LAMINATE LAYER SCHEME
- Protective layer (overlay) designed to protect against external influences.
- Decorative layer- this is a special paper that imitates the structure and color of various types of trees or ceramic tiles.
- HDF board is the base of the laminate, high-density fibreboard.
- Stabilizing layer designed to protect HDF boards from deformation and protect the laminate from moisture.
- Lock system With the help of these locks, the laminate panels are tightly fastened together without the use of glue.
Laminate technology
Making laminate from HDF board with impregnation of the top layers - this is a process consisting of the following stages:
- cladding the slab;
- cutting and milling of panels;
- package.
Impregnation is the impregnation of a material with special compounds. The top layers of the laminate are impregnated with resins with various additives, which form a durable layer when hardened. The strength and wear resistance of the top layer of the laminate, and therefore its class, depend on the formulation of the impregnation compositions. Basically, laminate manufacturers do not impregnate the top layers, but buy them ready-made.
The laminate plant produces direct compression laminate DPL. With DPL technology, all layers of the laminate are simultaneously compressed at high temperatures. This laminate production technology does not use glue, since layers are used that have undergone an impregnation process, which melt and glue the surfaces during hot pressing (up to 200°C). Once cured, the resin and overlay become a monolithic laminate surface layer.
Cladding of slabs
To obtain a laminated board, it is necessary to cover the HDF board with paper-resin films and an overlay.
Sawing and milling of panels
The last important stage of production is the production of the laminate of the required size. Using laminate sawing equipment, laminate sheets are cut to the required dimensions. Each laminate manufacturer has its own laminate sizes. After cutting into plates, using milling equipment, a tongue and groove are cut from the edges of the laminate. Modern HDF boards allow you to cut a tongue and groove of a certain profile, which are called laminate locks. With the help of these locks, the laminate panels are tightly fastened together without the use of glue. The quality, strength and tightness of the connection of laminate panels depends on the quality of the laminate lock and the strength of the HDF sheet.
Package
The finished laminate is packaged in shrink polyethylene (PE) film.
Equipment for laminate production
Comprises:
1. Hot press for laminating HDF boards with high pressure
Used in the production of laminate. Presses are manufactured for different sizes of HDF boards: 2800×2070 mm, 2440×1830 mm, 2440×2070 mm. High-pressure presses "ZYX" have different productivity and pressing force, and are supplied with a feeding and receiving table.
Technical features
| Specifications | ||
| Model | ZYX1400 | ZYX1600 |
| Total pressure (t) | 1400 | 1600 |
| Specific pressure (kg/cm2) | 27,4 | 27,4 |
| Cylinder arrangement | top | top |
| Diameter of hydraulic cylinders (mm) | 340 | 380 |
| Number of hydraulic cylinders (pcs) | 6 | 6 |
| Productivity (pcs/day) | 1200 | 1200 |
| Slab size (mm) | 2440x1830 | 2800x2070 |
| Maximum slab opening (mm) | 200 | 200 |
| Boiler power (kW) | 31 | 31 |
| Overall dimensions, mm) | 3300x2000x3500 | 3700x2200x3500 |
| Machine weight (kg) | 17000 | 20000 |
2. Laminate cutting machine DP-2700
Designed for cutting laminate into the required dimensions for subsequent milling of locks. Each manufacturer has its own laminate sizes.
| Specifications | |
| Maximum slab width (mm) |
2700 |
| Maximum cutting height (mm) | 30 |
| Saw diameter (mm) |
180-250 |
| Saw mounting diameter (mm) |
75 |
| Saw rotation speed (rpm) |
2500 |
| Total power (kW) | 23,7 |
| Feeding speed (m/min) |
3-15 |
| Overall dimensions, mm) | 2000x3300x1350 |
| Machine weight (kg) | 3450 |
3. Laminate milling line FHZ525+FHH625
The automatic high-speed line is designed for the production of a lock (Click) on laminate. It is equipped with additional cutting spindles, which eliminates chipping along the entire perimeter of the workpiece and guarantees high quality of the finished product. The working surface of the table is equipped with carbide plates, which ensures durability of the equipment and reduces wear on the table surface. The receiving table is equipped with an automatic workpiece feeder to increase the feed speed to 80 m/min.
