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The manufacturing process of automotive seat massage airbags is a complex, multi-step process involving key stages such as material selection, molding, assembly, testing, and integration. The following describes the core process flow based on industry practice.
**Material Selection and Pretreatment:** Airbag materials must possess high elasticity, abrasion resistance, and environmental adaptability. Thermoplastic polyurethane (TPU) has become the mainstream choice due to its good flexibility, durability, and environmental recyclability. The material is typically supplied in film form, with a thickness between 0.15-0.3mm, and can be customized according to massage intensity requirements. Precise cutting to design dimensions is required before production.
**Molding and Welding Process:** The cut material is heated and pressed in a mold using high-frequency hot pressing or high-frequency welding technology to form the airbag chamber structure. This process requires strict control of temperature, pressure, and time parameters to ensure accurate airbag shape, strong welding, and avoid localized bulges or weak points. TPU material supports high-frequency welding, enabling precise molding of multi-chamber irregular structures, improving processing efficiency by approximately 30% compared to traditional materials.
**TPU Material Supports High-Frequency Welding:** Assembly and Airtightness Testing: The molded airbag components are assembled into a complete system, with a focus on checking the seals at the seams. An inflation test is then conducted, simulating actual working pressure (0.3-0.5 MPa) and high-frequency cycling (3-5 times per second) to detect the risk of leakage, deformation, or rupture. The test standard must meet the requirement of 1 million cycles without degradation to ensure long-term reliability.
Control System Integration and Final Testing: The airbag system connects to the vehicle's electronic control unit, integrating the air pump, solenoid valves, and sensors, and controlling the inflation and deflation sequence through a preset program. Finally, a visual inspection, performance verification, and environmental adaptability testing (such as high and low temperature cycling) must be completed to ensure compliance with cabin safety and environmental standards (such as VOC emission limits).
Process Optimization and Quality Assurance: Modern production emphasizes the application of automated equipment, such as hot press coating machines and positive mold adsorption machines, to reduce human error. The recyclability of TPU material (recycling rate exceeding 90%) is also incorporated into the process design, contributing to sustainable production.