LAMILUX Composites Floor revolutionises caravan flooring design

Caravan construction is also seeing a trend towards weight reduction to provide greater efficiency. A lighter floor design is playing an increasingly more important role in this respect. Heavy wood, which also absorbs moisture and is susceptible to mould, can now be replaced by a lightweight sandwich structure laminated with composite. LAMILUX has developed a new material specifically for this field of use. An innovative, odour-free flooring is now available to caravan manufacturers in LAMILUX Composites Floor.

This new material will make it possible to use sandwich floor structures with less wood or even without wood in the future. This allows design engineers to achieve three key objectives: reduce weight significantly, improve resistance to damp and moisture, thus eliminating mould and swelling, and optimise thermal insulation in caravan flooring.

Whereas a single PVC layer has been affixed to wooden flooring surfaces in the past, LAMILUX Composites Floor now allows design engineers to take completely new approaches to floor design since this material is now an essential element in modern sandwich floor structures.

Inseparable bond between PVC and resin

Design concept: featuring a high proportion of woven material to ensure optimum strength, the flat glass-fibre reinforced composite (GRP) sheeting is given a PVC layer. This layer is added during the actual GRP manufacturing process itself, meaning that there is no need to use adhesive since a perfect bond is formed between foamed PVC and the GRP reinforcement layer.

The highly robust, lightweight composite material is only 3 millimetres thick and can be lined with any one of many different décor sheets. It is also completely odour-free since a styrene-free epoxide resin is used in the GRP. To form sandwich flooring, the client affixes the material to a foam structure, which preferably also features a GRP layer with a high proportion of glass-fibre woven material on its lower surface.

Tried and tested

LAMILUX has subjected this new composite material to numerous tests under conditions similar to practical use. These include a castor chair test (EN 425), an adhesion test to determine delamination behaviour, intensive exposure to halogen light (50 °C / 100h) and a shattering test with repeated cooling to -30 °C  followed by rapid heating and examination for cracks. A number of well-known caravan manufacturers are already using this material in their designs.

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