Another way to reduce weight is to replace copper wire with aluminum wire. However, when aluminum conductors are used, corrosion can occur between the aluminum conductors and the copper connectors. This problem has been solved today, and engineers have overcome the problem by applying a lightweight coating that prevents corrosion on aluminum conductors or terminals. Replacing copper conductors with aluminum conductors can reduce wiring quality and cost by up to 50%.
The use of breakout connectors can also reduce wire usage and cost. A distribution connector mounted on the battery pack can be connected to multiple electrical devices, eliminating the need for downstream wiring harness distribution devices, thus reducing the number of connectors and wiring in the car.