I have been trying to figure out what kind of material would be best to use as flooring in a van that I’m fitting out. It needs to be waterproof and reasonably durable - so that puts out the option that 99% of people would go for - plywood.
I finally found a German company that manufactures a product specifically designed for automotive flooring: http://www.seconect.de/
But unfortunately it seems like there is no retailer in Australia.
The idea has crossed my mind that I could just make my own…
I wondered if anyone here is familiar with the product?
From what I can tell, it’s based on another product that they make called VarioLine which is a foam core sandwiched with plastic sheets. To make the Seconect it seems like they add some additional layers to that product, maybe fibreglass?
I’m thinking that I could make two sheets to form the outer skins, then use some plastic standoffs (not solid, but a frame type so the foam could fill around them) to hold the two sheets apart at the correct distance. Then drilling holes into the top sheet to inject polyurethane foam. (I would flip this and use the drilled side as the bottom surface when in use.)
It would be installed over a bare metal floor in the van which has the usual type of corrugations/ribbing. They are probably not more than 50mm apart, so I don’t think I would even worry about filling the concave areas, although this could easily be done with rubber inserts to reduce the maximum possible deflection. I won’t be loading pallets etc., maximum load would be a motorcycle, say 220kg max.
As far as layup I think I would aim for 15mm total sheet thickness. For the outer layers I would guess that a biaxial (±45º) and unidirectional/uniaxial would be all that’s needed, maybe 6-700gsm total per layer (or just a layer or 600gsm quadriaxial)? The compressive strength would be the most important thing. Resin choice - I would be inclined to use a lower-spec epoxy resin which has more flexibility. The idea being that a more flexible resin is less likely to crack if something is dropped on it?
I would aim to make it as a single piece, about 4,200 x 1,780mm. Probably add some kind of anti-slip grit to the top side.
I just wanted to know what people think of this idea? Any comments and suggestions are welcomed!