The core process of inflatable air mattresses lies in heat sealing, the quality of which directly impacts product lifespan and safety. Mainstream processes include：
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High-Frequency Welding (High-Frequency Heat Sealing)
Principle: A high-frequency electromagnetic field causes PVC/TPU molecules to generate heat through friction, melting the material surface, which is then pressed to form a seamless weld.
Advantages:
- High weld strength and excellent airtightness, ensuring long-term use without air leakage;
- Smooth edges without burrs, preventing scratches to skin or car interiors;
- Suitable for large-area material welding with high production efficiency.
Application: Used in over 90% of inflatable air mattresses, particularly ideal for PVC materials.
Hot Air Welding
Principle: Heats the material edges to a molten state using a hot air gun, followed by pressing to bond them.
Advantages: Low equipment cost, suitable for small-scale production or repairs.
Limitations: Weld strength is slightly lower than high-frequency welding, and the process requires higher operational skills.
Adhesive Sealing (Auxiliary Process)
Principle: Applies specialized adhesive to the heat-sealed seams to enhance airtightness.
Application: Commonly used for details such as air valves and corners. Eco-friendly, odorless adhesive must be selected to avoid unpleasant odors in enclosed spaces like car interiors.
Quality Assessment Standards
- Weld Uniformity: High-quality welds exhibit consistent width without defects such as weak bonds or burn-through.
- Airtightness Test: After inflation, press the mattress to observe rebound speed; slow rebound may indicate air leakage.
- Edge Finishing: Smooth and burr-free edges to prevent damage to car interiors or skin.
Synergistic Effects of Materials and Processes
PVC + High-Frequency Welding:
- A classic combination where PVC’s weather resistance and high-frequency welding’s strength make it suitable for long-term outdoor use.
- A flocked surface enhances tactile comfort and improves warmth in winter.
TPU + High-Frequency Welding:
- Combines TPU’s eco-friendliness with the precision of high-frequency welding, ideal for users sensitive to odors.
- Superior flexibility in low temperatures compared to PVC, making it more suitable for northern regions.
Memory Foam + Sewing + Non-Slip Base:
- A non-inflatable process where multi-layer structures are fixed by sewing, with rubber dot patterns on the base enhancing anti-slip performance.
- Attention must be paid to fabric breathability to avoid discomfort in summer.
