩ/m NA
6.2.3.3 Surface Transfer Imp. - Tri Axial Per customer agreement Inquire NA
6.3.3 Flexibility Test Customer-Defined 101.4 N NA
5.4.2 6.4.2 Long-Term Heat Aging 150°C, 3000 hrs, 3kV, no breakdown No cracks, No breakdown Pass
5.4.3 6.4.3 Short-Term Heat Aging 175°C, 240hrs, 3kV, no breakdown No cracks, No breakdown Pass
5.4.4  6.4.4 Thermal Overload 200°C, 6 hrs, 5Kv No cracks, No breakdown Pass
5.4.5 Pressure at High Temperature Under load @150°C, 5kV 5min, no breakdown No cracks, No breakdown Pass
6.4.5 Pressure at High Temperature Thickness of insulation to be > 40% 92% Pass
5.4.6  6.4.6 Shrinkage by heat                              Insulation and Sheath 2mm max. @ 150°C 0.0 mm Pass
6.4.7 Low Temperature Winding 4 hrs @ -40°C, 3kV, no breakdown No cracks, No breakdown Pass
6.4.8 Cold Impact 16 hrs @ -15°C, 1kV,  no breakdown No cracks, No breakdown Pass
6.4.9 Temperature and Humidity Cycling 40 x 8 hour cycles -40°C to 150°C, relative humidity  80 -100%, 3kV No cracks, No breakdown Pass
5.4.10 Resistance to hot water 35 days in 85C water, IR not less than 1012 Ω/mm 4.46 x 1014 Ω/mm, no breakdown Pass
6.4.10 Resistance to liquid chemicals Groups 1 and 2, no breakdown. All fluids: no crack/damage/breakdown Pass
5.4.14 Ozone Resistance 65°C, 192 hours, Ozone (1+/- 0.05) x 10-6 No cracks Pass
6.4.14 Resistance to Flame Propagation Must extinguish within 30 sec. max. and a min of 50mm unburned 5.2 sec. Pass