2/28/2026
With the rapid growth of electric vehicles (EVs), many cable manufacturers are shifting toward the EV charging cable and charging infrastructure industry. This trend has also driven demand for advanced cable materials such as elastomers.
Because EV charging cables are often used in demanding outdoor environments, the material requirements are very strict.
The cable sheath (outer jacket)protects the insulation layer from water, air, and external damage. Common sheath materials include TPE, TPU, XLPO, NBR+PVC, and neoprene rubber.
Among them, TPU (Thermoplastic Polyurethane)has become a preferred material for EV charging cables due to its excellent performance.
Natural Environment
EV charging cables are often exposed to outdoor conditions such as:
Therefore, charging cables must provide:
These features are especially important in regions with harsh climates.
During daily use, charging cables are frequently:
To prevent damage, cables must offer:
In addition, cables may be exposed to acidic or alkaline liquids, requiring good chemical resistance.
In addition to power transmission, EV charging cables also support communication and control functionsduring the charging process.
EV charging typically involves:
Therefore, cable materials must provide:
The cable sheath is the outermost layer of the cable, protecting the insulation from moisture and mechanical damage. Because of this, sheath materials must meet strict performance standards.
TPU (Thermoplastic Polyurethane Elastomer) is a unique elastomer with:
For EV charging cables, polyether-based TPU is commonly used because it provides better hydrolysis resistance, strength, and low-temperature performance.
| Property | Unit | XLPO | TPE | Polyether TPU |
| Hardness | Shore A | 85 | 85 | 85 |
| Tensile Strength | MPa | 10–20 | 10–20 | 25–50 |
| Elongation | % | 150–300 | 300–700 | 500–800 |
| Resilience | % | 10 | 30 | 40 |
| Density | g/cm³ | 1.4 | 1.1 | 1.1 |
| Heat Resistance | °C | 125 | 125 | 125 |
| Low Temperature Resistance | °C | -25 | -40 | -50 |
| Brittle Temperature | °C | -40 | -60 | -70 |
| Tear Strength | kN/m | 30 | 30 | 80 |
| Abrasion Resistance | — | Excellent | Good | Excellent |
| Flex Resistance | — | Good | Good | Excellent |
| Oil Resistance | — | Excellent | Good | Excellent |
| Water Resistance | — | Excellent | Good | Excellent |
| Halogen-Free Flame Retardant | — | Good | Good | Excellent |
| Weather Resistance | — | Good | Good | Excellent |
Based on the comparison above, polyether TPU offers significant advantages:
1. Superior Mechanical Strength
TPU provides tensile strength above 25 MPa, much higher than other materials.
With elongation over 500%, it delivers excellent load capacity, impact resistance, and vibration absorption.
2. Excellent Low-Temperature Performance
TPU can withstand temperatures as low as −50°C, making it suitable for cold climates and northern regions.
3. Outstanding Tear Resistance
With a tear strength of up to 80 kN/m, TPU effectively prevents sheath cracking.
4. Halogen-Free Flame Retardant
TPU materials can achieve halogen-free flame retardancy, reducing environmental impact.
5. Excellent Durability
Polyether TPU also provides outstanding:
Based on the performance comparison of different sheath materials, polyether TPU demonstrates clear advantages for EV charging cable applications.
With its excellent mechanical strength, flexibility, weather resistance, and safety performance, TPU has become one of the most reliable materials for modern EV charging cables.
The following are our popular EV charging products that you may be interested in. If you have any questions, please feel free to contact us, and our specialists will answer within 24 hours.
