What is an XPE laminating machine? Types and composition of XPE laminating machines

XPE laminating machine is a specialized equipment that firmly adheres various functional films (such as PE film, PET film, aluminum foil, color film, flame retardant film, etc.) to the surface of XPE (chemically cross-linked polyethylene foam) sheets through hot melt adhesive bonding or hot pressing composite.

XPE laminating core purpose:
 Give new features such as waterproof, moisture-proof, flame-retardant, enhanced, beautiful (printed), easy to clean, etc.
 Improving surface properties: making XPE, which originally had a porous surface and was prone to dust adsorption, smooth and dense.
 Expand application scope: Enable XPE to be applied in fields with special surface requirements (such as yoga mat surfaces, automotive interiors, medical mats).

The main types and process principles of XPE film coating

 According to the bonding method, it can be mainly divided into three categories:

1. Hot air laminating machine
 The most mainstream and popular method of XPE laminating and embossing at present.
 Principle: Quickly pass the XPE sheet through hot air to melt a very thin layer (about 0.1-0.3mm) on its surface, and then immediately combine it with the film under the pressure roller. If the roller surface is engraved with patterns, the roller engraved patterns can be pressed out on the film surface. The pattern is clear and has a good sense of three dimensionality.
 Advantages: No need for glue, relatively low cost, suitable for certain composites that are sensitive to glue.

2. Hot melt adhesive laminating machine
 This is currently the most mainstream and widely used XPE laminating method.
 Principle: Apply a layer of molten hot melt adhesive (usually PUR polyurethane hot melt adhesive or EVA hot melt adhesive) between the XPE substrate and the laminating material, and then immediately press and cool to solidify.
 Advantages: extremely high bonding strength, good temperature resistance, environmentally friendly and solvent-free, fast speed.
 Process: XPE unwinding → (surface treatment, such as corona discharge) → application of hot melt adhesive → lamination with film → compression cooling → winding.

3. Flame laminating machine
 A traditional but still used method in specific fields.
 Principle: Quickly pass the XPE sheet through a high-temperature flame to melt a very thin layer (about 0.1-0.3mm) on its surface, and then immediately combine it with the film under a pressure roller.
 Advantages: No need for glue, relatively low cost, suitable for certain composites that are sensitive to glue.
 Disadvantages: There are safety hazards of open flames, difficult process control (easy to burn through or not stick firmly), poor environmental friendliness, and it is gradually being replaced by hot melt adhesive film coating.

The main components of hot melt adhesive laminating machine (taking mainstream models as examples)
 Unwinding system (dual unwinding):
 XPE unwinding rack: carrying XPE foam rolls, equipped with tension control.
 Film unwinding rack: carrying PE film, PET film, etc. to be composite, equipped with correction device (EPC).
 Preprocessing system:
 Corona treatment machine: Treatment of XPE and/or film surfaces to significantly increase their surface energy, which is a key step in ensuring adhesive or flame composite adhesion.
 Glue coating and composite unit (core):
 Hot melt glue machine: melts solid hot melt glue blocks into liquid form and precisely delivers them to the coating head through a gear pump.
 Coating head: Common methods include comma scraper coating or roller coating, which evenly applies molten glue to the surface of XPE or film.
 Composite pressure roller: After accurately aligning the coated XPE with the film, pressure is applied through a pair of heated or cooled steel rollers to instantly composite it.
 Cooling and shaping system:
 Cooling roller: It rapidly solidifies the hot melt adhesive to form the final bonding force.
 Adhesive curing channel: For PUR adhesive (moisture curing type), a constant temperature and humidity channel is required to allow it to fully react and achieve the final strength.
 Roll up system:
Roll the laminated finished product into a roll. Require stable tension control to ensure the flatness of the coil material.

Electrical control system:
 PLC controls the speed, temperature (each section, glue temperature), tension, glue amount, etc. of the entire line.
 Workflow (Hot Melt Adhesive Method)
 Unwinding and guiding: XPE substrate and functional film are smoothly released separately.
 Surface activation: Both are treated with corona discharge to improve surface adhesion.
 Precision coating: Molten hot melt adhesive is evenly coated on the surface of XPE (or the back of the film)
 Instant compounding: The adhesive surface and film are precisely adhered and compressed at the compounding roller.
 Curing and shaping: The composite is cooled by a roller, and the glue quickly solidifies, completing the initial bonding; For PUR adhesive, continue to cure to maximum strength in the environment.
 Roll up: Obtain laminated XPE finished roll material, which can be processed for subsequent slitting, punching, and other operations.

Core application areas
 The XPE performance is significantly improved after lamination, and it is widely used in:
 Sports and fitness equipment:
 Yoga mat: covered with PVC/PU/TPE film, providing a non slip, easy to clean, and aesthetically pleasing surface.
 Fitness mats and children's crawling mats: covered with PE colored film, printed with cartoon patterns, waterproof and easy to wipe.
 Automotive interior:
 The sound insulation layer of the door panel lining, roof, and luggage compartment cushion is covered with non-woven fabric or skin material.
 Architecture and Home Furnishings:
 Floor mats (such as moisture-proof mats under reinforced flooring), covered with aluminum foil or reinforced film.
 Wall panel insulation and sound insulation materials.
 Packaging and Industry:
 High end instrument packaging lining, covered with anti-static film or velvet cloth.
 Insulation pipeline wrapping material.
 Medical and Rehabilitation:
 Medical pads, nursing mattresses, covered with waterproof and breathable PU film or antibacterial film.
 Technical key and selection points
 Adhesive strength:
 The corona treatment must be sufficient and stable.
 Adhesive selection: PUR adhesive has the best comprehensive performance (temperature resistance, hydrolysis resistance, high strength), making it a high-end choice; EVA adhesive has a lower cost.
 Coating accuracy: The uniformity of coating directly determines the quality.
 Adaptability of substrate and film:
 The equipment needs to be able to handle XPE with different thicknesses (such as 1mm-10mm) and densities, as well as thin films of different materials.
 Equipment selection core:
 Effective width: matches product size.
 Glue application method and accuracy: The comma scraper is suitable for high-precision quantitative coating.
 Composite roller pressure and temperature control: precise and adjustable.
 Tension control system: XPE has high elasticity and requires higher tension control than ordinary film composites to prevent tensile deformation.
 Environmental Protection and Safety:
 The hot melt adhesive method is a solvent-free process and environmentally friendly.
 If considering flame recombination, special attention should be paid to fire safety and exhaust gas treatment.

 summary
XPE laminating machine is a key processing equipment that upgrades basic XPE foam into high value-added functional materials. Through lamination, XPE has transformed from a common cushioning and insulation material into a composite material that can meet specific needs in various high-end fields such as sports, automotive, home, and medical. Among them, the hot melt adhesive coating process has become the mainstream technology direction in the current market due to its excellent performance and environmental characteristics. When purchasing, special attention should be paid to the composite strength, adaptability, stability, and degree of automation of the equipment.