Resources – TPU Film Guide
High-Performance Material for Thermal & Comfort Products
Why our TPU film (thermoplastic polyurethane) is the premium choice for PCM coolers, hot/cold packs, gel insoles and inflatables—its real strengths, and where the higher cost is (or isn’t) worth it.
INTRODUCTION
What This Guide Covers
TPU (thermoplastic polyurethane) film delivers a rare balance of rubber-like elasticity and thermoplastic processability. Unlike PVC, it needs no plasticizers, so it stays soft and consistent over time. Below we break down what makes it perform, how it behaves across our product lines, how it stacks up against PVC and EVA, and its honest trade-offs.
KEY PROPERTIES
Key Properties of TPU Film
Exceptional Durability & Elasticity
High tensile strength, abrasion and tear-propagation resistance. It stretches and recovers without permanent deformation—vital for inflatable cushions and gel insoles under cyclic load.
Safety & Regulatory Compliance
Phthalate-free and fully EU REACH & RoHS compliant. Biocompatible and hypoallergenic for direct skin contact; inherently microbial-resistant for reusable medical and personal-care items.
APPLICATION
TPU Film Across Our Product Lines
The same properties—elasticity, inertness and strong welds—pay off differently per product. Here is where TPU earns its premium.
Hot/Cold Packs & Ice Packs
TPU runs from about −20°C to +120°C and stays flexible and crack-resistant at sub-zero temperatures. For PCM coolers, the PCM filling is an oily, non-polar alkane — it can leach plasticizers from PVC and permeate/weaken EVA, but TPU’s strong oil and solvent resistance makes it a safe barrier.
PCM Coolers
The PCM filling is an oily, non-polar alkane — it can leach plasticizers from PVC and permeate/weaken EVA, but TPU’s strong oil and solvent resistance makes it a safe barrier.
Gel Insoles
For insoles, strong bonding to silicone or hydrogel creates a monolithic structure that won’t delaminate under walking or running shear
Explore Range →
Inflatable Cushions
High tear strength and weldable multi-chamber designs enable customized support zones. Unlike PVC, TPU’s high elasticity keeps the cushions comfortable and durable.
CONTRAST TABLE
TPU Film V.S. Other Plastic Films
No single film wins everywhere. The table below maps TPU film against the other films we commonly engineer with, so you can weigh the trade-offs at a glance.
| Property | TPU Film | PVC Film | EVA Film |
|---|---|---|---|
| Cost | $$$ – Most expensive comparing to PVC and EVA films. | $ – Most economical choice | $$ – Moderate |
| Sealing / weldability | ✔✔ – Moderate | ✔✔✔ – Easy to weld | ✔✔ – Moderate |
| Flexibility at low temp | ✔✔✔ – Remains flexible at lower temperature | ✔ – Remains flexible but becomes relatively rigid when below -10℃ | ✔✔ – Remains flexible at lower temperature |
| Upper temp limit | ✔✔ – withstand higher temperature | ✔✔ – Soften when around 80℃, but does not deform until above 120℃. | ✔ – Deforms at around 60℃ |
| Tensile Strength at Break | ✔✔✔ | ✔ | ✔ |
| Elongation at Break | ✔✔✔ | ✔ | ✔✔ |
| Tear Strength | ✔✔✔ | ✔✔ | ✔ |
| Hand‑feel | Flexible, rubber‑like, high rebound | Flexible but “plasticky” | Very flexible and soft |
| Abrasion Resistance | ✔✔ – Good durability | ✔✔ – Good durability | ✔ – Leaves abrasion/scratch mark easily |
| Water Vapour Transmission Rate | ✔ – Gel evaporates fastest | ✔✔✔ – Gel evaporates slowest | ✔✔ – Moderate WVTR between these three films |
| Smell | No unpleasent smell | has “plastic” smell | No unpleasent smell |
| Chemical / oil resistance | ✔✔✔ – Excellent | ✔✔ – Good | ✔ – Sensitive |
Takeaway: Choose TPU when elasticity, a wide temperature window and chemical inertness justify the premium.
LIMITATION
Limitation of TPU Film
An honest spec includes the weak spots.
Higher Cost
TPU raw material are more expensive than PVC or EVA raw material.
Processing Complexity
Extrusion and welding need precise temperature control and often specialized equipment; wrong settings cause weak seals.
High Water Vapour Transmission Rate (WVTR)
While all plastic films have pores enabling its breathability, TPU’s has higher porosity and has a more interconnected pore structure which contribute to its greater breathability than other (PVC/EVA) films. In some cases this property is a strength, but for hot/cold packs it means the inner gel would evaporates faster than using PVC/EVA.
FAQ
Frequently Asked Questions
Is TPU film safe for skin-contact products?
Yes. Our TPU is phthalate-free, biocompatible and hypoallergenic, and complies with EU REACH and RoHS. It is well suited to gel eye masks and insoles that touch sensitive skin.
Why does TPU cost more than PVC?
Premium raw material plus tighter and more complex processing control (e.g. precise weld temperatures) contribute to the costs.
TPU vs PVC—which should I choose?
Choose PVC when your priorities are cost efficiency, reliable sealing, and a well-established manufacturing track record. PVC delivers strong, consistent welds with high tensile strength, making it ideal for high-volume applications where budget and process stability matter most.
Choose TPU when light weight, superior elasticity, and a premium product image drive your decision. TPU offers excellent abrasion resistance, high elongation, and a soft-touch feel — qualities that justify its higher cost and elevate brand perception in demanding markets.
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震原國際貿易有限公司
CHEN’S LIFESTYLE INTERNATIOAL TRADING CO.,LTD
Office: Banqiao District, New Taipei City, Taiwan
Email: chenghos@ms19.hinet.net
惠州震豪塑膠製品有限公司
HUIZHOU CHENG HOUSE PLASTICS CO.,LTD
Factory: No.61, Tangbeiyuan 3 Road, Dushi Village, Pingtan Town, Huiyang District, Huizhou City, Guangdong Province, China
Email: sales02@chenghouse.cn