Motorhome
Case Study:
Lamplas – Composite Reinforcement for Motorhome Skylight Cab Pod.
With a legacy of supplying high-quality motorhome components since the 1980s, Lamplas has established itself as a trusted partner in the industry.
Specialising in cab pods, roofs, side skirts, spare wheel covers, rear panels, and interior mouldings like bathroom pods and sinks, Lamplas has continuously innovated to meet the evolving demands of its clients.
In this case, a client approached Lamplas to develop a composite reinforcement component for a new motorhome model featuring a large skylight in the cab pod.
The challenge was to create a lightweight yet robust solution that could support the glass skylight while integrating seamlessly with the existing GRP structure.
Challenge: Reinforcing the Skylight Area
The client’s new motorhome design included a prominent glass skylight in the cab pod, which introduced specific structural and functional requirements:
- Strength and Rigidity: The reinforcement component had to provide sufficient support for the skylight without compromising the cab pod’s structural integrity.
- Weight Considerations: Keeping the component lightweight was essential to maintain fuel efficiency and adhere to vehicle weight regulations.
- Adhesion to GRP: A reliable method for bonding the reinforcement to the inner GRP layer of the cab pod was necessary to ensure long-term durability.
Solution: Composite Reinforcement with VPI Technology
Lamplas utilised its expertise in composite manufacturing and the Vacuum Press Infusion (VPI) process to deliver an optimal solution. The process included the following steps:
Rigid yet Lightweight Design
Leveraging the VPI process, Lamplas produced a rigid composite reinforcement component while minimising weight. The advanced manufacturing technique ensured consistent material distribution, resulting in superior strength and durability.Structural Adhesive Bonding
A two-component structural methacrylate adhesive was selected to bond the composite reinforcement to the inner GRP surface of the cab pod. This adhesive provided excellent shear strength and resistance to environmental factors, ensuring a secure and lasting attachment.Added Insulation for Enhanced Value
To increase thermal efficiency and add value to the component, Lamplas incorporated and installed insulation foam pieces within the reinforcement. This not only improved the motorhome’s energy efficiency but also enhanced comfort for end users.
Results and Impact:
The project delivered several key benefits:
- Robust Support for Skylight: The composite reinforcement effectively distributed the load of the glass skylight, ensuring structural integrity under various conditions.
- Lightweight Solution: The use of the VPI process minimised weight, contributing to overall vehicle performance and compliance with industry standards.
- Efficient and Durable Bonding: The structural methacrylate adhesive ensured a secure attachment to the GRP, providing long-term reliability.
- Enhanced Insulation: The addition of insulation foam pieces improved the motorhome’s thermal performance, delivering added value to the client and end users.
Conclusion:
Lamplas successfully addressed the client’s challenges by leveraging advanced manufacturing techniques and innovative bonding solutions. The project highlights Lamplas’s ability to collaborate with clients, tailor solutions to specific requirements, and deliver high-quality components that exceed expectations. This case reinforces Lamplas’s reputation as a leader in the motorhome component industry and its commitment to driving innovation and value.
How we Manage your Projects
Working closely with you at the design stage, to help develop your ideas into manufacturable components.
Translating designs through robust product development, into high quality finished products.
Producing patterns made by the traditional hand method, or cut by CNC for more complicated and accurate shapes.
Our processes include hand-lay, spray-up, RTM closed mould and solid surface casting.
