I. Core Production Process
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Material Selection and Customization
- Base Material: Uses TPU (thermoplastic polyurethane elastomer rubber) film with thickness ≥0.3mm, tensile strength ≥25MPa, and flame retardancy rating V-0 (UL94) to ensure airtightness and safety.
- Customized Formulation: Adjusts TPU properties based on vehicle model requirements:
- Sedans: Low hardness (Shore A 55-65°) with flexible modifiers for a delicate touch.
- Sports Cars: High resilience formula (elastic recovery rate ≥95%) for high-frequency gentle massage effects.
- Luxury SUVs: Composite antibacterial nano-silver ions and breathable microporous structure for hygiene and heat dissipation.
- Structural Design: Uses 3D scanning to capture seat data and customize airbag shape and size. For example, fastback sedans use "segmented TPU film airbags" with narrow, thin upper sections for shoulder-neck fit and wide, thick lower sections for lumbar support.
Hot Press Forming
- Process Parameters: Temperature 180°C-200°C, pressure 5-8MPa, time 10-15 seconds, ensuring dimensional accuracy of ±0.5mm.
- Equipment: Hot press machines with adjustable constant-temperature systems (0°C-300°C) and pneumatic/hydraulic drive modes to accommodate different material needs.
High-Frequency Welding
- Process Requirements: Seam width ≥5mm, burst pressure ≥300kPa, ensuring welding strength.
- Equipment: High-frequency welding machines (e.g., Puxiong’s automated car seat airbag production line) use high-frequency current (27.12MHz or 40.68MHz) to generate heat for stitch-free welding, eliminating air leakage risks.
Air Chamber Layout and Massage Head Design
- Air Chambers: 3-5 independent air chambers arranged in a bionic spinal curve for zoned massage.
- Massage Heads: Hemispherical protrusions with a height of 2-5mm and density ≤10/100cm² to avoid overstimulating the skin.
Valve Installation and Testing
- Valves: Opening pressure 5-10kPa, closing pressure 3-6kPa, ensuring precise inflation/deflation control.
- Airtightness Test: Inflate to 15-20kPa pressure, hold for 5-10 minutes; pressure drop ≤0.5kPa is considered qualified.
Coating Treatment and Packaging
- Coating: Surface coated with 0.05-0.1mm wear-resistant coating to extend service life.
- Packaging: Inner packaging uses PE bags + pearl cotton, outer packaging uses corrugated boxes labeled "Fragile" and "Moisture-Proof."
II. Key Production Equipment
High-Frequency Welding Machine
- Function: Simultaneously welds and cuts TPU film, supporting multi-station operations (e.g., four-station models with a capacity of 3,500 units/8 hours).
- Representative Models:
- Puxiong Automated Car Seat Airbag Production Line, suitable for cross-border exports.
- Puxiong 5KW High-Frequency Welding Machine, power 500
