How making durable Wear Layer ?

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The wear layer, combined with waterproof fiberboard for flooring by improving wear, scratch, and skid resistance while preserving aesthetics. This durable solution is widely used in domestic, commercial, and industrial settings, especially where moisture protection is essential.

1. Material composition of the wear layer

  • High-density polyethylene (HDPE) or polyurethane (PU) : These materials have excellent wear resistance and elasticity to effectively protect floor surfaces.
  • Alumina particles: Often added to coatings to increase hardness and wear resistance and improve surface scratch resistance.

2.Manufacturing process with waterproof fiberboard for flooring

  • Selection of Abrasive Materials:

    • The primary material used is aluminum oxide (Al₂O₃) or other high-hardness particles, chosen for their extreme hardness and wear resistance.
  • Preparation of Abrasive Paper:

    • Evenly spread aluminum oxide particles on the surface of decorative paper, ensuring uniform coverage and appropriate density.
    • Control the size and distribution of particles during spreading to ensure the final wear resistance and appearance.
  • Impregnation Treatment:

    • Immerse the abrasive paper in an impregnation solution, typically made of phenolic resin or melamine resin.
    • This treatment enhances the strength and durability of the paper, enabling it to bond more effectively with the underlying materials.
  • Pre-drying:

    • Pre-dry the impregnated decorative paper to remove excess moisture and solvents, ensuring a smooth lamination process.
    • Precisely control the pre-drying temperature and time to avoid deformation or damage to the paper.
  • Laminating and Hot Pressing:

    • Stack the pre-treated abrasive paper, decorative paper, core layer (high-density fiberboard or medium-density fiberboard), and backing layer in sequence, and place them in a hot press.
    • During hot pressing, the layers are bonded together under high temperature (usually 150-200°C) and high pressure (usually 7-9 MPa), forming a dense composite board.
    • The hot pressing time varies depending on the materials and process, generally around 20-30 minutes.
  • Cooling and Cutting:

    • Cool the hot-pressed laminate to stabilize its shape.
    • Cut and trim the cooled laminate, which features a waterproof fiberboard for laminate, according to actual requirements, ensuring precise dimensions and smooth edges.
  • Quality Inspection:

    • Conduct a comprehensive quality inspection of the finished waterproof laminate board, ensuring that its wear resistance, impact resistance, stain resistance, and appearance meet standard requirements.
    • Focus on inspecting the thickness and uniformity of the wear-resistant layer to ensure its durability.
  • Packaging and Storage:

    • Package the final qualified laminates to prevent damage during transportation and storage.
    • Store in conditions avoiding direct sunlight and moisture to maintain product quality.

3. Functional  of the wear-resistant layer

  • Wear-resistance: The wear layer can effectively resist daily wear from foot traffic, furniture movement, and pet scratching. Combined with waterproof fiberboard for flooring, it enhances impact resistance, shielding the floor from moisture and preventing warping. Additionally, the wear-resistant layer can resist ultraviolet light, prevent color fading, and ensure that the laminate remains bright and as good as new for a long time.
  • Scratch resistance: Due to the high hardness of the wear layer, it can prevent scratches caused by sharp objects.
  • Anti-slip performance: Some wear-resistant layers are specially treated to increase the surface friction, and the anti-slip effect is better.
  • Easy to clean: the surface of the wear-resistant layer is smooth, not easy to stain, and only a simple wipe can be cleaned.

4. Application advantages with waterproof fiberboard for flooring

These advantages make the wear resistant layer an important guarantee for laminate applications in homes,commercial and public places.Such as waterproof fiberboard for flooring

  • Prolong the service life: The wear-resistant layer significantly extends the service life of the floor and keeps the floor as new for a long time.
  • Beautiful and Durable: Protect the color and pattern of the floor surface, so that it is not easy to fade or damage, and maintain the beauty of the floor.
  • Cost effective: While floors with wear-resistant layers cost more initially, their durability and low maintenance costs make them more economical in long-term use.

5. Application Scope

  1. High-flow areas: Such as shopping malls, schools, offices and other places with large traffic, the wear-resistant floor can withstand frequent use and is not easy to damage.
  2. Family use: Living rooms, corridors, children’s rooms and other family areas vulnerable to wear and tear, wear-resistant flooring can provide additional protection.
  3. Industrial applications: Some light industrial workshops and warehouses are also suitable for using floors with wear-resistant layers to ensure durable floors.