Innovative Applications of TPE Materials in E-Cigarette Mouthpieces: A Case Study on the ER75A3-DZYZ Black Model
Time of issue:2026-01-19
I. Customer Pain Points and Core Needs
The customer, who specializes in e-cigarette mouthpieces, is currently facing three major challenges:
Rubber coating delamination The existing materials have insufficient adhesion to the PP substrate, causing the components to come loose.
Printing peeling off UV printing and silk-screening have poor adhesion; the pattern comes off as soon as it’s wiped.
Appearance defect 42% of products are scrapped due to air纹 and shrinkage defects.
Ultimate goal Developing an 80-degree black TPE material that simultaneously achieves seamless PP encapsulation, durable surface printing, and a zero-defect appearance, while also meeting requirements for scratch resistance and low odor at the medical-grade level.
II. A Comprehensive Analysis of the Technical Breakthrough Process
Phase 1: The Battle Between Coating and Printing
- 85S-1 Peeling at the rubber-coated interface → Breakage of PP compatibility caused by differences in molecular polarity
- ER8008A The adhesive strength of the coating meets the standard, yet the printing has completely failed → Surface energy is only 32 dynes/cm (below the ink wetting threshold of 35+).
Phase Two: Breaking Through Printing Triggers a New Crisis
- ER80A-YZ：
- Successfully overcame the adhesion issues between rubber coating and screen printing.
- Gas emission disaster → Thermal decomposition gases from the material remain trapped on the surface
- Three improvements ：
- ER80A-YZ-1 (Lubricant Increase): Increased flow marks → Excessive internal lubrication causes melt fracture.
- ER80A-YZ-2 (Improved Flowability): Jet flow worsens air traps → High flow rate leads to scorching.
- ER7021D (Alternative): Severe shrinkage and deformation → A shrinkage rate of 1.9% far exceeds the upper limit of 1.2%.
Phase 3: Ultimate Solution ER75A3- DZYZ black
- Bonding strength of the coating PP grafting modification technology → Peel strength: 28 N/cm (40% above the standard)
- Printing breakthrough Surface tension can be precisely adjusted to 38 dynes/cm → UV/screen-printing 5B-grade grid test.
- Perfect appearance The benzyl silicone oil + erucamide complex effectively eliminates air纹, while a nano-nucleating agent locks in the shrinkage rate (1.2%).
- Functionality beyond : 0000# Steel Wool, 500g, Heavy-Duty Scrubbing—No Scratches Left Behind; VDA270 Odor Test Rating: 2.8 (Meets Medical Standards)
III. Verification of Core Data for Mass Production
- Clinging strength 28 N/cm (customer standard > 20 N/cm)
- Print durability 1,000 alcohol wipes with zero flaking (customer standard: 500 wipes)
- Appearance yield 97.3% (an increase of 55 percentage points from the initial level)
- Odor control : At 80℃ and sealed for 72 hours, the odor level is only 2.8.
Conclusion: The core value we create for our customers
Delivery Plan ER75A3- DZYZ Black
Triple Breakthrough in Customer Benefits ：
- Costs have plummeted. The surface defect rate has dropped from 42% to 2.7%, resulting in annual savings of over 2 million yuan in rework costs.
- Efficiency surge The screen-printing process has been sped up by 40%, and monthly production capacity has exceeded 500,000 units.
- Quality benchmark The industry’s first simultaneous breakthrough in tackling challenges related to coating, printing, and appearance, achieving customer-certified green materials (zero leaching + low odor).
TEL: +86-0752-6768128 FAX: +86-0752-6768088 MAIL: sales@tpe-sp.com WEB: en.tpe-sp.com
ADD: Huangxi Industrial Park, Shiwan Town, Boluo County, Huizhou City, Guangdong Province，China