An Expert Guide to the Vinyl Manufacturing Process...
Construction
The most common construction for both sheet vinyl and vinyl tile is layered composite, consisting of four layers constructed of a substance called polyvinyl chloride (PVC).
First, a core PVC layer is applied to a backing made of felt or fiberglass. Next, a layer carrying the design is applied, which is created through a process of rotogravure printing – lending itself to almost unlimited possibilities. The design can be embossed to create the texture of natural materials, or “embossed in register,” which produces the most realistic replication of a natural look.
Finally, a wear layer is applied, the crucial element to the life (and your enjoyment) of your resilient vinyl floor. This wear layer can be a no-wax layer, which is common in products with entry-level price points, or it can be urethane, which is more scuff- and wear-resistant. The most advanced form of urethane is impregnated with aluminum oxide-only diamonds are harder-for superior resistance to tough wear. And, better quality products will also incorporate a cushioning layer for added comfort.
Vinyl also may be of a solid construction, with no backing layer. Or it may be inlaid, where vinyl chips on vinyl backing are heated with the wear layer so that color and pattern go all the way through, making the pattern more resistant to wear.
Keep in mind that the pattern appears only on the core layer, so it can be damaged if the wear surface does, in fact, wear.
Although inlaid vinyl is more wear-resistant, keep in mind that it only comes in 6-foot wide rolls.
One of the newest developments in sheet vinyl flooring is the production of a vinyl polymer backing that outperforms fiberglass and can be loose laid, perimeter-installed or full-spread installed (see installation, below). It’s guaranteed not to buckle, even when installed over wood subfloors without glue.
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