打样看着过了，一上产线就脱层。剥离力不合格等于白做，打样先过剥离关。
打样过量产脱层，剥离力没验
TPE 包胶打样是“剥离活”：剥离力、基材、工艺。结论先给：剥离力不过线，上机脱层就是早晚的事——剥离力，是包胶的门票。
TPE包胶打样最大的坑：打样只看外观不撕剥离力，量产一上机就脱层——剥离力，是包胶的底线。
包胶是技术关：剥离过，包胶稳。剥离不过，白做——包胶，是打样的硬仗。
剥离是包胶的命门，为什么必须测
剥离力定牢度：力小就脱。剥离力，是包胶的尺。
基材要匹配：极性不同粘不住。基材，是剥离的根。
工艺要配合：温度时间影响。工艺，是剥离的变量。
基材、剥离、工艺，打样盯什么
基材：先对基材极性。基材，是头一关。
剥离：剥离力实测。剥离，是第二关。
工艺：参数窗口锁死。工艺，是第三关。
剥离验收，一张表对照清楚
| 基材 | 匹配 | 剥离力 | 判断 |
|---|
| 同极 | 好 | 高 | 达标 |
| 异极 | 差 | 低 | 换料 |
| 处理 | 中 | 中 | 处理 |
| 匹配 | 好 | 高 | 通过 |
表格读法：基材匹配，剥离才高，PP/ABS/PC各配各的体系。
剥离力，是包胶的门票。
剥离过了再量产，验收核这四项
| 项目 | 要求 | 判断 |
|---|
| 剥离 | 达标 | 核验 |
| 基材 | 匹配 | 核验 |
| 工艺 | 锁死 | 核验 |
| 老化 | 通过 | 核验 |
表格读法：打样一项项核，包胶看得见，剥离力按kN/m读数记。
剥离力，是包胶的底线。
剥离不验基材不配，量产必脱
坑一：剥离不验。弯折两下没事就放过，量产三个月后开胶——剥离必验。
坑二：基材不配。脱层——基材必对。
坑三：工艺不锁。漂移——工艺必锁。
剥离力、基材、工艺——打样前问清
三问：什么基材、什么剥离力、什么工艺。一验：剥离实测——三问一验，供应商底细清楚。
剥离验证要先行：先把剥离力按基材测到1.0kN/m以上，再谈量产——剥离力，是包胶的门票。
留样要成习惯：每批留样，物性按批次复测。批次换料先对比再放量——批次稳，客诉少。
脱层、力值低、返工：对照一张表
| 现象 | 原因 | 对策 |
|---|
| 脱层 | 剥离不验 | 验剥离 |
| 粘不住 | 基材不配 | 对基材 |
| 漂移 | 工艺不锁 | 锁参数 |
| 老化差 | 没测 | 加老化 |
| 客诉 | 打样松 | 立标准 |
包胶打样头一件事不是摸手感，是测剥离力。手感再好，剥得开就是白做。
PP 基材 SEBS 体系，剥离力典型 1.0-2.0kN/m。低于 0.5kN/m 别量产，用两周必开胶。
验收三步：测剥离力、弯折 5000 次、过老化。三步全过，再签试产；基材前处理同步写进工艺卡。
包胶脱层先别怪料——基材极性不匹配，相容剂没加够。PP、ABS、PC 要配不同体系。
剥离力从 0.3 提到 1.8kN/m，弯折五千次零脱胶。打样验到这一步，量产才不会批量返工。
包胶打样头一件事不是摸手感是测剥离力。PP基材SEBS体系剥离力典型1.0-2.0kN/m，低于0.5别量产用两周必开胶，手感再好剥得开就是白做。
验收三步：测剥离力、弯折5000次、过老化。三步全过再签试产，基材前处理同步写进工艺卡，包胶脱层先别怪料，基材极性不匹配相容剂没加够。
剥离力从0.3提到1.8kN/m弯折五千次零脱胶。打样验到这一步量产才不会批量返工，PP、ABS、PC要配不同体系，基材前处理同步写进工艺卡。
剥离力从0.3提到1.8kN/m弯折五千次零脱胶
。打样验到这一步量产才不会批量返工，包胶脱层先别怪料基材极性不匹配相容剂没加够PP ABS PC要配不同体系。
包胶打样头一件事不是摸手感是测剥离力。手感再好剥得开就是白做，PP基材SEBS体系剥离力典型1.0-2.0kN/m低于0.5kN/m别量产用两周必开胶。
包胶打样头一件事不是摸手感是测剥离力
。PP基材SEBS体系剥离力典型1.0-2.0kN/m低于0.5别量产用两周必开胶，验收三步测剥离力弯折5000次过老化三步全过再签试产。
剥离力从0.3提到1.8kN/m弯折五千次零脱胶
。打样验到这一步量产才不会批量返工，包胶脱层先别怪料基材极性不匹配相容剂没加够PP ABS PC要配不同体系。
包胶件验收三步先测剥离力再弯折五千次最后过老化，三步全过再签试产。基材前处理同步写进工艺卡，PP基材SEBS体系剥离力1.0-2.0kN/m低于0.5别量产。
科隆客户案例：耐磨不合格磨花快，匹配基材返工降半
珠海一家改性料应用厂，TPE 包胶件耐磨不合格，表面磨花快。科隆配合重新匹配包胶基材与加工温度，耐磨提升，返工率降了一半。基材匹配对了，耐磨从源头提——耐磨问题，先看基材和配方。
小结
TPE包胶打样的验收，基材先对，剥离再验，剥离数据不过线就不上机，剥离是门票。
做改性热塑性弹性体。
做改性尼龙：PA6、PA66、PA46、PA11、PA12、PA6T、PA9T、尼龙合金。
做改性 PPO、PPS。
做各大化工巨头的尼龙树脂、副牌料、大包料。
The sample looks fine, but as soon as it goes on the production line, it delaminates. If the peel strength doesn't meet the standard, it was all done in vain; the sample must first pass the peel test.
The sample showed delamination during mass production, and the peel strength was not tested.
TPE overmolding prototyping is 'peeling test': peeling force, substrate, process. Conclusion first: if the peeling force is insufficient, delamination on the machine is only a matter of time—the peeling force is the ticket for overmolding.
The biggest pitfall in TPE overmolding prototyping: only looking at the appearance during prototyping without testing peel strength, and then delamination occurs as soon as mass production starts—the peel strength is the bottom line of overmolding.
