Production process of floor balancing film

The production process of underlayment (commonly used at the bottom of engineered wood flooring or composite flooring to balance stress, prevent moisture, and prevent deformation) mainly includes the following steps:

1. Raw Material Preparation

Substrate selection: High-quality wood pulp paper or polymer materials (such as polypropylene, polyester, etc.) are usually used as the base film.

Impregnation solution preparation: Using melamine resin as the main raw material, additives such as curing agents, waterproof agents, and pigments are added to prepare the impregnation solution.

2. Impregnation Process

The base film is sent to the impregnation tank and fully soaked in the melamine resin solution to ensure that the resin penetrates evenly into the paper fibers or polymer materials.

Control the impregnation time and temperature to ensure that the resin adsorption amount meets the standard, while avoiding excessive impregnation that causes the film material to become brittle.

3. Drying and Curing

The impregnated film material enters the drying channel, and water is removed by hot air or infrared heating, and the resin is preliminarily cured.

The drying temperature is generally controlled at 120~150℃, and the time is adjusted according to the thickness of the film material to ensure moderate resin curing and avoid cracking or insufficient bonding strength of the film material.

4. Hot Pressing and Lamination

The dried underlayment is aligned with the floor substrate (such as high-density fiberboard, plywood), and sent to a hot press.

Under high temperature (180~220℃) and high pressure (3~5 MPa), the resin is completely cured and bonded tightly to the substrate, forming an integrated structure.

The hot pressing time is adjusted according to the substrate thickness and equipment performance to ensure bonding strength and film flatness.

5. Cooling and Cutting

The hot-pressed board is cooled by a cooling line to further cure the resin and stabilize the structure.

According to the floor specifications, the underlayment is cut to ensure accurate size and neat edges.

6. Quality Inspection

Physical properties: Test the thickness, gloss, wear resistance, water resistance, tensile strength, etc., of the film material.

Bonding strength: Test the peel strength between the underlayment and the substrate to ensure firm bonding.

Appearance inspection: Remove defective products with bubbles, impurities, scratches, or uneven colors on the surface.

7. Special Processes (Optional)

Surface treatment: Such as applying a wear-resistant layer, an antibacterial coating, or using embossing to enhance the texture.

Functional strengthening: Add moisture-proof agents, flame retardants, etc., to enhance the overall performance of the underlayment.

The entire production process needs to strictly control parameters such as temperature, pressure, and time to ensure the stability and functionality of the underlayment, while meeting environmental protection requirements (such as the treatment of waste gas during resin curing).