If you are thinking about purchasing laminate flooring for your home, durability and price are major considerations. It is helpful to learn more about how different laminates are manufactured so that you can make an informed purchase decision. There are two manufacturing methods: direct pressure and high pressure.
Direct Pressure Method:
Laminate flooring made by the direct pressure method consists of four layers:
Stabilizing (backing) layer: This is the bottom material that adds stability and strength to the laminate board.
Core layer (board): This central layer of the laminate board supports the stress and weight of foot traffic. It usually consists of high-density fiberboard but may also be made from medium-density fiberboard or particle board.
Decorative layer: This is the photo rendering of the design which is made to imitate a natural material surface, such as hardwood or slate.
Wear layer: This is a resin-based coating which typically consists of several coats of aluminum oxide (second only to diamonds in hardness) or melamine and is designed to resist abrasion and provide protection for fading, staining and wearing.
Laminate flooring is made by fusing these layers together at a temperature of approximately 400 degrees Fahrenheit and at a pressure of over 600 pounds per square inch. The decorative and stabilizing layer are pressed together onto the core layer in the direct pressure process.
High Pressure Method:
Laminate flooring made by the high pressure method consists of five layers instead of four. The fifth layer consists of special high-strength paper. The decorative layer and overlay are pressed onto this fifth layer first, then the resulting fused material is glued to the core layer. The backing and top wear layers are treated separately and then fused directly onto the core. This process creates a very strong floor that is suitable for very heavy foot traffic.
Depending on the process, flooring thickness varies from about 6 mm to 14 mm; the thicker the flooring, the greater the durability and the higher the price. Laminate flooring made by the high pressure process is generally more expensive than that made by the direct pressure process.
Final Manufacturing Steps:
Surface textures are imprinted onto the laminate flooring sheets (made by either method), which are then cut into planks or square tiles. The tongue and groove locking system is cut into the edges using specialized machinery.
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