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German SEW electric motor with high torque and built-in industrial PID feed controller, achieving a high feed speed of 80 m/min. |
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V-HOLD developed precision linear guides with carbide inserts for high-speed feeds (increase wear resistance and reduce table friction). |
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Control system - SIEMENS with a multifunctional and intuitive interface, easy to manage and configure. |
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French Legris air preparation system. |
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Optionally supply of diamond tools. |
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Input material size control for safe operation. |
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High pressure air blowing system that removes dust and chips from the guides and table. |
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Control of workpiece thickness using a tenon cutter. |
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The hardness of the table cover is HV-700-1000, the hardness level is YG8. |
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Patented vertical spindles for precision milling of parts. |
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Dustproof inverters from SIEMENS. |
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The combined feeding system distributes pressure evenly over the entire area of the workpiece being processed. |
| Specifications | |
| Automatic Feeder | SSJ01 |
| Feeding speed (m/min) | 20-80 |
| 0,75 | |
| Dimensions (mm) | 3100x600x1400 |
| Longitudinal milling machine | FHZ525 |
| Maximum processing width (mm) | 250 |
| Minimum processing width (mm) | 95 |
| Feeding speed (m/min) | 20-80 |
| Feed drive power (KW) | 9 |
| 6000-8000 | |
| 6x8KW | |
| 4x6.5KW | |
| 1,5 | |
| Spindles diameter (mm) | 40 |
| 280 | |
| 120 | |
| Total power (kW) | 83 |
| Conveyor | SSJ02 |
| Feeding speed (m/min) | 20-80 |
| Total power (kW) | 2 |
| Dimensions (mm) | 2880x600x1400 |
| Double-sided tenoning machine | FHH625 |
| Maximum workpiece length (mm) | 2500 |
| Minimum workpiece length (mm) | 400 |
| Feeding speed (m/min) | 10-60 |
| Feed drive power (KW) | 5,5 |
| Spindle speed (rpm) | 6000-8000 |
| Vertical spindle power | 6x6.5KW |
| Power of finishing spindles "Click" | 4x6.5KW |
| Width adjustment motor power (KW) | 1,5 |
| Spindles diameter (mm) | 40 |
| Tool diameter on spindles (mm) | 220-250 |
| Diameter of aspiration pipes (mm) | 120 |
| Total power (kW) | 92,6 |
4. Laminate packaging machine TS-200
Designed for semi-automatic packaging of finished laminate into shrink PE film.
| Specifications | |
| Maximum package dimensions (mm) | 250x250x4000 |
| Air heating temperature in the chamber (degrees) | 150-170 |
| Film used | PE heat shrink. from 60 to 120 µm |
| Total power (kW) | 12 |
| Overall dimensions, mm) | 5000x1800x1000 |
| Machine weight (kg) | 250 |
Fashionable and relatively “young” flooring appeared in the 80s of the last century and quickly gained popularity among consumers. Despite the wide variety of textures and shades presented on the market, an increasing number of people prefer high-quality and relatively inexpensive laminated material, which is an excellent alternative to traditional linoleum, carpet and parquet boards.
Among the main advantages of laminate are durability, ease of maintenance and a wide range of applications. This flooring is successfully used in apartments, houses and office spaces. It is a thin multilayer panel, each layer of which is made of different materials, which allows for excellent performance characteristics of the material.
When did laminate appear?
The history of laminate production goes back to 1977, when the Swedish company Pergo created the first laminated board. Of course, the product was significantly different from the coating we are used to - it consisted of two layers connected using thermoactive glue using the hot pressing method. The new material was called “laminated plastic”, and its production technology (HPL - High Pressure Laminate), which turned out to be very expensive, continued to be improved.
