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Detailed production process of laminate flooring

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From raw materials to packaging, the details of each step and the things and equipment that must be used. Which expert knows, please tell me, thank you.

the user carries out warehousing quality inspection on the purchased raw materials. Among them, wear-resistant paper, decorative paper and balance paper are stored in the environment of constant temperature 20 ℃ and constant humidity (relative humidity 50% – 60%), and the density of high-density board is ≥ 0.85g/cm ³。

the user uses the low-pressure short cycle process to hot press the four materials of wear-resistant paper, decorative paper, high-density board and balance paper at one time. Generally, the hot pressing temperature is about 200 ℃, the plate surface pressure is about 3.6mpa, and the hot pressing time is 30-40 seconds. The specific parameters are adjusted according to different products. The defects on the floor surface after fine sand molding (including natural defects such as knots and skin clips) shall be repaired manually, and the processing defects in the previous production processes shall be repaired at the same time

extended data:

precautions for the use of laminate flooring:

1. Before purchasing laminate flooring, users should understand the level, noise direction, orientation and area of their housing. It is best to draw a plan for overall planning, specifically allocate the use functions of each room, and then choose the floor according to local conditions

2. When purchasing, check whether the density of trademark line is lower than 0. 8g /cm3. If it is lower than 8mm, the floor is too thin, which will affect the firmness and deform later. The international standard is 8mm. It also depends on the emission of formaldehyde, which can not be higher than 9mm /100g, or you can get close to smell the smell. These methods can ensure whether the floor is toxic

3. Mainly observe whether the surface gloss of the laminate floor is uniform, whether the pattern is symmetrical, whether there are white spots and stains, whether the interface is neat without damage, and whether there are small sawtooth cracks

4. When buying the floor, you should not only look at it, but also check it by hand. Check whether the floor splicing is tight, whether the waterproof is good, base course inspection, wear resistance, etc

reference source: Baidu Encyclopedia – composite floor

reference source: Baidu Encyclopedia – hot pressing

explanation of bell flooring production process, production process and basic product knowledge
(improved version for new salesman training)
from raw materials to packaging, details of each step and necessary things and equipment. The scientific name of laminate floor is “impregnated paper laminated wood floor”. It is generally composed of four layers of composite materials, namely wear-resistant paper, decorative paper (pattern paper), high-density substrate and balance (moisture-proof) paper

wear resistant paper: aluminum oxide, wear-resistant, mainly to protect the floor surface from scratch and prevent water from penetrating the floor from the surface
according to the weight of grams, there are generally 25g, 38g (4000 turns), 45g (6000 turns) and 58G
decorative paper (pattern paper): the pattern color of the floor is printed on this paper
base material (high-density board): high-density board made of wood fiber with specially prepared glue and pressed under high temperature and high pressure
the base material can be divided into white core and green core. Green core is added with waterproof chemicals, and green pigment is added to distinguish it from white core substrate
Jiangxi washed Daya base material: fast-growing eucalyptus and Masson pine, peeled and broken to millimeter grade wood fiber, with very high toughness, white color, few impurities and fine particles
base material a (white), B, B +
Daya: the world’s third largest manufacturer of MDF, Heyuan, Fuzhou, Fuyang, Danyang and Jiamusi
b jiufangyuan: the only one in China that uses masson pine as base material. Pine oil reduces the use of glue and has less formaldehyde content

balance paper: because the wear-resistant paper and decorative paper on the upper layer of the substrate will pull on the substrate layer during the pressing process, resulting in the deformation of the board, there should be balance paper to balance the pull up and down of the board. Another function is to prevent water from seeping up and corroding the floor
generally 33g, 45g, 90g, 110g – 120g
the gram weight of balance paper is generally equal to the sum of the gram weight of wear-resistant paper and pattern paper

laminate flooring is generally divided into three types according to the edge treatment process around the surface: flat plate, chamfered paint rolling plate and molded plate
flat plate: there is no gap or groove at the seam of the floor after paving. This kind of floor looks generally low-grade, but it is generally easy to clean
chamfered paint rolling plate: when slotting, cut an angle around the floor surface, generally 30 and 45 degrees, and then seal it with paint. This kind of floor is to imitate solid wood. After paving, there is a V-shaped notch at the joint, which is very similar to the assembly effect of solid wood. This kind of floor generally looks high-grade. But this kind of floor has a disadvantage. The V-shaped groove is easy to accumulate dust and difficult to clean. The paint will fall off after a period of time. Therefore, it is generally necessary to seal the notch with wax after paving
molded plate: patented by Dewei. When pressing, the edges around the board surface together with the wear-resistant layer are pressed out to a certain extent, and there is a smooth U-shaped groove around the assembly. The paving effect is a bit like solid wood, and it is easy to clean, because its seam is a smooth radian and has a wear-resistant layer. It can be dragged with a wrung mop at ordinary times. If not, wrap a towel with chopsticks

manufacturing process of bell flooring laminate
printing: cut the natural decades or even centuries old wood into pieces, then scan the one with the clearest and most beautiful texture with laser, then carve it on the printing plate roller with fine laser, and print it on the base paper with imported ink specially made by the printing machine

bell floor printing line is synchronized with four rollers. Different plate rollers have the same texture and different colors to increase the saturation of color
selection of pattern: break the log, select the wood grain with the clearest and most beautiful texture, laser photocopying and fine laser engraving on the plate roller
the selection of ink is very important, Color fastness to light (bell grade 8 – top level) strong ultraviolet radiation for 12 hours and seven years