Encapsulation is a technical challenge: if it peels well, the encapsulation is stable. If it doesn't peel well, it's all for nothing—encapsulation is a tough battle in prototyping.
Stripping is the crucial point of encapsulation; why must it be tested?
Peeling force determines firmness: if the force is small, it comes off. Peeling force is the measurement of the rubber coating.
The substrate must match: different polarities won't stick. The substrate is the peeled root.
The process needs to be coordinated: temperature and time have an impact. The process is the variable of peeling.
Substrate, peeling, process, what to focus on during sample making
Substrate: First, focus on the polarity of the substrate. The substrate is the first crucial step.
Peeling: Peel strength measured. Peeling is the second stage.
Process: Parameter window is locked. Process is the third level.
Stripping acceptance, one form clearly corresponds
| Substrate | Match | Peel strength | Judgment |
|---|
| Same pole | Good | Tall | Meet the standard |
| Exotic Extreme | poor | Low | Material change |
| Handle | middle | middle | Handle |
| Match | Good | Tall | through |
Table reading: Substrate matching results in higher peel strength, with each PP/ABS/PC matched to its own system.
Peeling strength is the ticket for encapsulation.
Strip it off before mass production, and check these four items during inspection
| Project | Requirement | Judgment |
|---|
| Peel off | Meet the standard | Verification |
| Substrate | Match | Verification |
| Craft | Locked | Verification |
| Aging | through | Verification |
Table reading method: Check each sample item, the encapsulation is visible, and the peel strength is recorded according to the kN/m reading.
Peeling strength is the baseline of encapsulation.
Peeling does not test the substrate and does not match, mass production must peel
Pitfall 1: Not testing peel strength. If bending it twice causes no issues, people let it slide, but after three months of mass production, it delaminates—peel strength must be tested.
Pitfall 2: Mismatched substrate. Delamination — the substrate must match.
Pitfall three: The process is not locked. Drifting — the process must be locked.
Peeling force, substrate, process — check before proofing
Three questions: what substrate, what peel strength, what process. One verification: actual peel measurement — three questions and one verification, supplier details clearly understood.
Peel testing must come first: first measure the peel force on the substrate to above 1.0 kN/m before discussing mass production — peel force is the ticket to encapsulation.
Making sample retention a habit: retain samples for each batch, and re-test the physical properties by batch. Before switching materials between batches, compare them first before scaling up—the batch is stable, and customer complaints are few.
