In the new energy vehicle (NEV) sector, the safety and reliability of high-voltage electrical systems are critical to overall vehicle performance and user protection. These systems operate under high voltage and current, strong electromagnetic environments, and are often exposed to vibration, temperature fluctuations, and chemical exposure. As a result, automakers and suppliers are increasingly demanding integrated solutions that provide insulation, mechanical protection, flame retardancy, and clear visual identification.

Orange Series high-voltage heat shrink tubing has become an essential component to address these needs, especially in battery systems, high-voltage distribution units, on-board chargers, and motor drive connections.

1. High-Voltage Identification and Industry Standards

In NEVs, orange has become the universal identification color for high-voltage systems. Orange heat shrink tubing, such as Oranergy-S busbar heat shrink tubing, offers high visual contrast, enabling quick identification during assembly, maintenance, or emergency situations. This color coding helps comply with international and regional automotive safety standards and significantly reduces misoperation risks, safeguarding both personnel and equipment.

2. Insulation Protection and Flame Retardancy

Manufactured from flame-retardant polyolefin or modified high-performance polymers, orange heat shrink tubing provides excellent dielectric strength—≥15?kV/mm (some products up to ≥20?kV/mm)—effectively preventing dielectric breakdown and creepage. In terms of flame resistance, these products meet UL224 VW-1, UL94 V0 standards, ensuring that even in case of localized overheating or short circuits, the tubing slows flame propagation and allows valuable time for safety measures.

3. Material Advantages for NEV Operating Conditions

High-voltage components in NEVs are often positioned in battery compartments, underbody harnesses, engine bays, or exposed areas where they are subject to hot-cold cycles, long-term vibrations, and exposure to liquids such as coolant, antifreeze, and lubricants.

The Orange Series provides tailored solutions for different needs:

Oranergy-S (Single-wall orange busbar tubing): Soft and lightweight, ideal for complex geometries such as laminated busbars.

Shrivox-R (High-voltage resistant busbar tubing): High mechanical strength, designed for 1?kV–35?kV busbar applications, durable and flame retardant, available in multiple colors for section management.

Shrivox-F (Flexible high-voltage busbar tubing): Large shrink ratio (2.5:1), excellent flexibility for both straight and bent busbars, suitable for confined spaces and irregular shapes.

4. Key Application Areas in NEVs

Battery Packs and High-Voltage Distribution Units (PDU)
Providing both insulation and high-voltage safety marking for busbars and cable connections.

On-Board Chargers (OBC) and High-Voltage Connectors
Offering reliable protection against electrical stress, mechanical damage, and environmental exposure.

Motor Drive and Inverter Connections
Ensuring long-term insulation stability under high-frequency vibration and elevated temperatures.

Vehicle High-Voltage Harnesses
Used for continuous or localized marking and reinforcement, improving cable routing safety and aesthetics.

5. Selection and Usage Guidelines

Temperature Rating: Standard NEV systems may use tubing rated at -55?°C to 125?°C; for prolonged high-temperature zones (e.g., near motor busbars), choose higher temperature grades.

Shrink Ratio and Size: Select 2:1 or 2.5:1 shrink ratio depending on the busbar or cable diameter; ensure snug fit after recovery for optimal insulation performance.

Flexibility and Wall Thickness: Use flexible types (e.g., Shrivox-F) for bends or tight routing, and high-strength types (e.g., Shrivox-R) for large straight busbars.

Compliance: Ensure products meet UL, RoHS, and REACH standards for global compliance and OEM approval.

6. Purchasing & Collaboration Tips

When sourcing Orange Series high-voltage heat shrink tubing, assess the intended installation location, working voltage, environmental exposure, and safety certifications. Partnering with a qualified supplier that offers custom dimensions, color matching, and shrink ratios ensures the tubing meets your NEV program’s specifications and performance targets.

We provide a complete range of orange high-voltage heat shrink products optimized for NEV applications, delivering stable, high-performance insulation and safety marking solutions.