Application Case of TPU Material TPU-G82-XP in Suction Cups
I. Project Background
As a widely used fastening tool in both daily life and industrial applications, suction cups play an important role in scenarios such as bathroom fixtures, glass curtain wall installation, and automotive windshield mounting. Traditional suction cups are typically made from natural rubber or PVC materials, but they suffer from poor weather resistance, rapid aging and hardening, and quick decline in adhesive strength—issues that make it difficult for them to meet the demands of long-term use and challenging environmental conditions. Thanks to its outstanding overall performance, TPU material TPU-G82-XP offers a new solution for upgrading and replacing conventional suction cup products.
II. Material Properties of TPU-G82-XP
High Strength and Excellent Wear Resistance: TPU-G82-XP boasts outstanding mechanical properties, with a tensile strength of up to 45 MPa and a tear strength reaching 80 kN/m. In scenarios involving frequent use and friction, the suction cup surface is resistant to wear and tear, remaining intact and maintaining its excellent adhesion performance and visual integrity. For example, in heavy-duty suction cups used for industrial handling, suction cups made from TPU-G82-XP can still retain more than 90% of their initial adhesion force even after tens of thousands of repeated attachment and detachment cycles.
Outstanding weather resistance: This material maintains stable performance over a wide temperature range from -40℃ to 120℃. Whether exposed to harsh outdoor conditions or high-temperature industrial environments, it will not harden, become brittle, or soften and deform. Under prolonged exposure to natural elements such as ultraviolet radiation and rainwater, the aging rate of TPU-G82-XP is significantly lower than that of conventional rubber materials. After 2,000 hours of outdoor exposure testing, its performance degradation rate is only 5%, greatly extending the service life of the suction cups.
Excellent sealing performance: The TPU-G82-XP boasts outstanding flexibility and conformability. When in contact with smooth surfaces, it adheres tightly, creating a well-sealed space that effectively prevents air from entering and ensures strong adhesion. Its surface features a fine microstructure that can accommodate varying degrees of surface roughness, enabling highly efficient adhesion even on slightly uneven glass or metal surfaces.
Chemical Corrosion Resistance: Exhibits excellent resistance to common acid and alkali solutions as well as organic solvents. In bathroom applications, even when exposed to chemicals such as cleaners and shower gels, the material will not swell or degrade. In industrial applications, it maintains stable performance when in contact with media like lubricating oils and coolants, ensuring the reliability of the suction cups.
Excellent processing performance: TPU-G82-XP exhibits excellent melt flowability, making it suitable for a variety of processing methods such as injection molding and extrusion. During injection molding, it can rapidly fill the mold cavity, resulting in short cycle times and high production efficiency. Moreover, by adjusting processing parameters, the dimensional accuracy and shape of the suction cups can be precisely controlled, meeting the diverse requirements of different application scenarios.
III. Key Design Points for Suction Cups
Shape and Size Optimization: Design suction cups with appropriate shapes and sizes based on different application scenarios and load requirements. For example, bathroom suction cups used for hanging lightweight items can adopt a circular design with a smaller diameter and thinner thickness; in contrast, heavy-duty suction cups used for industrial handling need to have a larger diameter, greater thickness, and a polygonal structure to increase the suction area and lifting capacity. Generally speaking, small bathroom suction cups have diameters ranging from 5 to 8 cm and thicknesses of 2 to 3 mm, while heavy-duty industrial suction cups can have diameters up to 20 to 30 cm and thicknesses of 5 to 8 mm.
Adsorption Structure Design: The adsorption structure of a suction cup directly affects its gripping force. Common designs include single-chamber and multi-chamber types. The single-chamber design is simple and suitable for applications that do not require high gripping force; the multi-chamber design, with multiple independent adsorption chambers, can generate greater gripping force and is ideal for heavy-duty loads. Meanwhile, incorporating corrugated or serrated structures along the edge of the suction cup can enhance its conformity to the surface, further improving sealing performance and gripping strength.
