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Laminate Flooring Construction

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How is Laminate Flooring Made? Think, “Cheese Sandwich”.

Want to know how is laminate flooring made? Think, “cheese sandwich”, because the similarities are uncanny. Laminate flooring construction is made up of 4 layers. The top and bottom layers are like the bread of a sandwich – protecting the filling inside and keeping it compacted together. Inside there are 2 fillings – 1 big chunk of cheese and 1 decorative piece of lettuce on top. Let us introduce the 4 layers of laminate flooring construction with a little more technical lingo:

Wear Layer – This is the top layer. It is not made of bread but of cellulose paper saturated with melamine plastic resins or aluminum oxide to resist abrasion. This exceptionally hard layer protects the laminate flooring from stains, fading and wear.

Decorative Layer – This is the “lettuce” part of the laminate floor – a high- resolution image printed on the core layer below that gives the floor its real wood appearance.

Core Layer – The “cheese chunk” of the laminate floor. This central core board is comprised of Medium Density or High Density Fiberboard (MDF or HDF) made of highly compact wood fibers and resins to support the weight and stress of foot traffic. The best laminate flooring manufacturers will only use HDF because it is more durable than MDF.

Stabilizing Layer – The other “slice of bread” is the very bottom layer of the flooring. Like the wear layer it is also a cellulose paper saturated with melamine plastic resins. This stabilizing layer provides a protective barrier between the subfloor and the core board, which creates equality on either side of the plank ensuring there is no unnecessary movement within the board. After all, a cheese sandwich wouldn’t be complete without 2 slices of bread.

The Full Laminate Floor Manufacturing Process:

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The 4 layers of the “cheese sandwich” now need to be assembled and fused together. Most laminate flooring manufacturers use the Direct Pressure Laminate Flooring (DPL) process to bond them. All 4 layers will be placed in a pressing machine, stacked from the stabilizing layer up and will be pressed together at over 600 pounds of pressure per inch at temperatures of around 200 degrees Celsius (400 degrees Fahrenheit).

*During the DPL process, if the planks require a special real wood texture to the touch, many laminate flooring manufacturers can produce this. One method of texturing the top layer is in-register embossing. This creates a dramatic level of realism to the laminate flooring construction making embossed in register laminate flooring the ideal choice for people who want their floor to look as close to real wood as possible.

Once the layers have been successfully pressed together, they will require a short-time acclimation to allow the planks to cool down making them stable and suitable to the environment. This short-time acclimation is usually 24 hours.

After this, the next step is to cut the large board into planks according to the ordered sizes, after which a 5-7 days acclimation period is necessary for the planks to acclimatize further.

Next comes the grooving process to make the “jigsaw like” tongue and groove click systems that laminate flooring is so famous for. This requires each plank to be filtered through a special “grooving” machine that cuts the edges into shape.

Once fully grooved, unqualified boards will be picked out by Quality Control and the "quality laminate flooring" will be packed into paper cartons all ready to go.

If you’re looking for laminate flooring manufacturers to make your requirements, don’t hesitate to email details of your requests to sales@sunspeedflooring.com. Sunspeed Flooring are the best laminate flooring manufacturers in China with highly competitive laminate flooring prices.