TPU Thermoplastic Polyurethane is not a completely new material, but its use in cables has gradually matured in recent years. Compared with traditional materials, its value does not come from a single performance advantage. Instead, it balances multiple properties such as wear resistance, flexibility, oil resistance, and environmental stability, making it more adaptable in specific applications. Therefore, understanding TPU in cables is less about "what properties it has" and more about "what practical problems it solves."
A very practical question is:
Where should TPU Thermoplastic Polyurethane be used? When is it necessary? When should it not be used?
TPU is a type of thermoplastic polymer made by reacting polyols with isocyanates. Its molecular structure consists of soft and hard segments. This structure allows TPU to balance mechanical strength and flexibility well.
In wire and cable applications, TPU performance is not about a single standout property but its overall performance.
Wear resistance comes first. According to common DIN abrasion tests, TPU usually has a wear volume below 50 mm³, which is clearly better than most PVC materials. In real applications, this means TPU sheaths wear more slowly under dragging, floor contact, or long-term friction, extending cable life.
Flexibility and low-temperature performance are also important. TPU can stay soft even in low temperatures; some formulas remain bendable at -40℃. This is critical for outdoor cables and use in cold regions because materials that become brittle at low temperatures can crack easily during bending.
Chemical resistance is another advantage. TPU can resist motor oil, lubricants, and some coolants, making it suitable for new energy vehicles and industrial equipment without the performance degradation seen in some rubber materials.
Additionally, TPU is easy to process, can be formed using standard extrusion equipment, and allows stable diameter control. This is practical for cable manufacturers, as they can adopt TPU without major changes to their production lines.
It’s important to note that TPU in cables is not meant to replace high-voltage insulation but to improve overall reliability in complex environments. Therefore, it is mainly used in the sheath or outer protective layers, not in the core insulation.
In practice, TPU use depends on the scenario. Different cables have different material requirements, and TPU is often used where high mechanical performance is needed.
Charging cables are the most mature application of TPU in the cable industry, widely used in EV charging guns and charging pile cables.
Charging cables need frequent bending and long-term outdoor exposure, facing UV light, rain, and temperature changes. Conductor sizes usually range from 2.5 mm² to 35 mm², with overall cable diameters of 10 mm to 30 mm.
In these cables, the insulation layer typically uses XLPE or TPE, while TPU is chosen for the outer sheath to provide wear and weather resistance.
Common materials: TPU for EN50620 charging pile cables.
In industrial automation and robotics, drag chain cables face stricter requirements. They need high-frequency bending in limited spaces, with bending cycles reaching millions and bending radii of 5–10 times the cable diameter.
TPU is mainly used as a sheath material, 0.8–2.0 mm thick. Its high wear and tear resistance reduces sheath damage, and its strong tear resistance prevents mechanical cracking, ensuring long-term cable stability.
Common materials: TPU sheath for drag chain cables, TPU sheath for robot cables.
Cables in vehicle underbody wiring systems face occasional stone impacts and long-term vibration. TPU’s wear resistance, vibration resistance, and coolant resistance offer higher mechanical protection than PVC, providing better stability and service life.
TPU is mainly used for non-insulated core structures, such as underbody protection layers, high-voltage harness outer sheaths, and Ethernet or data cable sheaths.
Common materials: TPU for Ethernet cables.
With 5G optical communication, industrial communication, and in-vehicle Ethernet systems, cable material requirements have increased.
In data and optical fiber cables, TPU mainly improves structural stability. Fiber optic, communication, and in-vehicle Ethernet cables usually have small conductor cross-sections (0.13–0.35 mm²) and require strict diameter and structural stability. TPU maintains flexibility while keeping size stable, supporting long-term signal reliability.
Common materials: TPU for microtube optical fiber cables, TPU for Ethernet cables, TPU for communication cables.
Cables in wind power, outdoor power, submarine, and ship applications face humid, cold-hot alternating, and long-term UV conditions. Modified TPU formulations provide excellent weather resistance, making it widely used in these cables, mainly as ether-based TPU sheaths.
Common materials:
TPU sheath for ship cables,
TPU sheath for submarine cables
TPU sheath for wind power cables
TPU sheath for multi-core cables
high flame-retardant TPU cable sheath
high-performance power cable TPU sheath
Material selection in cables usually balances performance and cost. TPU does not fully replace traditional materials but acts as a supplement.
| Materials | Key Advantages | Main Limitations |
| PVC | Low cost, simple processing | Low heat resistance; environmental restrictions |
| Rubber | High temperature resistance, excellent flexibility | Low processing efficiency; average wear resistance |
| XLPE | Superior electrical properties | Lacks elasticity |
| TPU | Abrasion-resistant, flexible, oil-resistant | Relatively high cost |
High-voltage cables and insulation layers still mainly use XLPE.
For very high-temperature areas (above 150℃), silicone rubber is used.
TPU is suitable for sheath layers that require high mechanical performance.
When choosing TPU for engineering projects, key factors include:
Environment: Oil, UV, low temperature, etc., affect TPU formula selection.
Mechanical requirements: Bend frequency, wear resistance, etc., need TPU with appropriate hardness and structure.
Cable structure: TPU is better for sheaths, not high-voltage insulation.
Regulations and certification: Different markets have standards like UL, EN, which must be considered during material selection.
Common TPU materials for wires and cables:
High wear TPU: for robots, power tools, and high-dynamic applications.
Low-temperature TPU: for cables in cold regions.
High flame-retardant TPU: designed to VW-1 standard for higher safety.
Bio-based TPU: to reduce carbon emissions, supporting sustainability.
Q1: Can TPU be used to produce EV charging pile cables?
A1: Yes. TPU is mainly used for charging pile and charging cables. It can be used for both DC and AC charging cables. For example, Angreen's TPU for charging pile cables meets EN50620 international standards and CQC1692 product requirements. Options include glossy or matte surfaces, with fast extrusion and smooth, flow-free surfaces.
Q2: What flame-retardant level can TPU achieve?
A2: For Angreen TPU, flame retardancy can reach UL94 V0 and VW-1 standards, suitable for drag chain and robot cables.
Q3: Can optical fiber cable manufacturers use TPU, and what types are common?
A3: Yes, especially for microtube optical fiber cables. Common types include TPU for microtube cables, flame-retardant ether TPU 91ATPU for cables, and tear-resistant ether TPU 90ATPU.
Q4: Can Angreen TPU pass biocompatibility certification?
A4: Yes, Angreen has TPU for medical use, which can pass biocompatibility tests and has certification documents, suitable for medical device cables and visible catheters.
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