Applications of TPU in Electrical and Industrial Cables
TPU in wire and cables
Thermoplastic Polyurethane (TPU) is a highly versatile polymer that combines the properties of both plastic and rubber. Known for its excellent mechanical strength, flexibility, abrasion resistance, and chemical resistance, TPU is widely used in various applications, particularly in electrical and industrial cables. Below, we explore the key applications of TPU in these industries.
1. Cable Jackets
TPU is commonly used as the outer jacket or sheath of electrical and industrial cables due to its superior mechanical properties, including resistance to wear, tear, and environmental factors.
Key Benefits of TPU Jackets:
- Durability and Wear Resistance: TPU offers outstanding abrasion resistance, making it suitable for cables exposed to physical wear and friction.
- Abrasion Resistance: TPU shows >2000 cycles in abrasion resistance, as per ISO 4649 testing, making it ideal for high-stress environments.
- Flexibility: TPU maintains its flexibility even in low temperatures, allowing cables to perform in extreme conditions without cracking.
- Low-Temperature Flexibility: TPU remains flexible at temperatures as low as 40°C, ensuring reliable performance in cold environments.
- Chemical and Oil Resistance: TPU provides excellent resistance to oils, fuels, and various chemicals, which is crucial for industrial cables exposed to harsh environments.
- Chemical Resistance: TPU resists oils, fuels, and solvents, making it suitable for use in petrochemical, automotive, and industrial cable applications.
| Property | Measurement/Standard | Benefit |
|---|---|---|
| Abrasion Resistance | >2000 cycles (ISO 4649) | High wear and tear resistance in industrial settings |
| Low-Temperature Flexibility | -40°C | Flexibility even in extremely cold environments |
| Chemical Resistance | Resistance to oils, fuels, and solvents | Ideal for cables used in chemical and industrial environments |
2. Cable Insulation
TPU is also used as insulation material in electrical cables, especially in environments where flexibility, strength, and electrical performance are critical. It helps maintain electrical integrity while ensuring durability and flexibility.
Key Benefits of TPU Insulation:
- Electrical Insulation: TPU provides excellent dielectric properties, which prevent electrical leakage and ensure the safety of cables.
- Dielectric Strength: TPU typically offers a dielectric strength of >25 kV/mm, making it suitable for medium- and high-voltage cables.
- Thermal Stability: TPU is capable of withstanding high temperatures, ensuring the insulation remains intact and effective under heat stress.
- Operating Temperature Range: TPU insulation can operate at temperatures ranging from 40°C to +125°C.
- Environmental Protection: TPU insulation offers resistance to moisture, UV radiation, and ozone, which enhances the longevity of cables exposed to outdoor environments.
- UV Resistance: TPU provides excellent resistance to UV light, maintaining its mechanical and electrical properties even with prolonged exposure.
| Property | Measurement/Standard | Benefit |
|---|---|---|
| Dielectric Strength | >25 kV/mm | High electrical insulation capacity |
| Operating Temperature | -40°C to +125°C | Reliable performance in wide temperature ranges |
| UV Resistance | High | Ideal for outdoor and exposed installations |
3. Flexible and Moving Cables
TPU is widely used in flexible cables that are exposed to continuous bending, movement, or vibration. These types of cables are often found in robotics, automation, and heavy machinery applications.
Key Benefits of TPU in Flexible Cables:
- Flexibility and Elasticity: TPU’s high elasticity and flexibility allow cables to bend and twist repeatedly without damaging the internal components.
- Flexural Endurance: TPU cables can endure more than 10 million bending cycles, making them suitable for applications involving constant motion.
- High Mechanical Strength: TPU offers high tensile strength and resilience, ensuring that cables maintain their integrity under mechanical stress.
- Tensile Strength: TPU cables typically have a tensile strength of 30-60 MPa, making them resistant to breaking or stretching.
- Abrasion Resistance: TPU’s abrasion resistance ensures that flexible cables can withstand repeated friction in dynamic environments.
- Abrasion Resistance: TPU provides abrasion resistance levels of >3000 cycles in industrial cable applications.
| Property | Measurement/Standard | Benefit |
|---|---|---|
| Flexural Endurance | >10 million bending cycles | Suitable for cables exposed to constant movement |
| Tensile Strength | 30-60 MPa | High mechanical strength and resistance to stress |
| Abrasion Resistance | >3000 cycles (ISO 4649) | Ideal for cables in dynamic and abrasive environments |
4. Low-Voltage and High-Voltage Power Cables
TPU is also utilized in both low-voltage and high-voltage power cables, particularly in industrial applications where both flexibility and durability are required.
Key Benefits of TPU in Power Cables:
- Enhanced Electrical Performance: TPU ensures that the electrical conductors are well-insulated, preventing short circuits and electrical failures.
- Dielectric Constant: TPU’s dielectric constant is typically 2.2-2.5, which makes it ideal for insulating cables in high-voltage systems.
- High-Temperature Resistance: TPU’s high thermal stability allows it to be used in power cables operating in environments with fluctuating temperatures.
- Thermal Stability: TPU cables can withstand temperatures ranging from 40°C to +125°C, making them suitable for harsh industrial environments.
| Property | Measurement/Standard | Benefit |
|---|---|---|
| Dielectric Constant | 2.2-2.5 | Suitable for electrical insulation in power cables |
| Thermal Stability | -40°C to +125°C | Withstands high-temperature environments without degradation |
5. Hybrid Cables for Automotive and Industrial Applications
In automotive and industrial settings, TPU is used in hybrid cables that combine power and signal transmission within the same cable. TPU ensures that both the power conductors and signal wires are well protected and able to perform in demanding environments.
Key Benefits of TPU in Hybrid Cables:
- Multi-Functionality: TPU’s flexibility allows the cable to carry both power and data signals without interference, making it ideal for hybrid cables used in automation, robotics, and automotive applications.
- Signal Integrity: TPU helps maintain signal integrity while providing reliable power transmission, even in harsh industrial environments.
- Impact Resistance: TPU’s impact resistance makes it suitable for cables that need to endure vibration, shock, and physical stress in automotive and machinery applications.
- Impact Resistance: TPU hybrid cables are rated for impact resistance of up to 3 J, ensuring reliability in tough environments.
| Property | Measurement/Standard | Benefit |
|---|---|---|
| Signal Integrity | High | Ensures reliable data transmission in hybrid cables |
| Impact Resistance | 3 J (Impact Rating) | Withstands physical stress and shocks in automotive and industrial applications |
Conclusion
TPU (Thermoplastic Polyurethane) is an essential material used in a variety of applications in electrical and industrial cables. Its excellent mechanical strength, flexibility, abrasion resistance, chemical resistance, and thermal stability make it an ideal choice for power cables, flexible cables, hybrid cables, and cable sheathing. TPU ensures the longevity, performance, and safety of cables in environments exposed to high stress, temperature variations, and mechanical wear, making it a critical material for demanding industrial applications.