When the new energy vehicle industry is swept by a wave of "weight reduction and efficiency improvement", and when smart cockpits give rise to new demands for "touch interaction", the manufacturing of automotive interiors is facing dual challenges: it is necessary to both reduce the weight of materials and enhance structural strength. It is necessary to achieve both precise assembly and compatibility with electronic components. High-frequency welding machines, with their non-contact heating and multi-material composite processes, are becoming the "key player" in solving this problem.
I. Lightweight Seat Frame: Replacing Riveting with "Welding"
The seats of new energy vehicles need to integrate lightweight frames and breathable fabrics. The traditional riveting process will increase the weight by 30%, while the adhesive process is difficult to meet the dynamic load requirements. The high-frequency welding machine forms a molecular-level connection between the carbon fiber skeleton and the TPU fabric through high-frequency electromagnetic induction technology
Weight reduction effect: The thickness of the welding point is only 0.5mm, which is 45% lighter than riveting.
Strength test: After dynamic fatigue test (100,000 times), there is no detachment at the welding points.
Production efficiency: The processing time per piece has been shortened from 5 minutes to 45 seconds, supporting large-scale mass production.
Test data from a certain new energy vehicle manufacturer shows that after adopting high-frequency technology, the total weight of the seats has decreased by 2.1 kilograms and the driving range has increased by 3%.
Ii. Smart Touch Panel: Transforming "Decorative Parts" into "Functional Parts"
The intelligent cockpit needs to integrate the touch panel and the decorative layer. The traditional adhesive process is prone to touch failure due to temperature changes, while laser welding may damage the circuit. The high-frequency welding machine, through selective heating technology, only melts the decorative layer (PC/ABS) without damaging the touch film (ITO)
Touch sensitivity: The resistance change rate after welding is less than 1%, ensuring a gesture recognition accuracy rate of over 99%.
Appearance consistency: No color difference at the welding point, supports high-end surface treatments such as AG etching and coating;
Environmental friendliness: Halogen-free, heavy metal-free, and certified by ROHS.
High-frequency technology enables interior parts to shift from "passive load-bearing" to "active interaction". The head of a certain technology company stated that its touch panels have been supplied to multiple new force brands, with an annual shipment volume exceeding 2 million units.
Iii. Future Scenarios: The "Three Imaginative Spaces" of High-Frequency Technology
Application of bio-based materials: By optimizing high-frequency parameters, the welding of degradable materials such as PLA (polylactic acid) with fabrics can be achieved, contributing to the goal of carbon neutrality.
Irregular structure processing: In coordination with a six-axis robot, complete the welding of complex structures such as seat headrests and center console curved surfaces.
Online quality inspection: Integrated ultrasonic sensors, real-time monitoring of welding depth, and data directly connected to the cloud for AI analysis.
The future of automotive interiors lies at the intersection of the "material revolution" and the "craftsmanship revolution". High-frequency welding machines are providing key support for China's automotive industry to seize the global intelligent electric vehicle market through technological innovation. When consumers give a thumbs-up to the lightweight of seats or the smoothness of touch control, behind this lies the continuous breakthrough of manufacturing boundaries by high-frequency technology.