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Jaguar cars using battery cables with aluminium

Replacing copper in automotive battery cables

February 26, 2019

LEONI Kabel is replacing copper with aluminium in its automotive battery cables to save money and reduce weight. There is no difference in performance.

Passenger vehicles have more cabling than you might imagine. Your car probably has about 25 kg in total. Copper is the material traditionally used in the cables.

Extruded solid aluminium rod

The wiring systems and cable technology leader LEONI has partnered with Hydro to come up with an aluminium solution that replaces copper in its automotive battery cables. The cable is an extruded solid aluminium rod that is HYCOT®-coated with either PA, PE or XPE coatings.

automotive battery cables using aluminium

One-third the weight, same performance

It is one-third the weight of the copper cables and costs less. Their performance is the same.

LEONI is not the only large customer to substitute materials in its battery cables. Jaguar is also using aluminium instead of the heavier copper alternative.

These are individual, case-by-case processes with weight and cost savings as the incentives. And they are very successful cases, as well. 

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