Abstract
This review provides an indepth analysis of the heat-resistance performance and associated technological trends of automotive wires, which are critical components of modern vehicle electrical and electronic (E/E) systems. This study begins with a comparative analysis of two key standards: the global ISO (International Organization for Standardization) 19642 series, which defines material performance limits through accelerated 3,000-h thermal aging tests, and the Japanese JASO (Japanese Automotive Standards Organization) D 625 series, which emphasizes practical durability based on a cumulative 10,000-h service-life concept. This study examines the evolution of insulating materials from conventional polyvinyl chloride (PVC) to widely used crosslinking polyolefins (XLPE/XLPO) and high-performance polymers, such as fluoropolymers, polyether ether ketone (PEEK), and silicone rubber, which are essential for extreme operating environments of electric vehicles and advanced driver assistance systems. Furthermore, it addresses the industry-wide trend of lightweighting by exploring the transition from copper to aluminum conductors, detailing the significant technical challenges, such as crimping reliability, oxide-film control, galvanic corrosion, and mechanical strength, along with their engineering solutions. The analysis concludes that future automotive wire technology faces new paradigms, including sophisticated thermal management for high-voltage systems, electromagnetic compatibility requirements for high-frequency electronics, and signal integrity demands for gigabit-speed data transmission. Consequently, the role of wiring harnesses is transforming from a collection of distributed components into a core vehicle infrastructure, requiring a multidisciplinary, system-level approach that integrates materials science with electrical, thermal, and E/E architectural engineering to drive future innovation.
Keywords: automotive wire;heat resistance;ISO 19642;JASO D 625;Electric Vehicles (EV);aluminum conductor;E/E architecture