Factory Direct Selling UV Coating Plastic Flooring Self Adhesive LVT Flooring Planks

Short for luxury vinyl tile, LVT is designed to replicate hard surface flooring materials such as stone or wood, yet provide many more practical benefits. Available in planks or tiles, LVT uses a realistic photographic print film and a clear vinyl layer that opens up a wide variety of design concepts. Even the most trained of eyes have a hard time distinguishing LVT from the products that it mimics.
To go the extra mile in understanding LVT, let’s take a look at how it’s made. LVT is manufactured through the following five primary processes.
1. Research and Development
From the beginning, research and development teams aim to simulate and evaluate new innovative concepts through trial and error. Large amounts of raw materials are mixed so that the team can study their interactions. The raw materials used in the production of LVT include polyvinyl chloride resins (PVC) and calcium carbonate. Once the team has a satisfactory compound to work with, it is ready to begin the calendering process.
2. Calendering Process
The calendering process uses a series of heated rollers to “roll or squeeze” the compound into a continuous sheet. By manipulating the rolls, the width and thickness of the sheet can be controlled with precise accuracy and consistency. Once the sheet is passed through the heated rolls, it is then sent through a cooling section and sent to lamination.
3. Lamination Process
Through the use of heat and pressure, lamination is a continuous process that bonds one layer to the next until all layers are fully formed. The tiles are constructed of the following four layers:
● Backing layer – Sound absorbing layer with textured grip
● Fill layer – Stability layer for indentation resistance
● Print layer – Certain premium types of LVT come manufactured with realistic, 3D visuals that can be installed to resemble ceramic or stone.
● Wear layer – The wear layer plays a crucial role in the lifespan of your tiles. Clear coatings such as aluminum oxide will keep your flooring from rapidly wearing.
Once the layers are fully formed, the sheet enters into the embossing section.
4.Embossing Process
Here, under heat and pressure, engraved rollers apply the textured design onto the face of the product which can be a light “tick” or a “deep” emboss. Once the texture is applied, the scratch and scuff Top Coat will be applied. The slabs then pass through an annealing oven that uses heated air to raise the temperature of the entire slab to a point that any stress between the layers are relieved. Once cooled back down, this process is added “insurance” to produce a stabilized product that will reduce the opportunity for “doming or cupping” due to stresses between the layers in the finished planks. From there the slabs are pallet and taken to Inspection, the final stop.
5. Inspection Process
During inspection, the slabs are brought into an air controlled room that will maintain the same temperature year round. This is important because it keeps the product in a uniform state during the milling process which helps to ensure consistent milling from one board to the next. Being able to inspect each slab before milling allows technicians to inspect and mark defective areas. The non-defected slabs will then be loaded into the press which offers alternative product sizes and is then sent to milling. Once milled, the product is boxed, wrapped, stacked on a pallet, and ready for shipment.