It took almost 10 years for another company, Hornitex, to introduce a new laminate production technology - the direct pressing method (DPL - Direct Pressure Laminate). In the new product, the number of layers has increased to four, and their composition began to include foil impregnated in phenolic and melamine resins.
A little later, the German company HDM proposed a fundamentally new technology, the essence of which was to create a laminate board coated with an acrylate layer. The decorative film hardened under the influence of an electron beam, and the technology was called EOF.
In our country, laminated flooring appeared not so long ago - about 15-20 years ago. The first laminated boards were highly expensive and were inaccessible to the mass consumer. Currently, thanks to the constant improvement of laminate production technologies, new players are entering the market, offering high-quality coatings at an affordable price.
If previously all laminate production was concentrated in Europe, now you can purchase products from Asian and Russian manufacturers, which have a lower price. Traditionally, the best material is considered to be laminate made in Germany, as well as French, Belgian and Swedish. By the way, some European factories producing laminate flooring have opened their representative offices in Russia, which has made it possible to reduce the cost of the coating manufacturing process and, accordingly, offer a product in the middle and low price category. The first Russian manufacturing companies were Kronostar and Kronospan, subsidiaries of well-known European brands; they were later supplanted by brands created by domestic entrepreneurs.
Basic technologies for manufacturing laminate boards
Laminate production technologies at different factories may vary, but the principle of manufacturing laminated boards is largely similar. The first stage involves the production of high-density fiberboard, the quality of which determines the mechanical strength and moisture resistance of the future coating. The main raw material for the production of such fiberboard is steamed, crushed to the required fraction and dried wood chips. It is obtained using special machines that chop the bark-free tree into small pieces.
Resins, binders, antiseptics and paraffin are added to the material obtained in the refiner. The process of impregnating the fiberboard used to make the top layers of laminated boards is called impregnation. The future class of the finished product depends on it, because As a result of impregnation, the wear resistance and strength of the future coating increase. To impregnate the material, baths filled with a resin solution with various additives are used. The mass impregnated with it is sent to drying chambers, and then to the primary pressing unit.
There, the chipped carpet becomes almost 5-7 times thinner (the air is squeezed out of it) and takes the shape of a slab. The primary formation of the slab surface occurs at a temperature of 200-300°C and a pressure of about 300 mPa. As a result of repeated pressing, the plate is heated to 190°C under a pressure of 40-120 MPa. The final leveling of the slab surface is carried out under a pressure of 60-150 mPa.
A conveyor belt, part of a laminate production line, moves the compressed fiber to a machine where the carpet is cut into pieces according to the specified dimensions (most often 2800 x 4140 mm). In order for the slabs to acquire a stable structure, they are placed in a special cooler for 20-30 minutes, after which they are stacked for several days.
Next, the pressed boards are sent to a formatter - equipment for laminate production, which cuts the workpiece in half and polishes it, making the surface perfectly smooth and the thickness equally even. To obtain a moisture-resistant laminate, some manufacturers impregnate the resulting board with special moisture-repellent agents.
At the next stage, the blanks are sent to the pressing area, where they are covered with paper-resin films and an overlay (from the English overlay - top layer). As already mentioned, today manufacturers use several laminate production technologies, or rather technologies for connecting individual layers to each other.
The most common is the DPL method, according to which all layers of the laminate are pressed together simultaneously under the influence of high temperatures. The use of glue is not intended, since the layers impregnated with a resin solution are transformed into a single monolithic surface of the board during the hot pressing process. If additional layers of kraft paper are used, then this technology is called CML or RML.
PDL pressing technology allows you to apply a decorative design directly to the slab, which eliminates the need for a top decorative layer of paper. Otherwise, the PDL technology repeats the previously described steps.
If manufacturers use ELESGO technology, the main difference from previous pressing methods is the overlay hardening process. Coated with acrylate resin, it is exposed to an electron beam. The final product is considered more environmentally friendly, and the clearer acrylate resin allows for better visibility of the top layer.