main process requirements:
1 For flower printing, the textures of several plate rollers on the same paper should coincide without error, otherwise it will cause “double eyelids”, resulting in blurred patterns and color saturation
2. Color modulation. Very demanding. The color shall be consistent with the color of the customer’s sample. The two batches before and after shall reach 98% and there is no difference with the naked eye. Different batches of the same design and color may have color difference

there are three production lines, one of which was added in August 2010, two in Germany and one in China. They are all high-speed printing lines, 130 meters per second

dipping: also known as dipping. Patterned paper, wear-resistant paper and balance paper all go through the process of dipping glue to prepare for the next step of sticking to the substrate
glue is specially prepared, generally melamine formaldehyde resin and other glues. There are strict requirements for the amount of paper impregnation. Unqualified quality will cause problems such as white spots on the floor surface, bending deformation of the board surface, cracking of wear-resistant paper and so on
10 dipping lines
the dipping capacity is the largest in China, with 6000 pieces per line per day
impregnated paper is also used in the production of doors, veneers, computer desks and office desks
glue production, secondary impregnation and secondary drying: it blocks the gap of the paper and will not cause quality problems due to the entry of air, such as pinholes, whitening, white spots, blisters, etc. At the same time, the surface bonding strength is increased. The bonding strength of Bell’s impregnated paper is much higher than that of other manufacturers, and the finished paper of the floor is not easy to fall off

pressure paste: the heat transfer oil is heated by the boiler, enters the press, heats the upper and lower steel plates fixed on the press, then places the three kinds of paper and substrate plates in order, and then puts them into the press. Set the press temperature (170 ~ 210 ℃), press pressure (18 ~ 23mpa) and holding time of 30 ± 5S (45g) and 25 ± 5S (below 45g) different surfaces and materials, Process procedures and temperature control are different
the texture on the surface of the floor and the printing on the back are pressed out by pressing. There are steel plates on the upper and lower parts of the press in contact with the floor
there are dozens of floor surface textures, such as hand scratch pattern, small relief, medium relief, mirror molding, antique molding, synchronous real wood grain, silk surface, etc. Different upper steel plates have different textures on the surface
the printing on the back of the floor is printed by the pattern of the lower steel plate
there is a molding board in the pressing. The board is like square chocolate. After assembly, there is a U-shaped (some V-shaped) notch at the seam for easy cleaning. The process requirements are relatively high. Dewei’s patent
bell 10 presses
the general press pressure is 1400 tons, bell 8 presses are 1800 tons, and bell 2 presses are 2400 tons. The equipment has been updated
about 700 in the day shift and about 800 in the evening shift. The area of a large plate is about 3 square meters

saw plate: saw the pressed large plate into a small plate the size of the finished product. First cut two or three according to the size, and then saw into corresponding specifications
there are two kinds of saw plates: chamfering, rolling paint and flat floor are directly sawn out by machine; Moulded plates are sawn manually or with special machines

curing: make the sawn plate adapt to the surrounding moderate temperature and normal shrinkage and expansion, so as to prevent deformation after grooving and making the finished product, which will affect the pavement. The health preservation period is 3-5 days in winter and one week in summer
in fact, it’s better not to walk around or move furniture in within 48 hours after the floor is paved, which is also the reason for health preservation after paving

slotting: open smart locks around the small board to facilitate assembly and glue free. There are many kinds of locks. Generally, round locks are used for domestic sales. Valinge buckles are often used in foreign trade
bell has 7 slotting lines. 70000 square meters /day
the accuracy of slotting is very high, especially for molded plates. If the tool adjustment accuracy is not good, it is easy to have quality problems such as inclined head seam and height difference
generally, the finished products of flat floor and molded plate are finished after slotting. Sometimes, sealing wax or film will be added according to the customer’s requirements, and then packaged and put into storage
the chamfered plate is to enter the paint rolling process and roll the paint on the notch. Then package and put into storage
there are many exports of v-buckles, and the installation cost abroad is high. The installation of v-buckles is good. Foreign basic DIY
Haomai line is the best manufacturer of pressing, pasting and slotting production lines. 130 m /min (the highest in the world), Laser knife calibration
bell standard:
name
assembly separation
assembly height difference
length deviation
width deviation
edge irregularity
requirements
average ≤ 0.05 mm
maximum ≤ 0.1 mm
average ≤ 0.05 mm
maximum ≤ 0.1 mm
≤ 0.5mm
≤ 0.1mm
≤ 0.3mm /M
name
warpage
squareness
thickness deviation
length concave
length convex
width concave
Width convex
requirements
≤ 0.5%
≤ 1%
≤ 0.15%
≤ 0.2%
≤ 0.15mm
+ 0.3, – 0.2

national standard:

quality control department: responsible for the inspection of raw materials, semi-finished products and finished products. Provide quality supervision and quality improvement suggestions to each production and sales department according to customer orders. Also responsible for inspecting and identifying products with quality problems after sales, and providing relevant treatment suggestions

the quality control department has very complete quality standards and is equipped with very complete quality testing instruments and equipment. Focus on the top five physical and chemical indexes and wear resistance list. It is necessary to understand the standards and testing methods of these six indicators, especially the testing methods of wear resistance
wear resistance: 180 mesh sandpaper, double track, 500 conversion sandpaper, 10 * 10cm small sample block, divided into four quadrants, stop when there are white spots in the three quadrants, count the number of sandpaper strips, and then multiply by 250, which is the wear resistance revolution of the floor

formaldehyde detection: finished product (dry)

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