How We Make Laminate

Summary

The video script delves into the manufacturing process of high-pressure decorative laminate (HPDL) by Wilsonart. It details how decorative and core papers are impregnated with resins, pressed under high heat, and fused into a durable material. The script highlights the use of melamine resin for enhanced scratch and scuff resistance, the application of Eon technology for added grit, and the importance of decorative papers for design. The process includes cutting, assembly, and pressing layers to achieve desired thickness and impact resistance. The script also emphasizes Wilsonart's unique ability to produce custom laminates with various textures, patterns, and thicknesses, showcasing the company's commitment to quality and innovation in the industry.

Takeaways

• 🌟 High-pressure decorative laminate (HPDL) is a durable and versatile material made by combining decorative and core papers with resins and pressing them under high heat.
• 🔍 Laminate sheets are composed of 70% paper and only 30% resin, which is a surprising fact about their composition.
• 🏭 Production of HPDL takes place in advanced facilities located in Temple, Texas, and Fletcher, North Carolina.
• 💧 Melamine resin is applied to the surface of the laminate to enhance scratch and scuff resistance, as well as improve clarity and overall durability.
• 🔬 The Eon process adds extra grit to the surface of the laminate, providing superior scratch and scuff resistance compared to standard laminates.
• 🌐 Decorative papers used in laminate come from various parts of the world and are cut to specific lengths to match production requirements.
• 📚 The design of the laminate, such as wood grain or abstract patterns, is printed on a white base paper before the melamine surface is layered on top.
• 🔄 Wilsonart's unique ability to produce one sheet at a time on any run allows for a variety of textures, patterns, and thicknesses to be created.
• 🔩 Phenolic resins are used as a binding agent to bind the layers of craft paper together and with the melamine resins from the decorative side of the laminate.
• 🔩 The high-pressure laminate pressing department is where the raw materials from the decorative and core sides are combined under high heat and pressure to create the final product.
• ✅ Wilsonart's commitment to quality, innovation, and advanced processes has made it a leader in high-pressure decorative laminate for over 50 years.

Q & A

What is HPDL and how is it made?

HPDL, or high-pressure decorative laminate, is created by saturating sheets of decorative and core paper with resins and then pressing them under high heat to fuse the layers into a single sheet.

What is the composition percentage of resin in a sheet of laminate?

A sheet of laminate is composed of only 30% resin, with the remaining 70% being paper.

Where are the state-of-the-art facilities that produce HPDL located?

The state-of-the-art facilities that produce HPDL are located in Temple, Texas, and Fletcher, North Carolina.

What is the role of melamine resin in the laminate production process?

Melamine resin is added to the surface of the laminate to increase its scratch and scuff resistance, improve overall clarity, and enhance the look and durability of the product.

What is the purpose of the overlay paper in the laminate process?

The overlay paper serves as a carrier for the melamine resin, which is applied to the final product to provide additional durability.

What is the Eon process and how does it benefit the laminate?

The Eon process adds additional grit to the surface of the laminate, providing better scratch and scuff resistance compared to standard laminates.

How does the sheeting process separate decorative papers from melamine?

The sheeting process cuts the decorative papers separately from the melamine because the melamine provides the scratch and scuff resistance, while the decorative paper provides the design.

What is the significance of the storage racks in the laminate production?

Storage racks are crucial for storing paper rolls, allowing for the efficient retrieval of specific patterns and quantities needed for assembly.

How does Wilsonart's assembly process differ from others in the industry?

Wilsonart's assembly process is unique in that it can produce a single sheet or multiple sheets with various textures, patterns, and thicknesses on any run.

What is the function of craft paper in the laminate's construction?

Craft paper is used to build up the layers of the laminate, with the number of layers determining the thickness and impact resistance of the final product.

How is the phenolic resin applied to the paper and what is its purpose?

Phenolic resin is applied to the paper through a patented process involving a bath filled with the resin, which then binds the layers of craft paper together and with the melamine resins from the decorative side of the laminate.

What is the role of the press in the laminate production?

The press is where the raw materials from the decorative and core sides are combined under high pressure and heat to create the final thin sheet of laminate.

How does Wilsonart ensure the quality of its laminate products?

Wilsonart ensures quality through a final inspection area where the laminate is sanded, trimmed, and stamped with identifying information, including the Wilsonart logo and production details.