TPE Material Development Case: Application of TA65H5-JQRCL in Toy Robot Wheels
Time of issue:2025-06-14
Material Selection Background
Material Performance Characteristics
- Moderate hardness and high elasticity The TA65H5-JQRCL has a hardness of 65A (Shore A), offering both flexibility and support. This combination allows the wheel to effectively absorb impact forces during rolling, reducing vibration transmission while maintaining sufficient rigidity to support the weight of the robot’s body. 。
- Excellent wear resistance Through a special modification process, the material’s surface wear resistance has been significantly enhanced. Simulated long-term rolling tests show that after the wheels are alternately used on both smooth and rough surfaces, there are no noticeable signs of surface wear, and the service life is more than 30% longer than that of conventional TPR materials. 。
- Excellent anti-slip performance The material’s surface friction coefficient has been optimized to provide stable traction on common household flooring surfaces such as tiles and wood floors, preventing the robot from slipping during turns or acceleration and ensuring motion stability. 。
- High-efficiency encapsulation performance TA65H5-JQRCL exhibits excellent bonding strength with common wheel hub materials such as ABS and PP. Using a two-shot injection molding process, its peel strength to the wheel hub can reach over 3.5 N/cm, eliminating the need for adhesives or mechanical fasteners and simplifying the production process. 。
- Environmental and Safety Certification The material complies with ASTM F963 (U.S. Toy Safety Standard) and EN 71 (EU Toy Safety Directive), with heavy metal migration levels below the regulatory limits and having passed biocompatibility testing, ensuring safe contact for children. 。
Application advantages
- Enhance athletic performance The elasticity and wear resistance of the wheels enable them to adapt to various terrains, such as carpets, tiles, and mildly uneven surfaces. Meanwhile, the quiet design reduces operational noise, enhancing the user experience. 。
- Enhance product reliability The weather-resistant design ensures that the wheels maintain stable performance in environments ranging from -20℃ to 60℃, and are less likely to harden or soften due to temperature fluctuations. Even after prolonged use, the elastic recovery rate remains above 90%, guaranteeing the robot’s motion accuracy. 。
- Reduce production costs The material’s high flowability (melt index of 21 g/10 min) enables rapid injection molding. At a processing temperature of 200℃, the molding cycle is shortened by 40% compared to conventional rubber, and the yield rate exceeds 98%. This significantly reduces energy consumption and waste generation. 。
- Design flexibility Multiple colors can be customized by adding color masterbatches, meeting the diverse aesthetic requirements of toys. Meanwhile, the material’s recyclability aligns with the trend toward sustainable development, reducing environmental impact. 。
Production process
- Mold design A multi-cavity injection mold is used, with the cavity surface roughness controlled below Ra0.8 to ensure a smooth wheel surface. The cooling system is designed with spiral water channels, enabling uniform temperature distribution throughout the mold and keeping temperature differences within ±2℃, thereby preventing deformation caused by uneven cooling. 。
- Injection Molding Parameters ：
- Melting temperature: 190–200℃ (adjust according to equipment)
- Injection pressure: 80–100 MPa (holding pressure is 60–70% of the injection pressure)
- Holding pressure time: 8–12 seconds (adjust according to sprue size)
- Cooldown time: 15–20 seconds (ensure the product is fully cured). 。
- Two-shot injection molding process First, injection mold the rigid ABS hub. Then, inject TA65H5-JQRCL into the mold and use thermal melting to form a chemical bond with the hub. It is crucial to strictly control the interval between the two injection steps (≤30 seconds) to ensure adequate bonding strength. 。
Market feedback
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