As new energy vehicles (NEVs) grow quickly around the world, the performance requirements for automotive materials are changing. Higher voltage systems, stronger lightweight targets, and more complex thermal systems all require better materials for wire harnesses, cables, and structural parts.
In traditional automotive cables, crosslinked polyethylene (XLPE) and silicone rubber are still widely used.
However, in NEV systems—especially in high-voltage platforms, charging systems, and data communication systems
TPU (thermoplastic polyurethane) has become an important complementary material.
TPU combines the flexibility of rubber with the strength of engineering plastics. It offers balanced performance in abrasion resistance, oil resistance, weather resistance, electrical insulation, and environmental compliance. This makes it suitable for both high performance and sustainability needs in electric vehicles.
NEVs operate under demanding conditions:
High voltage systems, often 600V-1000V
High temperatures in motor and battery compartments
Long-term vibration and mechanical stress
Contact with coolant, electrolyte, and lubricants
Strict flame retardant and low-smoke requirements
Traditional PVC may age quickly under high heat. Silicone or Rubber materials may have limits in abrasion resistance and processing efficiency. Compared with these materials, specially formulated TPU offers several advantages.
TPU shows strong resistance to engine oil, coolant, and some battery-related fluids. It is suitable for battery systems and chassis wiring areas.
With proper halogen-free flame retardant systems, TPU can meet common automotive cable standards such as UL94 V-0 or GB/T 2408 levels. It also helps reduce corrosive gases during combustion.
TPU provides stable dielectric performance. It can be used in some high-voltage cable sheath designs and signal cable insulation layers. It supports the needs of high-voltage NEV platforms.
In areas with frequent bending or friction, such as underbody wiring or charging cables, TPU offers strong wear resistance. This helps extend cable service life.
TPU can support thinner wall designs while keeping good mechanical strength. This helps reduce overall vehicle weight.
As TPU technology develops, it is used in several NEV systems.
In high-voltage connections between the battery and the drive system, TPU is often used as an outer sheath or protective layer. It provides:
Abrasion and impact protection
Halogen-free and low-smoke design options
Suitability for charging cables and movable high-voltage cables
In charging station cables, TPU is widely used because of its flexibility and environmental resistance.
TPU can be used for:
Battery pack sealing strips
Cushion pads between modules
Parts in thermal management systems
It keeps good elasticity at both low and high temperatures. This makes it suitable for complex thermal cycles in battery systems.
NEVs use more communication systems, such as automotive Ethernet, radar, and camera wiring.
TPU can be applied to:
Ethernet cable sheaths
Outer layers of data cables with light abrasion needs
Flexible harness coverings
In applications that require both flexibility and wear resistance, TPU has advantages over traditional PVC.
In non-load-bearing parts, TPU can replace some traditional materials:
Soft-touch interior components
Weather-resistant exterior trims
Waterproof sealing structures for charging ports
TPU offers good UV resistance and weather resistance. It is suitable for long-term outdoor exposure.
As NEV platforms continue to improve, TPU materials are also being optimized.
For automotive Ethernet cables and complex wiring layouts, new TPU grades are developed with higher abrasion resistance and stable processing performance. These materials support lightweight and reliable harness systems.
TPU made partly from renewable raw materials is being developed to help reduce carbon footprint. These materials maintain basic mechanical performance while supporting sustainability goals in the NEV supply chain.
TPU does not fully replace crosslinked polyethylene or silicone rubber. Instead, it works together with them in NEV material systems:
High-voltage insulation layers mainly use crosslinked polyethylene
Very high temperature areas often use silicone rubber
Abrasion-resistant sheaths, flexible parts, and charging cables are well suited for TPU
A proper combination of materials is key to long-term stability of NEV cable systems.
The growth of new energy vehicles is driving material upgrades. With its abrasion resistance, oil resistance, flexibility, and environmental compliance, TPU plays an increasingly important role in high-voltage cable sheaths, battery components, vehicle data harnesses, and charging systems.
As voltage platforms increase and lightweight targets become stricter, TPU will take on a clearer and more specialized role in NEV material systems.
