Automotive Carpet Acoustic PU Foaming Line in China

Illustration notice. Process illustrations are not verified photographs of this installation.

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Haifeng successfully engineered and commissioned an automated polyurethane acoustic carpet backfoaming line for a premier Chinese automotive NVH supplier, cutting cabin structure-borne noise by 18 dB while stabilizing production cycles down to 90 seconds. The turnkey delivery encompassed high-pressure dual-component metering units, a 6-axis robotic trajectory dispensing gantry, dynamic fluid conditioning skids, and multi-station mold clamping fixture interfaces.

Prior to commissioning, the customer experienced high scrap rates and localized acoustic leakage with legacy low-pressure equipment. Expanding carpet geometries with deep footwells frequently trapped air, creating localized foam voids and density variations that failed OEM acoustic compliance tests. The customer required an automated, high-precision high-pressure dispensing solution capable of continuous stoichiometric ratio locking and precise robotic pathing across complex multi-contour floorpans.

Operating since October 2024 on a two-shift daily schedule across a 280 m² workcell, the installation provides consistent component output. By utilizing Haifeng's closed-loop Ratio Lock flow control and automated robotic pouring, the client manufactures dimensionally stable, highly resilient acoustic carpet assemblies compliant with strict automotive acoustic specifications.

Concept illustration: The process image is a concept illustration used to explain the equipment arrangement; it does not document the delivered site.

Haifeng deployed a high-pressure polyurethane foaming cell optimized for semi-rigid acoustic formulations, achieving seamless mold wetting and 90-second cycle times:
1. Precision Stoichiometric Ratio Lock: High-pressure axial piston pumps meter polyol and isocyanate under real-time closed-loop control (±0.5% accuracy), guaranteeing uniform open-cell density.
2. 6-Axis Robotic Dispensing Trajectory: A robot-guided mixing head executes programmed variable-speed pouring, depositing chemical mass precisely into deep footwells without splashing.
3. Dynamic Temperature Conditioning: Dual-circuit TCU units maintain raw chemical temperatures within ±0.5°C, ensuring consistent foaming kinetics across seasonal ambient shifts.
4. Clean Mechanical Cut-Off: An L-shaped self-cleaning high-pressure mixing head executes rapid 0.3s needle shut-offs, eliminating solvent flushes and resin drooling.