How is the inflatable cushion for hip massage produced by heat sealing
Manufacturing Process of Inflatable Butt Massage Cushions
The production involves material preparation, airbag fabrication, HF welding processes, and quality control, with HF welding equipment playing a critical role in airbag sealing.
I. Materials Preparation
Membrane Materials Selection:
- PVC (Polyvinyl Chloride): Low cost (¥8-12/m²), easy processing (Shore A hardness: 75-85), suitable for mass production
- TPU (Thermoplastic Polyurethane): Eco-friendly (REACH compliant), superior elasticity (300-500% elongation), preferred for premium products
Key Requirements:- Tensile strength ≥18 MPa (ASTM D882 standard)
- Tear resistance ≥40 N/mm (ISO 34-1 method)
Auxiliary Components: - Inflation valves (Φ10-15mm silicone/POM valves)
- Air connectors (ABS/PVC quick-connect fittings)
II. Airbag Fabrication
- Cutting & Surface Treatment:
- CNC die-cutting with ±0.5mm precision
- Surface treatments: Screen printing (100-200 mesh), hot foil stamping (130-150°C)
- Sealing Structure Assembly:
- 10-15mm wide edge sealing strips (EPDM/SBR rubber)
- Internal foam inserts (25-35 kg/m³ density polyurethane)
- Component Installation:
- Valve mounting torque: 0.6-1.2 N·m
- Leakage rate <0.5% @ 20kPa (ISO 4637 test)
III. HF Welding Process
Working Principle:
HF generators (27.12/40.68 MHz) induce molecular polarization in PVC/TPU, achieving 130-180°C interfacial melting without adhesives.
Equipment Selection:
- HF Synchronous Cutting Machines:
- For PVC: 8-15kW power, 300-600 mm/s cutting speed
- Simultaneous welding/sealing with <0.2mm edge tolerance
- Dual-head Hydraulic HF Presses:
- For TPU: 30-50 ton pressure, 500×800mm working area
- Weld strength: ≥25 N/15mm (EN ISO 11339)
Process Parameters:
| Parameter | PVC Settings | TPU Settings |
|---|---|---|
| Temperature | 140-160°C | 170-190°C |
| Pressure | 0.8-1.2 MPa | 1.5-2.0 MPa |
| Time | 3-5 s | 6-8 s |
| Frequency | 27.12 MHz (±0.05%) | 40.68 MHz (±0.05%) |
Welding Sequence:
- Align materials with <0.5mm positioning error
- HF activation (5-15kW power output)
- Simultaneous compression (20-50kN force)
- Natural cooling (60-90s cycle time)
IV. Quality Control
- Weld Integrity Testing:
- Peel strength ≥18 N/15mm (ISO 11339)
- Burst pressure ≥35 kPa (ASTM D3786)
- Leakage Detection:
- Helium mass spectrometry: ≤1×10⁻⁴ mbarl/s
- Dimensional Inspection:
- Laser scanning with ±0.1mm accuracy
V. Industrial Applications
Automotive Massage Seats:
- Multi-chamber PVC airbags (Ø80-120mm cavities)
- HF welding cycle: 45-60s per unit
- Vibration resistance: 5-50Hz @ 1.5g acceleration
Home Massage Cushions:
- TPU airbags with 3D contour welding
- Service life: >50,000 inflation cycles
- 24h pressure drop: <5% @ 25°C
This HF welding process achieves >98% production yield with energy consumption reduced by 30-40% compared to thermal bonding methods, while meeting ISO 13485 medical device standards for inflatable products.
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