Automotive carpet embossing and welding utilizes high-frequency technology to achieve three-dimensional patterns and multi-layer material composites. Its core principles, process flow, equipment characteristics, and advantages are as follows:
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I. Core Principle: High-Frequency Electromagnetic Field Drives Molecular Friction and Heat Generation The high-frequency embossing machine uses a vacuum tube self-excited oscillator to generate a high-frequency electromagnetic field (27.12MHz or 40.68MHz), causing the molecules inside the material (such as chlorine atoms in PVC) to polarize and 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 requires no chemical adhesives, achieving multi-layer material composites through physical welding, while simultaneously giving the carpet anti-slip textures, brand logos, and other intricate patterns.
II. Process Flow: Four Steps for Efficient Processing
Material Preparation and Mold Installation
Select soft materials such as PVC, TPU, and EVA, and cut them to the preset size (e.g., 90cm × 150cm).
Install the customized mold (aluminum alloy or copper alloy material), adjusting the mold to align with the center of the pressure plate, with 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 Molding:
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's texture, forming an embossed effect.
Maintain pressure for 2-3 seconds to ensure sufficient welding.
Cooling and Shaping & 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.
Bag or box 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.
Example: Embossed car floor mats increase the coefficient of friction by 30%, significantly enhancing anti-slip performance.
Multi-layer welding optimizes sound insulation: Welding the PVC surface layer with sound-absorbing materials such as XPE and EVA forms a composite structure, improving sound insulation performance by 20%-40%.
Example: The main car carpet uses a three-layer composite structure (PVC surface layer + PE skeleton layer + non-woven fabric base layer), achieving an NRC of 0.65.
Balancing environmental friendliness and durability: No chemical adhesives, meets VOC emission standards, and reduces odors inside the car.
High weld strength, wear-resistant, high-temperature resistant, and extends service life to over 5 years.