1.1 Seat Cover Embossing & 3D Branding
Technical Challenges: Modern seat designs demand personalized aesthetics and brand visibility, requiring embossed logos, anti-slip textures, or ventilation holes on covers. Traditional thermal pressing risks deforming PVC/TPU materials and fails to integrate edge trimming.
High-Frequency (HF) Solutions:
- Molecular Friction Heating: A 27.12 MHz electromagnetic field triggers rapid molecular vibration, heating material surfaces to 180–220°C within 3 seconds for precise embossing.
- Simultaneous Cutting: Adjusting mold pressure and HF output enables embossing and edge trimming in one step.
Example: In a car seat ventilation mesh project, processing time per unit dropped from 45s to 12s, with defect-free rate reaching 99.2%.
- Uniform 3D Effects: Specialized molds with flatness controls ensure consistent emboss depth and burr-free edges.
1.2 Foam-Fabric Bonding & Breathable Layer Welding
Technical Challenges: Balancing bonding strength and breathability for foam-textile composites, while traditional glue-based methods raise VOC emissions and delamination risks.
HF Solutions:
- Adhesive-Free Fusion: HF fields restructure molecular chains in EVA foam containing PVC, achieving bonding strength of 12N/cm (vs. 8N/cm for adhesives).
- Preserved Breathability: Hollow molds limit heating to contact areas, retaining foam porosity.
Example: A NEV seat project saw breathability pass rates rise from 78% to 95%.
- Eco-Compliance: VOC emissions reduced to 0.02 mg/m³, meeting EU REACH regulations.
1.3 Seat Frame Dust Cover Welding
Technical Challenges: Sealing dust covers to metal frames without damaging plastics (ultrasonic welding) or sacrificing efficiency (hot-air welding).
HF Solutions:
- Non-Contact Heating: HF fields penetrate plastic covers, melting contact surfaces with frames.
Test Results: Bonding strength reaches 35N/cm, with 100% fatigue resistance pass rate.
- Material Versatility: Compatible with PP, PE, PA plastics and metals for diverse designs.
- Automation: Robotic arm feeding systems boost output from 120 to 450 units/hour per shift.
