Embossing and welding of automotive carpets utilizes high-frequency technology to achieve three-dimensional patterns. The core principle is to use a high-frequency electromagnetic field to drive the internal molecules of the material to generate heat through friction, combined with mold pressure to complete the welding and embossing process. The following is a detailed analysis of the implementation method and advantages:
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I. Core Principle: High-Frequency Electromagnetic Field Drives Molecular Friction and Heat Generation
The high-frequency embossing machine generates a high-frequency electromagnetic field (27.12MHz or 40.68MHz) through a vacuum tube self-excited oscillator. This polarizes the internal molecules of the material (such as PVC, TPU, EVA) and causes them to vibrate at high speed, generating frictional heat until softened. Under mold pressure, the material is welded according to the mold pattern to form a three-dimensional embossed pattern, which is then cooled and set. This technology eliminates the need for chemical adhesives, achieving multi-layer material composites through physical welding, while simultaneously imparting intricate patterns such as anti-slip textures and brand logos to the carpet.
II. Process Flow: Four Steps for Efficient Processing
Material Preparation and Mold Installation
Select soft materials such as PVC and TPU, and cut them to the preset size (e.g., 90cm × 150cm).
Install the custom mold (aluminum alloy or copper alloy material), and adjust the mold and pressure plate center alignment to an error ≤0.1mm.
Preset parameters such as high-frequency power (e.g., 12KW), heating time (3-5 seconds), and pressure value (800kg) via the PLC touchscreen.
High-frequency heating and pressure forming:
Start the equipment; the high-frequency electromagnetic field softens the material surface to a molten state (temperature approximately 150-200℃).
The pneumatic-hydraulic booster cylinder drives the upper mold to press down, applying the preset pressure. The material fills the mold pattern, forming an embossed effect.
Maintain pressure for 2-3 seconds to ensure sufficient welding.
Cooling and shaping, and quality inspection: Allow natural cooling or auxiliary air cooling for 5-10 seconds to completely solidify the material.
Check the clarity of the embossing (no blurring, broken lines), weld strength (peel strength ≥5N/cm), and anti-slip performance (coefficient of friction ≥0.6).
Post-processing and packaging: Trim excess material from the edges and clean surface dust.
Place in PE bags or cartons to prevent scratches during transportation.
III. Equipment Characteristics: High Efficiency, Precision, and Safety
Stable High-Frequency Output
Utilizing a high-Q vacuum tube, the output power is stable. Combined with a low-loss European-standard coaxial high-frequency resonator, welding efficiency is high.
Example: A 15KW machine can soften 1mm thick PVC material within 3 seconds.
Precise Pressure Control
The pneumatic-hydraulic booster cylinder provides 800-2000kg pressure, adapting to different material thicknesses (e.g., PVC + sponge composite layer).
The bidirectional slide design enables continuous reciprocating pushing of the mold, improving production efficiency.
Comprehensive Safety Protection
Spark Suppressor: Automatically cuts off the high-frequency circuit when sparks are detected, preventing mold damage.
Overload Protection: Power is cut off when current exceeds the limit, protecting the oscillator tube and rectifier.
Grounding Device: Ensures operational safety and prevents static electricity accumulation.
IV. Advantages: Combining Aesthetics and Functionality
3D Embossing Enhances Aesthetics
Through precision mold design, clear embossing of complex patterns (such as brand logos and anti-slip textures) can be achieved, enhancing product added value.
Multi-layer welding optimizes sound insulation. A composite structure is formed by fusing the PVC surface layer with sound-absorbing materials such as XPE and EVA, improving sound insulation performance by 20%-40%.
Balancing environmental friendliness and durability. No chemical adhesives are used, meeting VOC emission standards and reducing in-vehicle odors.
High weld strength ensures wear resistance, high temperature resistance, and an extended service life of over 5 years.