Today’s laminate floors are available in a multitude of designs, patterns, and textures, yet they all consist of four main components that are bonded together. The bottom layer, or backing, is a melamine plastic layer that lends dimensional stability to the planks or tiles and also helps guard against moisture from the sub-floor. (Moisture infiltrating any flooring, is the enemy.)
The next layer is a core board, generally made from high-density fiberboard or particle board which may also contain melamine plastic resins that help improve the moisture resistance of the core.
Then a decorative layer or print film is adhered on top of the core board giving the floor its hardwood or tile look. This decorative layer is a printed high-resolution photo-reproduction of wood grain, natural stone or ceramic tile pattern. (Now you know how the look-a-like is born.) On the top of our “cake” is a durable wear layer, providing protection and stain resistance.
Today, many wear layers also contain aluminum oxide, as well as melamine resin, and that creates exceptional durability. The kind that will stand up to the most active household. All four layers are then combined in a high-pressure or direct pressure manufacturing process.
Now we’ll take you through the manufacturing process of laminate.
The process begins with the assembly of the 4 layers of raw materials in large sheets. This typically takes place on a production line, where modern technology enables each layer to be stacked on top of another with incredible accuracy and precision. How precise you may ask? Most manufacturers use sophisticated electronic calibrating equipment and digital camera systems to keep the sheets in perfect alignment. The backing layer is first on the line, with the core board placed directly on top of that.
Next, the printed decorative layer is stacked on top of the core board. The final layer to be stacked on is the wear layer.
Once the 4 layers have been stacked, they are ready for pressing. The presses used to create laminate flooring have hydraulic rams that apply tremendous pressure to the stacks. The stacks of layers are pressed at high temperatures reaching 400 degrees Fahrenheit, with up to 600 pounds per square inch of pressure for 20 to 30 seconds. Manufacturers carefully monitor the time and temperature when pressing the layers to successfully cure and bond the stacks into a single sheet of finished decorative laminate. If the laminate that is being manufactured is designed to have a textured surface, the press has specialized plates that imprint the textured pattern onto the sheets, creating more natural looking planks or tiles.
After the sheets are pressed they are left to cool to ensure that they fully cure and to prevent any surface imperfections. Then the sheets are stacked and stored for a time so that they can continue to acclimate, thereby enhancing the stability of the boards.
Once the boards are fully acclimated, they are milled, or cut into planks or tiles. The freshly cut planks or tiles then move on to be profiled. Multiple profiling saws create the tongue and groove edges on the sides of the planks or tiles that enable the floor to lock together with ease. The blades on the profiling saws use electronic and laser systems that produce incredibly accurate edges for a perfect fit. Further assurance of the precision of your floor.
The finished planks or tiles then go through a quality inspection and are checked for color, texture, finish, size and correct interlocking capabilities.
Once approved, the planks or tiles are then stacked, packaged and loaded onto trucks for distribution.
While many people attempt to install laminate flooring on their own, this job is still difficult work, labor intensive and extremely exacting. We strongly recommend you call upon laminate floor installation professionals to install your laminate floor. That way you can be assured of a beautiful, efficient and correct installation. Which is precisely what our goal is for you.
However, while installing laminate flooring is a skill that is developed through years of experience, your understanding of the basics of installation will increase your knowledge of the process and enhance your confidence in the professionals working in your home.
Taking care of your laminate flooring investment will reward you and your home for many years to come.
Plus, knowing what’s expected of you regarding laminate flooring upkeep can be a determining factor in your purchase choices.
Laminate floors are beautiful and very durable but not indestructible.
Floors can dull when unattended dirt acts as an abrasive on its surface.
This can be avoided by sweeping, dust mopping or vacuuming regularly to remove loose dirt and grit.
You can use a broom or, to make the job faster, a vacuum cleaner without a beater bar is also recommended.
Vacuum cleaner attachments are useful to pick up dirt from between planks, tiles or along edges.
An occasional very light damp mopping is also suggested.
However, your laminate flooring can expand if excessive water is used while cleaning.
After damp mopping, a clean dry cloth should be used to wipe your floor thoroughly.
Placing doormats or walk-off mats at each entryway will collect excessive moisture and dirt before they enter your home.
Do’s and don’ts from our pros.
Glides or floor protectors on the bottom of your furniture will prevent possible scratching or abrasion.
It’s important to lift heavy furniture instead of dragging or pulling them.
Use pieces of carpet face down under heavy objects when moving them across your floor.
Spot cleaning and occasional complete cleaning of your laminate floor can be done using the manufacturer’s recommended products.
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