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The high-frequency embossing machine for car floor mats achieves welding and embossing of the mat material through the synergistic effect of a high-frequency electromagnetic field and mold pressure. The following is a detailed processing flow, covering the entire process from preparation to finished product:
I. Preliminary Preparation Stage
Material Selection and Pre-treatment
Material Type: Select PVC, TPU, EVA, or composite materials (such as PVC + sponge layer) according to the floor mat design requirements.
Size Cutting: Use a laser cutter or CNC cutting machine to cut the material to the preset size (e.g., 90cm × 150cm), ensuring neat edges.
Cleaning: Wipe the material surface with alcohol or a special cleaner to remove oil and dust, avoiding affecting the welding quality.
Mold Design and Installation
Mold Customization: Design the mold according to the floor mat pattern (e.g., anti-slip texture, brand logo). The material is usually aluminum alloy or copper alloy, ensuring good thermal conductivity.
Mold Installation: Fix the mold to the upper and lower pressure plates of the high-frequency machine, adjusting the position to align the mold center with the pressure plate center, with an error not exceeding 0.1mm.
Parameter Preset: Parameters such as high-frequency power (e.g., 12KW), heating time (3-5 seconds), and pressure value (800kg) can be set via the PLC touchscreen.
II. Processing Operation Stage
**Material Positioning:** Lay the cut material flat on the lower mold surface, ensuring the material completely covers the embossing area, leaving a 2-3mm margin at the edges.
For multi-layer composite materials (e.g., PVC + sponge), stack them sequentially and secure them with positioning pins to prevent displacement during processing.
Start High-Frequency Heating: Press the start button. The high-frequency machine begins outputting a high-frequency electromagnetic field (typically 27.12MHz or 40.68MHz).
The polar molecules inside the material (e.g., chlorine atoms in PVC) vibrate at high speed under the influence of the electromagnetic field, generating frictional heat that rapidly softens the material surface to a molten state (temperature approximately 150-200℃).
Pressure Molding: When the material reaches a molten state, the pneumatic-hydraulic booster cylinder or hydraulic system drives the upper mold to press down, applying the preset pressure (e.g., 800kg).
The mold and material are in close contact, and the molten material fills the mold's texture, creating an embossed effect (such as stripes, granules, or 3D logos).
Maintain pressure for 2-3 seconds to ensure full fusion and shaping.
Cooling and Shaping: After processing, the upper mold is lifted, and the material cools rapidly under natural cooling or auxiliary cooling devices (such as air-cooled fans).
Cooling time is approximately 5-10 seconds to ensure complete material curing and prevent embossing deformation.
III. Quality Inspection and Post-Processing
Appearance Inspection: Check if the embossed pattern is clear and complete, without blurring, broken lines, or burrs.
Confirm that the welded edges are smooth, without delamination, bubbles, or burn marks.
Performance Testing
Anti-slip Test: Measure the coefficient of friction of the embossed area using a coefficient of friction tester to ensure it meets the standard (e.g., ≥0.6).
Peel Strength Test: Conduct a peel test on multilayer composite materials to verify the interlayer bond strength (e.g., ≥5N/cm).
Temperature Resistance Test: Place the foot pad in an 80℃ high-temperature environment for 2 hours and observe whether the embossing deforms or falls off.
Post-processing Steps
Edge Trimming: Trim excess material from the edges of the pads using a cutting machine or by hand to ensure dimensional accuracy.
Cleaning and Packaging: Blow away surface dust with an air gun, then place in a PE bag or carton to prevent scratches during transport.
IV. Key Process Control Points
High-Frequency Power Matching: Insufficient power will result in incomplete material welding and blurry embossing; excessive power may burn through the material or generate sparks.
Example: When processing 1mm thick PVC pads, a power setting of 10-12KW is recommended.
Heating Time Control: Insufficient heating time will not fully soften the material; excessive heating time will over-melt the material, affecting embossing accuracy.
Example: The heating time for PVC material is typically 3-5 seconds, while for TPU material it needs to be extended to 5-8 seconds.
Pressure Uniformity: Uneven pressure will result in inconsistent embossing depth, or even areas where welding is incomplete.
Solution: Regularly check the pneumatic-hydraulic booster cylinder or hydraulic system to ensure stable pressure output; the mold surface must be flat and free of unevenness.
Spark suppression: Impurities on the material surface or burrs on the mold edge may cause sparks, damaging the mold or oscillator tube.
Solutions: Install a spark suppressor to monitor sparks in real time and automatically cut off the high-frequency circuit; sand the mold edges with sandpaper before processing.