Cables, Components and Complexity – IDTechEx Covers Copper’s Role in Vehicles
Copper can be found in almost every electrical component in a large network of components that make up the inner workings of vehicles. IDTechEx’s report, “Copper Demand for Cars 2024-2034: Trends, Utilization, Forecasts”, looks at the main applications and benefits of metal within the automotive industry.
Copper wiring and autonomous systems
Copper has been used in cars for as long as vehicles have had electrically powered features. Its main use today is as the vehicle’s central nervous system, connecting a network of sensors, actuators, displays, and more to the vehicle’s ECU brains. Companies such as Tesla are working towards a more simplified and efficient vehicle communication network, with better utilization of fewer wires, but copper will still be just as necessary as wires. As cars evolve and utilize more electronic components, the demand for wiring will inevitably increase.
Advanced driver assistance systems (ADAS) will be one of the main reasons for increased vehicle network complexity and a growing wiring harness. As the developments in autonomous driving continue to flourish, sensors such as cameras and radar will rely upon increased wiring in the vehicle to perform, using copper specifically within their internal circuit boards.
Copper’s role in vehicle electrification
While rising automation features will increase wiring, the main factor driving demand for copper will come from electrification within the automotive sector, with motors and batteries being copper intense in their composition. Every cell within a battery, which could number in the hundreds or thousands, will use copper foil to transport its power outwards. Copper bars are then used to transfer power from each cell to high voltage cables, reaching the motor and power electronics, highlighting the metal as playing a large role in the smooth-running of electric vehicle technology.
Rare earth materials were previously a common choice for permanent magnets in electric motors; however, these are trickier to source and are known for their negative environmental impacts and volatile prices. These factors have created space for new motor technologies and materials to replace rare earths, with copper being a strong choice. Copper windings on a wound rotor motor can be named as one of the best magnet-free alternatives, which will greatly increase the demand for copper as this type of motor could contain over double the amount of copper used in a permanent magnet motor.
Why copper?
Balancing conductivity with price is one of the main reasons copper is such a popular choice within the automotive industry, as it has a high enough conductivity to perform as needed and is not as expensive as alternatives such as silver or gold. Its high melting point allows it to work in engine bays without its performance being hindered by melting or becoming out of shape. Even when copper corrodes, it retains its conductivity, and is malleable, not breaking under vibration. IDTechEx’s report identifies aluminum as a viable alternative to copper, which is gaining interest within the industry due to its lower cost and reduced weight. However, corrosion is more of an issue for aluminum, and its melting temperature is lower than that of copper and is close to engine exhaust temperatures.
IDTechEx reports that the annual demand for copper in the automotive industry was over 3MT in 2023 and is predicted to increase by a further 2MT by 2034, with a compound annual growth rate of 4.8%. The latest report, www.IDTechEx.com/CopperForCars, goes into great detail about the emergence of copper as a main metal used in automotive manufacturing and explores its relevance in vehicle electrification. Downloadable sample pages are available for this report.
For the full portfolio of electric vehicle market research by IDTechEx, please visit www.IDTechEx.com/Research/EV.