- The balancing layer
- The core layer
- The pattern layer
- The wear layer
The balancing layer is the bottom or stabilizing layer. Its function is to resist moisture and stabilize the floor plank. The core layer is comprised of a high density fiberboard that has been saturated in resin to make the core tough and water resistant. The pattern layer is a thin paper that has been printed with a specific wood grain or stone finish. This is what makes the laminate look like a natural surface. The wear layer is a clear melamine resin, which protects the plank from gouges, stains and moisture penetration. This layer is extremely durable and makes laminate flooring one of your best choices!
All four layers are combined in a high-pressure process with temperatures reaching 400 degrees Fahrenheit and up to 600 pounds per square inch of pressure for 20 to 30 seconds. After the sheets are pressed, they are cooled to ensure that they fully cure and to prevent any surface imperfections.
The sheets are then stacked and stored so that they can continue to acclimate, enhancing the stability of the boards. Once the boards are fully acclimated, they are milled or cut into planks. Multiple profiling saws create the tongue and groove edges that enable the floor to lock together with one another. The finished planks go through a quality inspection and are checked for color, texture, finish, size and correct interlocking capabilities. Once approved, they’re stacked, packaged and loaded onto trucks for distribution — and ultimately installation in homes across the world.