Filter Materials Compositing

Pulan factory's durable Filter Materials Compositing Machine uses hot melt adhesive that is heated and melted before being evenly applied onto the glue coating roller. The nonwoven fabric is coated with adhesive and then laminated with wire mesh through the laminating roller. After passing through pressure rollers for enhanced bonding strength, the finished composite material is automatically rewound into rolls. As a professional filter media laminating machine manufacturer, we provide factory-direct supply, customization services, and bulk order support.

What is Filter Materials Compositing?

Filter Materials Compositing is an automatic laminating machine designed for hot melt adhesive bonding between nonwoven fabric and wire mesh. The machine consists of an unwinding system, glue coating roller, laminating roller, pressure rollers, tension rollers, rewinding unit, adhesive tank, and heating system.
During operation, hot melt adhesive is heated and melted inside the adhesive tank before being transferred evenly onto the glue coating roller. The nonwoven fabric passes over the glue coating roller and receives a uniform adhesive layer. It is then combined with the wire mesh at the laminating roller, compressed by pressure rollers to improve bonding strength, and finally rewound into finished rolls. The entire laminating process is completed automatically, providing high efficiency and consistent product quality.

Applications and Main Components

Application:

The machine is specially designed for laminating:
Wire mesh used in coarse and medium efficiency air filters
Nonwoven filter media used in coarse and medium efficiency air filters

Main Components

Unwinding System
Material shafts and positioning discs for nonwoven fabric and wire mesh rolls
Glue Coating Roller
Applies hot melt adhesive uniformly onto nonwoven material
Laminating Roller
Combines adhesive-coated nonwoven fabric with wire mesh
Pressure Roller Assembly
Enhances bonding strength through compression
Tension Roller System
Ensures smooth and stable material feeding
Rewinding Unit
Automatically rewinds finished laminated material
Adhesive Tank & Heating System
Melts and maintains adhesive temperature
Temperature control range: Ambient to 300°C
Electrical Control System
Variable frequency speed controller
Temperature controller
Main power switch

Working Principle and Production Process

Working Principle

Hot melt adhesive is heated and melted inside the adhesive tank. As the glue coating roller rotates, a uniform adhesive layer is transferred onto the nonwoven fabric. The adhesive-coated nonwoven fabric is then combined with wire mesh at the laminating roller. Pressure rollers reinforce the bonding process, and the finished material passes through tension rollers before being rewound automatically.

Production Process

Material Loading
Install nonwoven fabric rolls and wire mesh rolls onto their respective shafts and secure them using positioning discs.
Fabric Feeding
Guide the nonwoven fabric through the tension rollers toward the glue coating roller.
Mesh Feeding
Feed the wire mesh through the tension rollers toward the laminating section.
Material Alignment
Align the nonwoven fabric and wire mesh before laminating.
Laminating
The nonwoven fabric receives adhesive from the glue coating roller and is bonded to the wire mesh at the laminating roller. Pressure rollers reinforce the bond.
Rewinding
The finished composite material passes through tension rollers and is automatically rewound.
Synchronized Operation
Conveying and rewinding are driven by the same motor, ensuring synchronized speed without stretching or material accumulation.

Key Features

1. Synchronized Conveying and Rewinding Drive
Both conveying and rewinding systems are powered by a single motor, ensuring perfect synchronization and preventing material stretching or wrinkling.
2. Multi-Directional Adjustable Glue Scraper
The glue scraper can be adjusted vertically, horizontally, and laterally, allowing precise adhesive coating control for different materials and bonding requirements.
3. Smooth Transition Bridge Plate Design
The bridge plate surface is level with the laminating roller and lower pressure roller, while adjustable guide strips ensure smooth material movement without blockage.
4. Adjustable Pressure Roller Gap
The gap between upper and lower pressure rollers can be adjusted simultaneously via handwheels:
Clockwise: smaller gap and stronger bonding
Counterclockwise: larger gap and lighter pressure
5. Quick Adjustment Positioning Discs
Positioning discs can be easily adjusted by loosening the locking bolts, accommodating different widths of nonwoven fabric and wire mesh.
6. Wide Temperature Control Range
The digital temperature controller provides precise heating adjustment from ambient temperature up to 300°C, suitable for various hot melt adhesive grades.
7. Adjustable Production Speed
A frequency inverter controls machine speed. Standard production capacity is 3 m/min and can be adjusted according to production requirements.
8. Compact Structure and Efficient Layout
With a footprint of only 4161 × 1170 × 1400 mm, the machine can be integrated into filter production lines or used as a standalone laminating workstation.

Technical Parameters

Installation Notes

Install the machine on a flat, clean, and well-ventilated floor.
Mark the machine centerline according to the installation layout.
Remove the packaging and protective film before installation.
Use a forklift with a minimum capacity of 1 ton for transportation.
Keep at least 1 meter clearance on both sides and 1.5 meters clearance at the front and rear.
Connect and secure the machine frame, then level the machine.
Connect a 380V/50Hz power supply with independent grounding protection.
Check all electrical connections, emergency stop buttons, and safety guards before operation.

FAQ

Q1: What materials can this Filter Materials Compositing Machine process?
A: It is specifically designed for hot melt adhesive laminating of wire mesh and nonwoven fabric used in coarse and medium efficiency air filters.

Q2: What are the main machine components?
A: The machine consists of an unwinding system, glue coating roller, laminating roller, pressure rollers, tension rollers, rewinding unit, adhesive tank with heating system, and electrical control system.

Q3: What is the maximum material width supported?
A: The maximum material passage width is 700 mm, and the maximum raw material roll diameter is 800 mm.

Q4: Why is the bonding strength insufficient?
A: Common causes include:
Insufficient adhesive on the glue coating roller
Excessive gap between pressure rollers
Adjust the glue scraper position, increase adhesive supply, or reduce the pressure roller gap accordingly.

Q5: Why is the laminated material surface uneven?
A: Possible reasons include:
Nonwoven fabric and wire mesh are not aligned
Tension roller guide rings are not positioned on the same centerline
Proper alignment usually resolves the issue.

Q6: How long does the adhesive tank require for preheating?
A: Typically 15–20 minutes are required to reach the desired operating temperature, depending on the hot melt adhesive type.

Q7: What safety protection features are included?
A: The machine is equipped with an emergency stop button, safety guard protection, and grounding protection. Maintenance must only be performed after power disconnection.

Q8: What daily maintenance is recommended?
A: Clean residual adhesive from the glue roller, scraper, and pressure rollers after each shift. Disconnect power before leaving work and regularly check the lubricant level of the worm gear reducer.