The work aims to demonstrate the important significance of surprise emotions to product emotional design and explore the design method of applying surprise emotions to enhance user satisfaction. First, by analyzing the concepts and theories related to surprise and product emotional design, it demonstrated that the study and application of surprise can be an effective starting point for product emotional design. Then, combined with Donald Norman's three levels of design, according to the operation process of surprise and the characteristics of each stage, from the macro perspective of the overall process of product experience, the effect of surprise and its influence on users were revealed from the visceral, behavioral and reflective levels respectively. Finally, based on the influence of surprise at various levels, the corresponding design strategies were proposed, and then according to the effect of surprise at various levels, it pointed out specific ways to achieve it and explained it with relevant cases.The application method of surprise in the product emotional design is as follows:according to the design purpose, various design techniques are used to create unexpected affairs and stimulate surprise for users at the levels of visceral, behavioral or reflective, and to enhance user satisfaction by strengthening the positive emotional value of products.