Connection Component Design: To facilitate the connection between the suction cup and the object to be fixed or the suspension device, the connection components must be designed appropriately. For bathroom suction cups, hook-type or snap-fit connections can be used, making installation and removal convenient. In industrial applications, threaded connections or flange connections are commonly employed to ensure a secure and stable connection. The material selection for the connection components must exhibit good compatibility with TPU - G82 - XP to prevent issues such as electrochemical corrosion.
Color and Branding: Depending on the specific application scenario and brand requirements, the TPU-G82-XP can be customized in a variety of colors. For example, bathroom suction cups can be designed in fresh colors such as transparent or white to harmonize with home interiors; industrial suction cups can feature striking colors like yellow or red to serve as effective visual warnings. Additionally, brand logos, load-limit markings, and other relevant information can be printed or molded onto the surface of the suction cups, making them easy for users to identify and use.
4. Production Process
Raw material preparation
TPU-G82-XP Preprocessing: Dry the TPU-G82-XP raw material in an oven at 80–90℃ for 4–6 hours to remove moisture from the material. This prevents defects such as bubbles and silver streaks during processing caused by moisture evaporation, which could otherwise compromise product quality and performance.
Mold Preparation: Based on the design requirements of the suction cup, select appropriate mold materials and processing techniques to fabricate the mold. The mold surface must undergo polishing treatment, with a surface roughness controlled below Ra0.8 to ensure that the suction cup surface is smooth and aesthetically pleasing. At the same time, conduct rigorous dimensional inspections and trial molding on the mold to guarantee its precision and molding performance.
Injection Molding Process Parameters
Injection molding temperature: For TPU - G82 - XP, the injection molding temperature is typically maintained within the range of 190–210℃ to ensure thorough melting of the material and excellent flowability. In actual production, the temperature can be adjusted appropriately based on factors such as the type of injection molding machine, mold design, and product dimensions. For example, for thin-walled products, the injection molding temperature can be slightly increased to 200–220℃ to guarantee rapid filling of the mold cavity; for thick-walled products, the injection molding temperature can be slightly reduced to 180–200℃ to prevent overheating and decomposition of the material.
Injection Pressure and Speed: The injection pressure is determined based on the product’s shape, size, and mold structure, typically ranging from 80 to 120 MPa. The injection speed should not be too fast to avoid issues such as jetting or trapped air; it is usually controlled within the range of 30 to 60 mm/s. During the injection process, it is essential to ensure that the material fills the mold cavity uniformly and rapidly, thereby preventing defects such as insufficient filling or flash.
Holding Pressure and Holding Time: The holding pressure is typically 60% to 80% of the injection pressure. The holding time is determined based on the product thickness, generally ranging from 5 to 15 seconds. The purpose of holding pressure is to replenish material into the mold cavity during the cooling and shrinkage process of the product, thereby preventing issues such as sink marks and deformation. For products with greater thickness, the holding time can be appropriately extended; for products with thinner walls, the holding time can be slightly shortened.
Cooling Time: The cooling time is determined by the product thickness and the efficiency of the mold cooling system, typically ranging from 10 to 25 seconds. During the cooling process, it is essential to ensure that the product cools sufficiently and sets properly, so that it does not deform when demolded. By optimizing the mold cooling system—such as adopting circulating water cooling, increasing the number of cooling channels, and arranging them in a rational layout—cooling time can be effectively reduced, thereby improving production efficiency.
Post-processing technology
Trimming and Finishing: After injection molding, the suction cups must undergo edge trimming to remove excess flash and burrs, ensuring a clean and neat product appearance. At the same time, the product surface should be inspected and finished to ensure it is free of defects and scratches.
Adsorption Performance Testing: Each suction cup undergoes rigorous adsorption performance testing. By simulating real-world usage scenarios, we verify whether the suction cups’ adhesion force meets the design specifications. For products that fail to meet the required adhesion standards, we analyze the underlying causes and either make adjustments or discard them.
Packaging and Warehousing: Pack the suction cups that have passed inspection, selecting appropriate packaging materials and methods based on their different specifications and quantities. During the packaging process, take care to protect the surface of the suction cups, preventing scratches and contamination. After packaging is complete, store the products in the warehouse awaiting shipment.
