How Laminate Flooring is Made

Most of the people prefer to pick their laminate by measuring its durability and toughness. One way to do this is to understand how different laminates are made.

Direct Pressure Laminate Flooring

DPL is made of 4 layers:

• Stabilizing Layer: bottom layer also called the Backing Layer, provides strength and stability to the laminate board;
• Core Layer: the central layer of a laminate floor is also called the core board; this is the structural element made with high-density fiberboard (HDF), but sometimes is made from particle board or medium-density fiberboard (MDF). Its purpose is supporting the weight and stresses of foot traffic.
• Decorative Layer: is made to mimic the surface of a natural material, such as a hardwood species.
• Wear Layer: a resin-based coating typically made up of several coats of melamine oraluminum oxide (2nd only to diamonds in hardness) designed to resist abrasion and which protects the floor from stains, fading and wear.

Laminate flooring is made by fusing these layers together at over 600 pounds of pressure per inch at temperatures of around 400 degrees Fahrenheit. In the direct-pressure laminate process the decorative covering layer and stabilizing layer are pressed together onto the core layer.

Composition of a direct-pressure laminate floor (DPL)

• Overlay (wear layer)
• Decorative paper
• Core layer
• Stabilizing layer

High Pressure Laminate Flooring

High Pressure Laminate Flooring consists of the same four layers as in Direct Pressure Laminate, with the fifth layer being a special high-strength paper and creates a more durable laminate than direct pressure can. The backing and top wear layers are treated separately and then fused directly onto the core, with the purpose of creating a very robust floor suitable for very heavy traffic. In the high-pressure laminate process, the decorative paper and overlay are pressed onto a special high-strength paper first. Only in a second stage is this so-called high-pressure laminate glued to the core layer.

Composition of a HPL Laminate floor

• HPL layer
• Core layer
• Stabilizing layer

The resulting laminate flooring products can come in thicknesses varying from approximately 6mm to 14mm. The most durable floor is the thicker one. HPL flooring can be found for a higher price than DPL flooring.

The Final Steps in the Process

Once the sheets of laminate flooring are made, surface textures are imprinted onto the sheets. Furthermore, the sheets are cut into planks or square tiles. Specialized machinery is used to cut the tongue and groove locking system into the edges.