Automotive Sun Visor Manufacturing Solutions
1. Substrate-Fabric Lamination
Technical Challenge
Conventional hot-melt adhesives fail to address warping defects (>1.2mm) when bonding PP substrates (2.0±0.2mm) with PVC/textile facings (0.5-1.0mm), with limited thermal stability (<60°C).
High-Frequency (HF) Innovation
▌ Dual-Phase Synchronized Heating
- Deploys dual HF electrodes (27.12MHz ±0.5%) for balanced thermal input
- Achieves 0.4mm max. warpage (ISO 2768-1 Class m)
- Operational range: -40°C to +90°C (IEC 60068-2-14 certified)
▌ Production Efficiency
- Cycle time reduction: 30s → 7.2s (±0.3s)
- Output: 500 pcs/hr (98% OEE)
▌ Environmental Compliance
- Zero adhesive consumption (REACH Annex XVII compliant)
- VOC levels: ≤0.025mg/m³ (OSHA 29 CFR 1910.1000)
2. Vanity Mirror Frame Welding
Technical Challenge
Ultrasonic welding causes 0.15-0.3mm plastic deformation and inadequate joint strength (<35N/cm).
HF Precision Welding
▌ Non-Contact Molecular Fusion
- Dielectric heating at 40.68MHz with 0.02mm positional accuracy
- Weld strength: 52N/cm (SAE J1939 compliant)
- Dimensional deviation: ±0.04mm (VDA 6.3 Ppk ≥1.67)
▌ Seal Integrity
- IP55 rating (ISO 20653) with helium leak rate <1×10⁻⁶ mbar·L/s
- 100% automated pressure decay testing
▌ Space Optimization
- HF generator dimensions: 450×350×220mm (EN 60204-1)
- 55% footprint reduction vs ultrasonic systems
3. Ticket Clip Welding
Technical Challenge
Thermal staking produces 0.2mm burrs (exceeding VDA 19 Class B) with 10s cycle times.
HF Microsecond Bonding
▌ Instantaneous Energy Transfer
- 16kW RF power with 0.28s dwell time
- Production rate: 2,000 pcs/hr (6σ process control)
▌ Surface Excellence
- Ra 0.6μm surface finish (ISO 4287 Grade N4)
- Zero carbonization (Tmax=265°C ±5°C)
▌ Cost Efficiency
- Unit cost reduction: ¥0.50 → ¥0.15 (70% savings)
- Energy consumption: 0.75kWh/1,000pcs (ISO 50001)
Certifications & Standards
- IEC 61000-6-2/4 EMC Compliance
- ISO 9001:2015 Quality Management
- IATF 16949 Automotive Certification
*Request technical dossiers including:
- Warpage simulation reports (Ansys Mechanical)
- Cross-section micrographs of weld interfaces
- 5,000-cycle durability test data per GMW3172*
