‌SGX Automotive Wire‌

‌1. Technical Parameters‌

• ‌Standard:‌ Primarily defined by Japanese OEM specifications (e.g., Toyota, Honda, Nissan), often aligning with ‌JASO D611‌ (Japanese Automotive Standards Organization). Complies with core requirements of ‌SAE J1127‌ for cross-linked wires.
• ‌Conductor:‌
  • Material: Annealed, stranded, uncoated high-purity copper (SAE Type 2 equivalent).
  • Stranding: Fine-stranded (typically ≥ 16 strands) for flexibility and vibration resistance.
• ‌Insulation:‌
  • Material: ‌Cross-Linked Polyethylene (XLPE)‌. The "X" denotes cross-linking.
  • ‌Wall Thickness: Ultra-Thin Wall‌, comparable to or slightly thicker than TXL but significantly thinner than SXL/GPT. (e.g., Min. Wall for 20 AWG ≈ 0.35mm / 13.8 mils vs TXL's 0.27mm / 10.6 mils).
  • Color: Solid colors or tracers per OEM-specific standards (e.g., Toyota, Nissan color codes).
• ‌Dimensions:‌
  • Gauge: Standard AWG sizes (e.g., 24 AWG to 8 AWG).
  • OD (Outer Diameter): Slightly larger than TXL due to marginally thicker insulation, but smaller than GPT or SXL. Measured per OEM/JASO specs.
• ‌Identification:‌ Surface printed with OEM specification (e.g., "TOYOTA SGX", "SGX", "JASO D611"), gauge, manufacturer ID, and traceability codes. High-durability ink required.

‌2. Electrical Performance‌

• ‌Voltage Rating:‌ 50 Volts DC nominal automotive systems.
• ‌Dielectric Strength:‌ ≥ 1,000 volts AC/minute (after conditioning/short-term aging) – per SAE J1127/JASO core tests.
• ‌Insulation Resistance:‌ ≥ 100 MΩ per 1,000 ft at 75°F (24°C) after humidity exposure – per SAE J1127/JASO.
• ‌Current Carrying Capacity:‌ Similar to TXL/SXL for equivalent gauge, governed by conductor size and insulation thermal limits. Specific derating per OEM harness design rules.

‌3. Performance Specifications & Application Requirements‌

• ‌Temperature Rating:‌ ‌-40°C to +150°C (-40°F to +302°F)‌ continuous. ‌Key differentiator:‌ Higher continuous rating than TXL/SXL (125°C).
• ‌Chemical/Fluid Resistance:‌ ‌Exceptional resistance, specifically optimized for modern engine bay fluids:‌
  • High resistance to gasoline (including ethanol blends), diesel, engine oil (synthetic & conventional), transmission fluid (ATF, CVT), brake fluid (DOT 3/4), coolant, battery acid.
  • ‌Critical Requirement:‌ Superior resistance to ‌fuel injection cleaner additives‌ and ‌refrigerant oils (PAG, POE)‌ compared to standard TXL.
• ‌Abrasion Resistance:‌ High resistance to mechanical abrasion, chafing, and vibration (tested per OEM/JASO methods, typically exceeding SAE J1127 min. 150 cycles).
• ‌Heat Aging:‌ Excellent retention of flexibility and electrical properties after extended exposure to 150°C (critical for near-turbo/exhaust applications).
• ‌Cold Flexibility:‌ No cracking at -40°C (bend/impact tests).
• ‌Flame Retardancy:‌ Self-extinguishing per SAE J1127/JASO test methods.
• ‌Environmental Resistance:‌ Resistant to humidity, moisture (salt spray), ozone, and UV degradation.
• ‌Deformation/Cut-Through Resistance:‌ Good resistance at high temperatures, though less than thick-wall SXL.

‌4. Primary Applications & Usage‌

• ‌Purpose:‌ Designed for ‌ultra-high-temperature, chemically demanding underhood circuits‌ in modern vehicles, particularly Japanese models. Used where standard TXL (125°C) is insufficient but thick-wall SXL is not required for space/weight constraints.
• ‌Typical Vehicle Circuits:‌
  • ‌Direct fuel injector wiring‌ (highest priority - extreme heat + fuel/cleaner exposure).
  • Turbocharger sensors/actuators (exhaust manifold proximity).
  • EGR system components.
  • Oxygen sensor connectors (near exhaust).
  • Engine control unit (ECU) to sensor/actuator circuits in high-heat zones.
  • Hybrid/electric vehicle power electronics cooling systems.
  • Transmission control sensors (high ATF temps).
• ‌Key Advantages:‌
  • ‌150°C Continuous Temperature Rating‌ (superior to TXL/SXL's 125°C).
  • ‌Enhanced Chemical Resistance‌ to aggressive modern fluids, especially fuel injector cleaners and refrigeration oils.
  • ‌Space/Weight Savings‌ due to ultra-thin wall insulation (vs. SXL).
  • Robust mechanical and environmental performance.

• ‌OEM Requirement:‌ ‌Mandated‌ by specific Japanese automakers (especially Toyota, Lexus, Honda, Acura, Nissan, Infiniti) for designated high-heat circuits. ‌Must‌ meet exact OEM specifications (e.g., Toyota TS-001, Honda N-001, Nissan 01-001).

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• Summary of American Automotive Wire

• ●TWP---ThinWall, Thermoplastic Insulated

• ●GPT---GeneralPurpose,Thermoplastic Insulated

• ●HDT---HeavyDuty,Thermoplastic Insulated

• ·●STS---StandardDuty,Thermoset Elastomer(Synthetic Rubber) Insulated

• ●HTS---Heavy Duty, Thermoset Elastomer(Synthetic Rubber) Insulated

• ·●TXL---Thin Wall, Corss(X) Linked Polyolefin insulated

• ●GXL---General Purpose,Corss(X) Linked Polyolefin insulated

• ●SXL---SpecialPurpose, Corss(X) Linked Polyolefin insulated

• ·●TWE---ThinWall, Thermoplastic Elastomer Insulated

• ·●GTE---General Purpose, Thermoplastic Elastomer Insulated

• ●THE---HeavyDuty, Thermoplastic Elastomer Insulated

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