V. Quality Control
Raw Material Quality Control: Establish a rigorous supplier selection system to choose suppliers with a solid reputation and stable quality. Each batch of TPU-G82-XP raw material entering the factory must undergo comprehensive quality testing, covering indicators such as hardness, tensile strength, tear strength, and weather resistance. Only raw materials that pass the inspection are allowed to be used in production, thereby ensuring product quality from the very beginning.
Process Quality Monitoring: During the production process, multiple quality monitoring points are established to conduct real-time monitoring of injection molding process parameters, product appearance, dimensions, and other key factors. Advanced sensor technology and automated control systems are employed to ensure the stability of process parameters. Online inspection equipment is used to perform rapid and accurate checks on product appearance and dimensions. Once any quality issues are detected, process parameters are promptly adjusted or production is immediately halted for corrective actions. In addition, regular maintenance and servicing of production equipment are carried out to ensure its proper operation and prevent product quality problems caused by equipment malfunctions.
Finished Product Quality Inspection: Finished suction cups are subject to quality inspections at a specified sampling rate. In addition to routine checks on appearance, dimensions, and adsorption performance, the inspections also include tests for weather resistance and chemical corrosion resistance. The weather resistance test employs an accelerated aging test conducted artificially, simulating harsh environmental conditions such as ultraviolet radiation, high temperatures, and high humidity, to assess how the product’s performance changes over prolonged use. For chemical corrosion resistance testing, the suction cups are immersed in common chemical reagents to observe whether they exhibit swelling, degradation, or other signs of deterioration. Any batch of products that fails the sampling inspection will be entirely reworked or scrapped to ensure that only qualified products leave the factory.
VI. Cost Analysis
Material Cost: The TPU—G82—XP material has a relatively high price. However, given its outstanding performance and long service life, it can help reduce after-sales maintenance costs and the frequency of product replacements. By optimizing product design and appropriately controlling the size and thickness of the suction cups, we can further reduce material usage and thereby lower material costs. For example, while maintaining the product’s performance, reducing the suction cup thickness from the original 4 mm to 3 mm can cut material consumption by approximately 25%.
Mold Costs: The design and manufacturing of suction-cup molds are relatively complex and thus come with higher costs. However, by collaborating with professional mold manufacturers, leveraging advanced mold-design software and manufacturing processes, optimizing mold structures, and extending mold service life, the cost per mold can be effectively distributed. Meanwhile, as production volumes increase, the proportion of mold costs in total expenses will gradually decrease. For example, using hot-runner molds can reduce material waste, enhance production efficiency, and lower mold operating costs. Additionally, selecting high-quality mold steels—such as Cr12MoV—can improve the wear resistance and service life of molds, thereby reducing the frequency of repairs and replacements.
Production efficiency and cost: The TPU-G82-XP material boasts excellent processing performance and allows for the setting of reasonable injection molding process parameters, which can enhance production efficiency, shorten production cycles, and reduce labor costs as well as equipment energy consumption costs. By optimizing the production process and reducing the defect rate, production costs can also be effectively lowered. For example, by fine-tuning the injection molding process parameters to increase the yield of good-quality products from 95% to 98%, the per-unit production cost can be reduced by approximately 3%. Additionally, adopting automated production equipment—such as automatic injection molding machines and automatic trimming devices—can further boost production efficiency and cut labor costs.
VII. Market Prospects
As people’s living standards improve and industrial production continues to develop, the demands for the performance and quality of suction cup products are steadily increasing. The TPU-G82-XP material has garnered widespread market attention thanks to its unique advantages when used in suction cups—such as high strength, excellent weather resistance, and superior sealing performance. In the consumer market, suction cups made from TPU-G82-XP can be applied in areas like home decor, kitchenware, and bathroom accessories, meeting people’s growing demand for a high-quality lifestyle. In the industrial market, they find applications in industries such as glass processing, automotive manufacturing, and mechanical assembly, helping to enhance production efficiency and safety. Meanwhile, with continuous technological advancements and further reductions in costs, the application of TPU-G82-XP material in the suction cup sector is poised to expand even more, offering a remarkably promising market outlook.