Jan 21, 2026
As global regulations like EU REACH and US EPA TSCA tighten restrictions on "forever chemicals" (PFAS), automotive and industrial engineers face a critical challenge: How do we replace fluoropolymers (like PTFE, FEP, and ETFE) in high-temperature cables without sacrificing performance?
For decades, fluoropolymers have been the gold standard for heat resistance, chemical inertness, and dielectric strength. However, the transition to PFAS-free alternatives is no longer optional—it is a supply chain necessity.
The biggest misconception is that no other material can handle 200°C environments. While difficult, modern polymer engineering has developed robust alternatives that are fully compliant:
TPX: Offers excellent fatigue resistance and high-temperature performance, making it a strong contender for dynamic applications.
PEEK: Through advanced irradiation cross-linking, peek can achieve temperature about 260°C, suitable for many under-hood automotive applications.
TPI: A lighter, recyclable alternative with superior dielectric properties, often used in thin-wall wires.
Specialized Silicone Rubbers: For extreme heat (200°C+), treated silicone formulations offer the necessary thermal stability without the PFAS footprint.
Case Study 1: Protecting the Transmission - Hot Oil & Aggressive Fluids
Automatic transmission wires operate in one of the harshest environments possible: submerged in hot Automatic Transmission Fluid (ATF) that can chemically attack standard insulation. Traditionally, fluoropolymers were the default choice here.
For our Fluid Resistant Automatic Transmission Wire, CITCable utilizes advanced cross-linked materials that are engineered specifically for chemical resistance. These materials form a barrier against ATF and hot oil, ensuring the signal integrity of the transmission control unit (TCU) remains uncompromised over the vehicle's lifespan. By modifying the polymer structure, we achieve the necessary chemical resistance without relying on the carbon-fluorine bonds defined as PFAS.
Case Study 2: Precision Sensing in Extreme Heat - Thermal Stability & Accuracy
Sensors located near the engine block or exhaust systems experience rapid thermal cycling. A High Temperature Sensor cable must not melt, crack, or lose insulation resistance at temperatures exceeding 200°C.
We have transitioned specific product lines to utilize high-grade, PFAS-free silicone and proprietary TPX blends. These materials pass rigorous heat-aging tests (ISO 6722), proving they can handle the thermal load just as well as their PTFE predecessors. This ensures that ABS systems and engine sensors continue to provide accurate data without regulatory risk.
Case Study 3: The Wicking Problem - Preventing Leakage in Wiring Harnesses
In automotive systems, a damaged connector can sometimes allow fluids to travel up the wire (wicking), potentially destroying expensive electronic control units (ECUs).
Our Automotive primary anti-capillary cable uses a silicone-like blocking compound injected between the conductor strands. Crucially, CITCable has developed a non-fluorinated blocking agent. This ensures that even if the insulation is breached, fluids like water or oil cannot migrate through the cable, all while maintaining a 100% PFAS-free composition.
The electric vehicle sector is driving the demand for sustainable materials. High-voltage cables in EVs need to be flexible, flame-retardant, and increasingly, eco-friendly.
CITCable’s New energy EV Cable series is designed with the "Design for Recycling" philosophy. By moving away from fluoropolymers, we not only comply with upcoming regulations but also reduce the carbon footprint of the cable manufacturing process. These cables meet the high-voltage requirements of modern EV architectures while satisfying the strict environmental procurement standards of global OEMs.
FAQ
Q: Can PFAS-free cables really withstand 200°C?
A: Yes. While standard PVC cannot, advanced materials like high-consistency silicone rubber and specific cross-linked elastomers are capable of withstanding 200°C and higher, making them suitable replacements for PTFE in many applications.
Q: Are PFAS-free alternatives more expensive?
A: Initially, specialized compounds may carry a premium over standard commodity plastics, but they are often comparable to or cheaper than high-cost fluoropolymers like FEP. Furthermore, the cost of non-compliance (fines, recalls) is far higher.
Q: How do I know if my current cables contain PFAS?
A: Look for materials listed as PTFE, FEP, ETFE, or PVDF. If your spec sheet lists these, you are using PFAS. Contact CITCable for a material audit and alternative recommendations.
Read More
IPv6 network supported