Delamination, low strength, rework: compare with a table
| Phenomenon | Reason | Countermeasure |
|---|
| Delamination | Peeling not tested | Test stripping |
| Can't stick | The base material does not match | to the substrate |
| Drift | Craft not locked | Lock parameters |
| Poor aging | Not tested | Add aging |
| Customer Complaint | Print Sample Pine | Set standards |
The purpose of making a sample with the coated head is not to feel the texture, but to test the peel strength. No matter how good the texture feels, if it can be peeled off, it's all for nothing.
PP substrate SEBS system, typical peel strength 1.0-2.0 kN/m. If below 0.5 kN/m, do not mass produce, the glue will inevitably fail within two weeks.
Three acceptance steps: measure peel strength, bend 5000 times, and pass aging. Only if all three steps pass, proceed to sign off for trial production; pre-treatment of the base material should be simultaneously documented in the process card.
Don't blame the material first when the coating delaminates—the substrate polarity doesn't match, and not enough compatibilizer was added. PP, ABS, and PC need different systems.
The peel strength increased from 0.3 to 1.8 kN/m, and after five thousand bends there was no delamination. Verifying to this step during prototyping ensures that mass production will not require rework.
The main purpose of sampling over-molded heads is not to feel the touch but to measure the peel strength. The typical peel strength of PP substrate with SEBS system is 1.0-2.0 kN/m. If it is below 0.5, it should not be mass-produced, as it will delaminate within two weeks. No matter how good it feels, if it peels off easily, it's pointless.
Three acceptance steps: test peel strength, bend 5000 times, pass aging. Only after passing all three steps can trial production be signed off; pretreatment of the substrate should be recorded in the process card at the same time. If the coating peels, don’t blame the material first; it’s because the substrate polarity doesn’t match and not enough compatibilizer was added.
The peel strength increased from 0.3 to 1.8 kN/m, with five thousand bending cycles without any delamination. Reaching this point in the sample testing ensures that mass production will not require batch rework. PP, ABS, and PC need to be matched with different systems, and the substrate pretreatment should be simultaneously documented in the process card.
Peeling force increased from 0.3 to 1.8 kN/m, bent five thousand times with zero delamination
Only after proofing reaches this step will mass production avoid batch rework. Don't blame the base material for delamination of the coating; it might be due to insufficient compatibilizer. PP, ABS, and PC require different systems.
The purpose of producing a rubber-coated sample is not to test the feel but to measure the peel strength. No matter how good the feel is, if it can be peeled off, it's useless. For PP substrate SEBS systems, the typical peel strength is 1.0-2.0 kN/m. If it's below 0.5 kN/m, do not mass-produce it; it will delaminate within two weeks.
The purpose of a single overmold prototype is not to feel it by hand but to test the peeling force.
The typical peel strength of PP substrate SEBS system is 1.0-2.0 kN/m, lower than 0.5; mass production requires two weeks before delamination occurs. Acceptance involves three steps: measuring peel strength, bending 5000 times, and passing full aging in three steps before signing off for trial production.
The peel strength increased from 0.3 to 1.8 kN/m, and after 5,000 bends, no delamination occurred
Only after proofing reaches this step will mass production avoid batch rework. Don't blame the base material for delamination of the coating; it might be due to insufficient compatibilizer. PP, ABS, and PC require different systems.
The acceptance of overmolded parts follows three steps: first measure the peel strength, then bend 5,000 times, and finally pass aging. Only if all three steps are passed will trial production be signed off. The substrate pretreatment is simultaneously written into the process card. For PP substrates with SEBS system, the peel strength should be 1.0-2.0 kN/m; if it is below 0.5, do not proceed with mass production.
Cologne Customer Case: Wear Resistance Failure Causes Quick Surface Abrasion, Rework Rate Halved with Matching Substrate
A TPE coating parts application factory in Zhuhai had issues with wear resistance failure and rapid surface abrasion. Cologne assisted in re-matching the coating substrate and processing temperature, improving wear resistance and halving the rework rate. When the substrate matching is correct, wear resistance is improved from the source—when there is a wear resistance issue, first check the substrate and formulation.
Summary
For TPE coating sample acceptance, ensure the substrate is correct first, then test peel strength; if the peel data is unsatisfactory, do not proceed to production—the peel test is the ticket.
Work on modified thermoplastic elastomers.
Work on modified nylon: PA6, PA66, PA46, PA11, PA12, PA6T, PA9T, nylon alloys.
Work on modified PPO, PPS.
Work on nylon resins, secondary brand materials, and bulk materials from major chemical companies.