Special machines for laminate production make it possible to produce boards with both a smooth and structured surface that follows the relief of natural wood. Using sawing devices, the pressed panels are cut into elements, then tenons and grooves (laminate locks) are cut out, which allow the individual flooring boards to be fastened together and are lubricated with a wax coating that prevents moisture from getting inside. At the final stage of the production process, the boards are packed into bundles and sent to the warehouse.
Despite the availability of seemingly well-developed technologies for the production of laminated coatings, experts never tire of improving them, offering even higher quality, durable and moisture-resistant material with improved sound-absorbing properties. In addition, work continues on the creation of new forms, original patterns and textured surfaces of laminate boards, which reduces the existing differences between natural parquet, tiles and laminate to almost a minimum.
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Laminate takes a leading position among many types of facing materials. This is due to its undeniable advantages: impeccable appearance, durability, reliable operation, easy installation. The wear resistance of this material is ensured by production technology that appeared in the last century. Having reached the present day, it has undergone significant changes, but today only the positive experience of manufacturers is used. What does laminate consist of and what is the process of its manufacture?
The laminated board consists of four layers. The top one is a protective coating made of malamine and acrylic resins; it is necessary to prevent marks, scratches, abrasions and dents from walking on the panels. The next one is decorative. The compatibility of the floor covering with other attributes of furniture and interior depends on it. The third layer is undoubtedly the main one in the composition of the laminate; it is responsible for the rigidity, strength and other characteristics of the product. The base is equipped with special locks for connecting the panels. At the bottom there is a stabilizing layer, which is needed to protect the boards from deformation. There are products with an additional fifth layer; usually such panels have a higher level of sound insulation.
How is the material produced?
The main components of the production of laminated panels are chipboard, MDF and HDF boards. Any laminate production technology is based on the use of these materials; today DPL, CPL, DPR, HPL methods are used. However, in each case, the process consists of connecting all the layers under the influence of high temperatures and pressure.
DPL technology is considered the most common; it is used by 90 percent of foreign and domestic enterprises. We already know what laminate is made of and that the main element in it is fiberboard. It is sanded until normal conditions for gluing are created. Having combined all the layers, the tiles are sent under the press. The duration of sintering does not exceed one minute, during which time the layers are firmly bonded to the base and to each other. Aluminum oxide, which is added to the composition, gives the product additional strength. Corundum, as it is also called, significantly increases the wear resistance of the product and increases the strength class by several times.
High-tech equipment is used to produce panels. A special mold guarantees high-quality embossing. The output material is a monolithic product that is very difficult to destroy. To produce elements of various structures, a special matrix is used, which is located in the press; if necessary, it can be replaced.
Laminate flooring is becoming more popular every day than its predecessors - parquet and floorboards. Its high durability and ease of maintenance have made it popular in private homes, apartments and offices. Today, laminate is an excellent alternative to any natural wood coverings.
Despite the popularity of this material, few people know how laminate is produced. What type of material is this, its design features.
Making laminate - everything ingenious is simple
History of laminate
The creation of laminate dates back to the late seventies of the last century. The first flooring material that vaguely resembled modern laminate was created by Perstorp from Sweden.
This company developed various materials for construction work and was quite popular throughout Europe. The new material is called laminated plastic, which means layered plastic.
The first development consisted of only two parts. On top, the material was treated with melamine resin, which helped to recreate the decorative layer, and on the bottom, phenolic resins took part in the production.
The layers were connected in several ways at once. Impregnation with thermoactive glue was not enough, and the creators began to use pressing under the influence of high temperatures.
Laminate as we are used to seeing it appeared only a decade later. The author of the global revision of the material was the German company Hornitex.
This company used a completely new technological approach and equipment to produce a new type of laminate and managed to create a laminated coating with unique properties. There were now four layers instead of two. The composition included foil impregnated in phenolic and melamine resins.
