Silicone Rubber Wire Application for Lithium Battery Systems

With its excellent high-temperature resistance, flexibility, and electrical performance, silicone insulated wires have become the ideal choice for lithium battery systems in drones. It’s able to operate stably in the temperature ranging from -60°C to +200°C  (with short-term temperature resistance reaching up to 250°C), makes silicone rubber insulated wire highly effective in addressing localized heating issues caused by high-rate discharge or fast charging of lithium batteries, thereby reducing the risk of short circuits.
Depending on it’s outstanding flexibility and bend resistance, silicone insulated wire is adapting to the high-frequency vibrations and tight-space wiring requirements during drone flights, making them particularly suitable for compact designs like FPV drones. In terms of electrical performance, silicone wires feature high insulation resistance and high-voltage resistance, making them suitable for safe connections in high-voltage lithium battery packs (such as 6S and above). Additionally, their chemical stability enables them to resist moisture, acids, alkalis, and UV rays, ensuring long-term reliability for outdoor use. In drone systems, silicone wires are commonly used for internal battery pack connections, power transmission from ESCs to motors, and BMS sensor wiring.
Compared to PVC and fluoro-plastic wires, silicone insulation wire offers a balanced performance in terms of temperature resistance, flexibility, and weight, making them the preferred solution for high-dynamic drone applications.
Hanstar provides a variety of high-quality silicone-insulated wires with different conductor specifications (6AWG-26AWG), insulation thicknesses, and certification standards (such as UL3132, UL3135, UL3239). Serving over 4,000 customers, we deliver reliable wiring solutions for lithium battery applications.