High-frequency welding and forming of TPU film empowers the ventilation and airflow layer of automotive seats
As the automotive industry continues to focus on intelligent and enhanced comfort features, seat ventilation systems have become an increasingly common feature in passenger vehicles, particularly in new energy vehicles (NEVs). By continuously circulating air through the seat, these systems help reduce heat and moisture buildup, providing a more comfortable driving and riding experience.
In modern automotive seats, the air distribution layer is typically manufactured by high-frequency (HF/RF) welding of TPU films to create sealed internal airflow channels. Working together with the blower system, these channels distribute airflow evenly across the seat surface, improving ventilation efficiency and passenger comfort.
Compared with conventional manufacturing methods, HF welding offers higher production efficiency, consistent weld quality, and excellent airtightness. Thanks to its outstanding weldability, flexibility, and durability, TPU film has become an ideal material for automotive seat ventilation air duct structures.
Customer Requirements
A leading automotive seat manufacturer was developing a new-generation seat ventilation system and required a TPU film that could meet the following performance criteria:
- Excellent high-frequency welding performance for stable, high-speed production
- Strong and reliable weld seams with long-term durability
- Outstanding airtightness to ensure stable airflow distribution
- High flexibility to accommodate complex three-dimensional seat designs
- Excellent flex resistance, fatigue resistance, and resistance to high and low temperatures
- Compliance with automotive interior requirements for low VOC emissions and low odor
Our Solution
To meet these requirements, we supplied a high-frequency weldable TPU film specifically designed for automotive air duct applications.
Under a high-frequency electromagnetic field, the TPU film rapidly softens and fuses with another TPU film, creating a sealed and continuous air channel without the need for additional adhesives. This enables one-piece manufacturing of the air distribution layer while simplifying the production process.
Through optimized material formulation and manufacturing technology, the TPU film provides a wide processing window during HF welding, producing smooth and uniform weld seams with excellent sealing performance and mechanical strength. The result is a reliable and efficient solution for automotive seat ventilation systems.
Product Advantages
- Excellent High-Frequency Weldability
The TPU film responds quickly and consistently during HF welding, offering fast welding cycles and a wide processing window. It is compatible with various HF welding equipment and supports automated, high-volume production.
The welded air channels provide excellent sealing performance, minimizing air leakage and ensuring stable airflow throughout the ventilation system for consistent cooling performance.
The fusion welds exhibit excellent mechanical strength and long-term durability, maintaining reliable performance under continuous vibration, repeated compression, and thermal cycling experienced in automotive applications.
The TPU film remains soft and flexible after welding, allowing it to conform to complex seat geometries without compromising passenger comfort or assembly efficiency.
- Excellent Environmental Resistance
The material offers outstanding resistance to high and low temperatures, humidity, aging, and repeated flexing, meeting the demanding durability requirements of automotive interiors.
The TPU film is formulated to meet automotive interior standards for low VOC emissions and low odor, making it suitable for modern passenger vehicles and new energy vehicle applications.
Application Results
After implementing the TPU film solution, the customer successfully achieved one-piece manufacturing of the seat ventilation air distribution layer through high-frequency welding.
During mass production, the material demonstrated stable welding performance, consistent weld quality, and excellent airtightness. The optimized process improved production efficiency while increasing product consistency and reducing defect rates.
Reliability testing, including thermal cycling, fatigue testing, and airtightness evaluation, confirmed that the welded air channels maintained stable airflow performance under demanding automotive operating conditions, fully meeting the customer's performance requirements.
Typical Applications
In addition to automotive seat ventilation systems, high-frequency weldable TPU film is widely used in:
- Automotive seat massage air chambers
- Lumbar support air chambers
- Automotive interior airtight components
- Medical inflatable products
- Outdoor inflatable equipment
- Wearable inflatable devices
- Other high-frequency welded airtight structures
As automotive seating systems continue to evolve toward greater comfort, intelligence, and lightweight design, manufacturers require materials that deliver outstanding welding performance, airtightness, and long-term durability.
With its excellent high-frequency weldability, superior sealing performance, flexibility, and environmental resistance, TPU film provides a reliable material solution for automotive seat ventilation air duct structures.
We remain committed to developing high-performance TPU film solutions that support the evolving needs of the automotive industry and other high-frequency welding applications.
From JCC Tianyang--an expert and leading hot melt adhesive solution supplier
2026.6.26
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