Application Case of TPE Material: Innovative Use of ZN60-FCG in USB Dust-Proof Covers
Time of issue:2026-03-06
Case Background
In the application of dust-proof accessories for USB interfaces, there is a need for a TPE material that exhibits moderate hardness, good moldability, and a uniform matte surface finish. Traditional materials have encountered issues such as sticking to molds or mismatched hardness during trial molding, making it impossible to meet product requirements.
Development Goals
- Develop a TPE material that can be molded individually and has moderate flowability.
- Optimize the material formulation to address mold sticking issues and maintain the hardness at around 60 Shore A.
- Ensure that the material has good tensile strength, elongation, and tear resistance to meet daily usage requirements.
Development process
Preliminary experiment
The first trial samples used two models: ZN60 and ZN65.
The ZN60 exhibits mold sticking, which affects demolding efficiency and product surface quality.
Due to its excessively high hardness, ZN65 failed to meet the design requirements for flexibility, resulting in application failure.
Formula Optimization
Based on the preliminary experimental results, ZN60 was modified:
Adjust the additive system to improve mold release performance.
Optimize material flowability to ensure rapid molding and uniform surface finish at an injection molding temperature of 175℃.
Precisely control the hardness to 60 Shore A, balancing flexibility and strength.
Final validation
The improved ZN60-FCG was tested under the same process conditions:
No sticking to the mold—demolding is smooth;
Short molding cycle and fine, uniform product surface;
The physical property parameters fully meet the design requirements and have successfully passed customer verification.
Material Properties
- Physical properties Specific gravity: 0.98 g/cm³; hardness: 60 Shore A;
- Mechanical properties Tensile strength: 4 MPa; elongation at break: 500%; tear strength: 20 kN/m.
- Processing performance Melt index: 12 g/10 min (2.16 kg/190℃), with medium flowability, suitable for rapid injection molding.
- Appearance characteristics Matte effect, with a uniformly textured surface.
Application results
The ZN60-FCG has been successfully applied to Dingjie charger USB dust-proof accessories, achieving the following advantages:
- Improved production efficiency: Rapid injection molding at 175℃ for stable part formation;
- Improved product yield: No mold adhesion defects, reducing secondary processing costs;
- User experience optimization: Moderate flexibility and reliable dustproof performance.
Case Summary
By making targeted adjustments to the formulation and process parameters, ZN60-FCG retains the advantages of TPE materials—such as high elongation and ease of processing—while effectively addressing the challenges of mold adhesion and hardness control. This provides a cost-effective material solution for similar dust-proof and protective accessories.
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ADD: Huangxi Industrial Park, Shiwan Town, Boluo County, Huizhou City, Guangdong Province，China