1. Material compounding and slitting: building a flexible matrix
Film cutting, accurately cutting the substrate according to the three-dimensional model of the airbag, with a smooth cut to avoid stress concentration caused by burrs on the edge of the heat seal.
2. Heat synthesis: forging the core structure with millimeter-level precision
Mold positioning: put the slit substrate into the heat sealer profiling mold, the mold has built-in pressure sensors and infrared temperature probes to automatically compensate for material thickness fluctuations (±0.1mm error).
High-frequency welding: start the 27.12MHz high-frequency electromagnetic field to make the TPU molecular chain complete cross-linking and curing within 0.3 seconds to form a molecular-level welding surface. The equipment simultaneously applies a pressure of 0.6MPa to ensure that the penetration depth reaches 85% of the material thickness and the weld tear strength is ≥18N/cm.
Microstructure molding: the bionic acupressure convex points (diameter 3mm, height 1.2mm) are hot-pressed on the surface of the airbag through the mold convex structure, and the subsequent inflation test can simulate the acupressure technique of professional masseurs.
3. Inflation verification and function integration: opening up a healthy travel closed loop
Airtightness test: connect the heat-formed airbag to the inflation system, maintain the pressure at 0.15MPa for 30 minutes, and detect the leakage rate ≤0.02sccm, far exceeding the automotive industry standard of 0.1sccm.
Dynamic charging and discharging cycle: simulate the 10-year use cycle of the seat, conduct 500,000 charging and discharging tests on the airbag (0-0.12MPa), monitor the weld deformation and material fatigue, and ensure that there is no debonding or bulging.
Healthy function implantation: pre-embed the flexible circuit board inside the airbag, integrate the pressure sensor and micro vibration motor, and link with the seat ECU through Bluetooth to realize the intelligent health closed loop of "pressure monitoring-algorithm analysis-massage intervention".
4. Lightweight and environmentally friendly finishing: technological breakthrough and sustainable compatibility
Honeycomb structure weight reduction: heat-bond the hexagonal honeycomb support structure in the non-load-bearing area of the airbag to reduce the weight of the airbag by 22% while maintaining the inflation stiffness.
Degradable coating treatment: Spray bio-based polyester coating on the surface of the airbag, which can be decomposed into carbon dioxide and water within 180 days after being discarded and hydrolyzed at 75°C, meeting the requirements of the EU ELV Directive.
Through the deep integration of materials, structures and functions by heat sealing machines, car seat massage airbags are evolving from a single supporting component to an active health management terminal, and its production process has also become a microcosm of the technical strength of automobile companies.