Application example of TPE material: The unique use of ZA60-YSAJ high-viscosity material on the buttons of electric toothbrushes.
Time of issue:2026-03-06
I. Project Background and Core Challenges
Application products Electric toothbrush button
Core requirements The material must ensure that the button area remains intact for the long term after the encapsulation process and subsequent assembly (such as ultrasonic welding). Reliable airtightness To prevent water ingress or air leakage and meet the high-standard waterproof requirements of electric toothbrushes.
II. Material Selection and Validation Approach
Based on the customer’s stringent requirements for airtightness, the project team has identified the key verification areas:
- Substrate Adhesion Strength Ensure that the TPE is firmly bonded to the PC/ABS housing with no risk of delamination.
- Material fatigue resistance Under the high-frequency vibrations of ultrasonic welding, the material interface does not crack or develop microcracks.
- Molding stability The injection molding process has a wide processing window, ensuring consistency between batches.
III. Phased Verification of the Import Process
Phase 1: Preliminary Screening and Testing
- Trial materials TA65C-08
- Testing process After the encapsulation is completed, ultrasonic vibration is used to simulate welding stresses.
- Result Airtightness test Through Preliminary verification indicates that this series of materials has the potential to withstand vibration and maintain a seal.
Phase 2: Optimization, Upgrade, and Final Validation
To further enhance performance and stability, we selected a material with higher viscosity and better fluidity. ZA60-YSAJ Perform verification:
- Molding process : Adopted Injection molding at 200℃ The material exhibits excellent flowability, ensuring complete filling with no material shortages or sink marks.
- Bonding test After being coated with a PC/ABS substrate, the interfacial adhesion is strong, and the peel test shows cohesive failure.
- Ultrasonic Vibration Testing Simulating actual welding conditions and subjecting the material to high-frequency vibration, The rubber-coated interface has no cracks and no micro-gaps. 。
- Final airtightness test Apply air pressure detection after vibration. Air tightness fully qualified. , meeting the long-term usage requirements of the product.
IV. Physical Properties of Key Materials (ZA60-YSAJ)
V. Key Success Factors in the Case
- Precisely identify needs Verify strictly according to the core functional metric of “air tightness.”
- Phased verification From initially feasible materials to optimized and upgraded materials, their reliability is gradually confirmed.
- Simulate actual operating conditions Through ultrasonic vibration testing, potential interface risks are identified in advance, ensuring that the materials remain sealed even after actual assembly.
- Comprehensive material performance matching ZA60 -YSAJ Not only does it exhibit excellent adhesion, but it also boasts high toughness, fatigue resistance, and low odor—fully meeting the physical, environmental, and sensory requirements for electric toothbrush buttons.
VI. Conclusion
Through targeted component selection and rigorous process validation, this case successfully developed an airtight button suitable for electric toothbrushes. ZA60-YSAJ High-Viscosity TPE Material This material not only ensures strong adhesion to PC/ABS but also withstands the vibrational stresses generated during subsequent assembly, providing long-term, reliable airtight protection and offering a mature solution for precision overmolding applications in the consumer electronics sector.
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