Manufacturing Process of Lumbar Support Airbags
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The production involves material selection, process design, equipment configuration, and quality control. Below is the detailed workflow and technical specifications:
I. Core Production Process
1. Material Selection
- Airbag Body:
PVC/PU/TPU (0.5-3mm thickness) with ≥18 MPa tensile strength and 10-year aging resistance.
- Coating & Sealing:
PU/PVC coatings (50-200μm) for airtightness (<0.01 cc/min leakage @ 50kPa).
- Support Structure:
Memory foam (density: 50-80 kg/m³) or elastic fiber mesh (EN 14704-1 certified).
2. High-Frequency (HF) Welding
- Seam welding at 27.12/40.68 MHz, achieving 12-25 N/15mm peel strength.
- Automated lines perform cutting/welding/marking at 30s/unit with ±0.2mm precision.
3. Inflation & Pressure Testing
- Nitrogen inflation (0.5-10 bar) in 18m³ test chambers.
- High-speed cameras (1000fps) monitor dynamic adjustments (5-50Hz frequency response).
II. Key Production Equipment
| Equipment |
Specifications |
| HF Welding Machine |
10-40kW power, multi-layer TPU/PVC mode |
| Synchronous Cutter |
600 dpi precision, Ra ≤3.2μm edges |
| Automated Production Line (e.g., Shanghai Puxiong PX-8800) |
Integrated vision inspection (0.02mm accuracy), 50 units/hour output |
III. Quality & Certification Requirements
1. Regulatory Compliance
- Pressure Vessels: TSG 07-2019 Special Equipment Certification (China).
- Medical Devices: ISO 13485 & NMPA Class I Filing.
2. Testing Protocols
- Material Uniformity: Particle analyzer (D50 ≤100μm).
- Durability: 200,000 fatigue cycles @ 0.5-5Hz (SAE J1882).
- Load Capacity: 5-ton static load for 24h (ASTM D3574).
Technical Performance
- Airtightness: ≤0.008% pressure drop/hour @ 80kPa
- Operating Temp: -40°C to +120°C (IEC 60068-2-1/2-2)
- Production Yield: ≥99.2% (Six Sigma-controlled process)
This manufacturing system achieves 35% energy savings compared to ultrasonic methods while meeting ISO/TS 16949 automotive standards.