In 1994, laminate flooring was in huge demand in the building materials market. Having increased to enormous proportions, sales volumes required the introduction of a body that monitors the appropriate quality of products. This led to the creation of the Association of European Laminate Flooring Manufacturers.
Laminate device
As mentioned above, laminated coating consists of several layers.
I propose to take a closer look at the composition of this material, which is indicated in the figure:
- The bottom layer of the coating is moisture-resistant paper. It is necessary given the properties of wood to absorb various types of moisture in large quantities.
This layer is impregnated with resins and is intended primarily to protect the HDF board; - The main part of the coating lies on the paper, namely the high-density fiber HDF board— 880 kg/m3
It is the main load-bearing part of the laminated flooring and is designed to preserve the geometry and structure of the floor. This material is stronger than wood itself;
Note: To make HDF, round timber is used, which is cleared of bark.
After this, this material is processed into wood chips.
After sorting, large-fraction chips are used in the production of chipboard, and HDF is produced from the finer fraction. The chip crusher can be seen in the picture.
- The third coating layer is a film, which is designed to provide additional moisture protection for both the HDF board and the top two layers;
- Next, special paper is laid, or foil on which the structure of the simulated material is applied.
It can be stone, wood or any other organic material; - Upper layer designed to provide durability and appearance over time. It is he who undergoes treatment with melamine resins.
This process is called "lamination", which gives this coating its name. The top layer can be homogeneous or composite.
Advantages of laminate
- Resistance to mechanical stress and abrasion;
- The ability to withstand various loads and deformations for a long time;
- High-quality resistance to the abrasive effects of the top layer of material;
- The top layer of the material is easy to clean and remains resistant to chemical attack;
- Does not fade and is not flammable;
- Has excellent heat conductivity and is easy to clean;
- One of the cheapest flooring materials created using natural wood;
- Easy to install, do-it-yourself installation is allowed.
Technological process for creating laminate flooring
Laminate production at each plant may vary. Almost every manufacturer has its own technology and unique developments. Despite this, the essence of creation and the basic processes are practically the same.
Preparing wood chips
- First, the wood chips go to the sink, where the debris is washed away with hot water;
- The second stage is steaming the wood chips. This is done to obtain wood with uniform moisture content. The steam heats the wood chips up to 100 degrees Celsius;
- After this, the chips undergo secondary steam treatment under high pressure. The temperature of this chamber reaches 175 degrees. After these manipulations, the chips become sufficiently plastic and ready for further processing;
- After this, the wood chips are crushed to the desired fraction, which is carried out in an installation called a refiner. At the exit from it, resins and binders and paraffin are added to the resulting material, which reduces moisture absorption;
- The next step is drying the wood chips. In addition to the main functions, the tasks of this installation also include equalizing humidity. You can see one of the dryer options in the photo below;
Primary production
- Now the wood chips go directly into the production of components for laminate flooring. First, it is poured into a storage hopper, and then goes directly to the primary pressing unit.
This installation produces slabs that vaguely resemble the required product. After reduction by 5-6 times, the air is completely removed from the chips, but it still looks quite loose; - One of the main processes in the production of boards is pressing. The first treatment takes place at a temperature of 200-300 degrees and has a pressure of up to 300 MPa. This action is applied to form the surface of the slab;
- The second stage of pressing is heating. Here the temperature is reduced to 190 degrees and a pressure of 40-120 MPa is applied to the plate
- The final stage of pressing is to level the slab to an ideal, flat surface. The press pressure applied here is 60-150 MPa. This process can be seen in Figure 4
Making laminate
At the final stages, the following operations are performed:
- After quality control, the slab is sent for cutting. These manipulations are performed with a dividing saw. Basically, the output size of the slabs is 2800*4140 mm.
Immediately after cutting, the slabs are cooled for half an hour. The slabs are then given time to acquire a stable structure. For most manufacturers, this period is several days; - The next operation with the slabs is grinding and finishing with an installation called a formatter. This device cuts the slab to the generally accepted size of 2800*2070.
