1. Process characteristics: high-frequency energy-driven precision molding
1. High-frequency electromagnetic field penetration heating
◦ Principle: The equipment uses a 27.12MHz high-frequency electromagnetic field to make the internal molecules of the material vibrate at high speed and generate heat through friction. The energy acts directly on the inside of the material rather than the surface, achieving uniform heating from the inside out.
◦ Advantages: Avoid surface overheating or local coking caused by traditional heat conduction methods, suitable for precise hot pressing of multi-layer composite materials (such as TPU+leather, PVC+sponge), ensuring that the texture depth error is ≤0.05mm.
2. Instantaneous hot pressing
◦ Efficiency: The high-frequency heating speed can reach 0.3 seconds/time, which is more than 90% more efficient than the traditional hydraulic press (5-8 seconds/time), and is suitable for high-speed assembly line production.
◦ Case: In the false stitching embossing process of the car seat backrest, the high-frequency embossing machine can complete the embossing of a single 15cm long three-dimensional pattern in 0.2 seconds, and the line clarity reaches 0.1mm.
2. Production efficiency: Intelligentization and modularization improve production capacity 1. Fully automatic production process
◦ Integrated control: PLC+touch screen system supports one-button start, and can preset 100 sets of process parameters (temperature, pressure, time) to automatically match the embossing requirements of different materials.
◦ Linked production: Supports networking with AGV material vehicles and visual inspection equipment to achieve unmanned operation of the entire process of "raw material loading → embossing molding → quality inspection → finished product unloading" (taking the embossing of the side wings of automobile seats as an example).
2. Multi-station parallel operation
◦ Structural innovation: The four-station turntable design can simultaneously perform heating, embossing, cooling, and unloading processes, with an equipment utilization rate of more than 95%.
◦ Data comparison: Compared with single-station equipment, the four-station high-frequency embossing machine has a 300% increase in unit time capacity and a 40% reduction in energy consumption (due to shortened equipment idle time).
3. Quality assurance: molecular-level welding and process redundancy design 1. High-strength embossed structure
◦ Fusion depth: High-frequency energy reorganizes the molecular chains of the material to form a strong weld layer with a depth of 80% of the material thickness, and the tear strength is increased by 200% compared with the adhesive process.
◦ Durability test: After 300,000 inflation and deflation cycles, the embossed part of the car seat headrest has a texture retention rate of ≥98%, without degumming or cracking.
2. Intelligent quality monitoring
◦ Pressure closed-loop control: The pressure sensor provides real-time feedback data and dynamically compensates for ±0.05MPa fluctuations to ensure that the embossing depth consistency of different batches of products is ≥95%.
◦ Spark warning system: Using 5557 American spark arrester, the high-frequency output is cut off within 0.01 seconds and the sound and light alarm is sounded to avoid ignition and burns caused by material impurities or gaps.
IV. Environmental protection and economy: low-carbon process and cost optimization
1. Clean production with zero consumables
◦ Process comparison: High-frequency embossing does not require auxiliary materials such as glue and solvents, and reduces VOCs emissions by 100% compared with traditional hot pressing processes, in line with EU REACH regulations and China GB 30981-2020 standards.
◦ Energy consumption data: The power consumption of a single device is only 3.5kW·h per hour, which is more than 50% energy-saving compared with hydraulic presses (8-12kW·h). 2. Low maintenance cost design
◦ Modular structure: Core components such as high-frequency generators, molds, and cylinders can be quickly disassembled and assembled, and a single maintenance takes ≤30 minutes, and the annual maintenance cost is 60% lower than that of hydraulic equipment.
◦ Material compatibility: Supports materials such as TPU, PVC, leather, silicone, etc. with a thickness of 0.3-5mm, reducing equipment downtime due to line changes.