How is Vinyl Sheet Flooring Made?
Vinyl Flooring has become an extremely popular flooring option for many homeowners nowadays, especially in moisture-prone areas such as kitchens and bathrooms. It’s especially durable because it’s made from multiple layers and a thick core to keep you comfortable when you’re walking. Read on to know the construction process of vinyl sheet flooring.
What is Vinyl Sheet Flooring?
Often used as an alternative to natural stone, ceramic tile, or even hardwood, the Vinyl sheet is especially used in rooms like kitchens, laundry rooms, and bathrooms which are more prone to moisture. The layered construction of vinyl sheets helps in providing stability, cushioning, and a protective finish for durability. Sheet flooring is laid down in sheets that are 6 or 12 feet wide—is water-resistant and easy to install. This type of flooring is highly durable. If installed and maintained correctly, it can last upwards of 10-20 years.
Making of Vinyl Sheet Flooring:
Raw Material: The main components for the construction of vinyl sheet flooring includes polyvinyl chloride resins, plasticizers, trace stabilizers, pigments, backing, and a carrier sheet. The backing can be either felt or highly filled paper fabricated from wood pulp and calcium carbonate.
Manufacturing Process :
1.Plasticizers together with Vinyl Resins are mixed together in a vat to make plastisol. AZO compound, consisting of 2 nitrogen atoms that are united at both ends to separate the carbon atoms, is added to this plastisol.
2.The plasticizers, resins, and AZO compound are then heated which leads to the decomposition of the AZO compound forming nitrogen gas bubbles. For this mixture, vinyl foam is produced with a thick consistency that can be spread in the slurry mix on the installation medium or the backing.
3.Using a reverse roll coater, the slurry is then laid out on the wood pulp backing or the felt, and then smoothened out. This coated sheet is then put in an oven so that the vinyl foam is converted to gelled form.
4.Now, the gel is allowed to run through a printing press and metal intaglio plates are used to create impressions. This causes the patterns to get impressed on the gel sheet creating the desired decorative pattern.
5.After this, the second mix of vinyl and plasticizer is applied to the printing gel. The gel with the backing is then allowed in an oven with a higher temperature than the previous one.
6.Inside the oven, the plasticizer is absorbed by the vinyl resin and melts, which creates a clear vinyl. This is called the wear layer, which makes the vinyl flooring resilient as it takes on the brunt of all the footwork.
7.Now the sheet vinyl is ready to be rolled if the design requires a matte finish. Although, if the pattern requires a glossy finish, it receives a layer of polyurethane coating via roll coaters. To control the thickness of this coating, an air knife is used which ensures consistency in thickness.
8.Finally, the polyurethane coating is cured photochemically using UV radiation lamps and gets ready to be rolled.
9.The high-glossy or matte vinyl sheet flooring is now ready to be cut to rolls which are either 12ft wide x 1500ft long which can later be subdivided on the basis of the needs of retailers.
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