- Then comes the pressing process, which is not done in the same way. Both complete pressing of the laminate and its individual parts are used.
These technologies depend on what the manufacturer’s instructions prescribe. - The final process of making panels is to cut and laminate them, followed by milling of the edges, Figure 5.
Modern locking joints require the use of several dozen different cutters. The accuracy of the settings determines how high-quality locks the panels will be equipped with.
The technological process of laminate manufacturing can be seen in the video:
Laminate classification
Currently, the production of laminated coatings is subject to strict rules and GOSTs. One of the ways to control manufacturers is to divide the laminate into classes.
Each type of product is designated by a two-digit number. In this numbering, the first digit indicates the room for which this product is intended, and the second indicates the possible intensity of use. Improvements in class correspond to increasing numbers.
Classes are divided into:
- 21-22 – intended for covering floors in residential premises with low levels of use. These could be bedrooms and rooms with low traffic levels. The price of such products is also very low;
- 23 – fits in living rooms, halls, children's rooms. This type of coating can fully serve for up to six years;
- 31 – can be installed both in small office spaces and residential buildings. Moreover, in an apartment, its service life reaches more than 10 years, and the cost is slightly higher than class 23;
- 32-33 – These are the most wear-resistant types of laminate. They are purchased for installing floors in shops, large offices and places with high traffic.
The excellent protective layer of this type is supported by sound insulation, which can be used as.
If such a coating is installed in residential premises, it will remain in excellent condition for many years.
External features of the laminate
Laminate has a very wide range of colors (see). It can imitate any of the available materials: wood, stone, sand. It is worth recognizing that colors and shades are dominated by colors for different types of wood.
This, in turn, gave consumers the wrong idea about this material. Many people believe that laminate flooring is an imitation of wood.
There is a second name for this material – laminated parquet. These judgments do not correspond at all to the true state of affairs. Laminate is a completely original material, with many properties superior to those materials with which it is compared.
Laminate flooring can differ not only in color palette, but also in structure. We can purchase material structured like wood, oil, stone. It can be matte or have a glossy sheen.
Another feature of the external data of this coating is its ability to imitate parquet in stripes.
Laminate can have one, two or three stripes.
- Single-strip laminate is the most expensive. This is explained by the peculiarities of its production, which involve the use of the widest materials to create one strip. With its help, you can create a unique design, imitating various materials with minimal difference from the original.
- The two-strip coating does not have a chamfer, but is very similar to block parquet, with an increased width;
- Three-strip material is the least expensive. Without a chamfer, it perfectly imitates parquet laid using the “deck” method.
Cleaning and maintaining laminate flooring
No matter what class the chosen coating corresponds to, no matter what properties the manufacturers endow it with, improper cleaning and care can significantly shorten its service life and negate all the positive properties.
The basis for the manufacture of laminate flooring is wood, which is 90% of its component. From prolonged exposure to moisture, this coating can swell, changing its structure. To properly care for laminate flooring, it is enough to follow some simple rules.
- After installation work, it is necessary to carry out the first, general cleaning;
- This material has protective properties against dust deposition, built into the structure by the manufacturers;
- For regular, scheduled cleaning, it is enough to vacuum the laminate flooring;
- Dirt that has stuck to the floor can be easily cleaned off with a damp, well-twisted cloth, with minimal addition of vinegar;
- More stubborn stains can be removed using special products. After cleaning, the floor must be wiped with a damp cloth;
- For a longer life of the top floor covering, try not to use detergents that contain solid particles;
- When transporting furniture, lift it off the floor; dragging may damage the coating;
- If possible, try to use floor protection materials on the legs of chairs and tables;
- When cleaning using water or other water-based solutions, remember that moisture should not be absorbed into the floor;
- If a large amount of moisture gets on the floor, it must be removed without wasting a minute.
Conclusion
Laminate production is a complex technological process that helps produce excellent quality flooring material. Due to the peculiarities of the technological process, the material has unique properties and is easy to install and operate.