News - How to Make EV Cables More Durable, Scratch Resistant and flexible with UV Resistance

Flexible Cable Sheathing, Crack-Resistant Cable Elastomer, EV Charging Cable Materials, Eco Friendly Tpe, Modifier For Tpe, Durable EV Charging Cable Sheathing

Emerging EV Market Brings New Challenges for Cable Sheath Materials

With the rapid expansion of the new energy vehicle (EV) market, charging stations are becoming increasingly common at locations such as gas stations, parking facilities, and shopping centers. As essential infrastructure, the durability and safety of charging cables are critical to user experience and grid reliability. The sheath material—serving as the cable’s first line of defense—plays a decisive role in the commercial performance and service life of the entire application.

While thermoplastic elastomer (TPE) has been widely adopted in the wire and cable industry due to its rubber-like elasticity and plastic-like processability, it still presents certain limitations. In response, a new material—Si-TPV—has emerged as a high-performance alternative for cable sheathing. Recognized for its exceptional properties, it is gaining increased attention from manufacturers across the industry.

Limitations of Conventional TPE Materials as Protective Sheathing for EV Cables

Poor Weather Resistance, Prone to Cracking
While standard TPE offers decent abrasion resistance, its weak weather resistance is a significant drawback. Prolonged exposure to sunlight can cause the TPE surface to become sticky or brittle—particularly under high temperatures or extended UV exposure. Cracking often results from multiple factors, including suboptimal material formulation, insufficient antioxidants and stabilizers, the use of low-quality base materials, or improper addition of flame retardants, all of which may reduce flexibility and increase the risk of cracking.

Susceptibility to Scratching
During production and use, TPE cable surfaces are prone to scratching, which not only affects appearance but can also compromise mechanical properties and service life. Common causes include inadequate mold design, poor plasticization, and mechanical abrasion during handling or installation.

Poor Oil Resistance
EV cables may come into contact with oils in certain environments, such as charging stations co-located with fuel stations. Conventional TPE materials lack sufficient oil resistance, which can lead to cable failure under such conditions.

Insufficient Adhesion
During extrusion, the bonding between the TPE sheath and the conductor may be weak, reducing overall cable performance. Improving adhesion can be achieved through measures such as preheating the conductor, optimizing mold design, and adjusting material hardness.

How Si-TPV Provides Better Solution in Crack-Resistance, Durability and UV-Resistance Performance for EV Cables

Excellent Aging and UV Resistance
Even when consistently exposed to intense sunlight at charging stations, Si-TPV cable sheathing maintains long-term stability without chalking or cracking. The color remains vibrant, and the material effectively resists moisture erosion. This significantly extends the cable’s service life, ensuring both reliability and aesthetics throughout the product life cycle while reducing maintenance and replacement costs

Strong Bonding with PC, ABS, and Other Substrates
Si-TPV exhibits excellent compatibility with substrates such as PC and ABS. After injection molding, it forms a seamless and robust structure with high interfacial adhesion and bonding strength. Even under forceful pulling, stress is effectively dispersed without tearing at the interface. This ensures overall durability, structural integrity, and high-level protection for EV charging connectors.

Outstanding Abrasion Resistance and Weatherability
Si-TPV is inherently abrasion and scratch resistant. It resists scratching and abrasion even when dragged across rough concrete surfaces. Moreover, thanks to its superior weather resistance, this durability remains uncompromised through seasonal changes and years of exposure to sun, rain, and temperature variations. It guarantees long-term robustness and safety of cables, greatly enhancing end-product reliability.

Silky-Smooth Tactile Feel
Si-TPV delivers a silky, skin-friendly touch comparable to high-grade baby usings or silicone kitchenware, significantly improving user experience. Its inherent hydrophobicity repels water and allows mud and stains to be wiped away easily, keeping surfaces clean with minimal effort. This premium tactile quality also enhances the brand image and user perception of the entire charging station product.

Although the cost of Si-TPV material is higher than that of conventional TPE, its long-term safety, exceptional durability, and premium user experience make it an ideal choice for high-end and high-reliability charging cable applications. It fully aligns with the market's stringent requirements for quality and service life in charging infrastructure. To discover how Si-TPV give your most reliable solution. Contact us via amy.wang@silike.cn, and visit our website www.si-tpv.com to learn more.

Post time: Sep-19-2025