Polycarbonate insulating layer D4S
UNDER CONSTRUCTION
Utility model INPI 12-01148, April 18, 2012.
Commercialization: San Miguel - Design 4 Sea EIRL.
Material produced by Tubus Bauer
Figure 1. Polycarbonate insulating layer D4S
A simple solution against humidity in boat upholstery
Self-evidence: boats are often very humid: rain, direct aspersion, atmospheric humidity, human breathing, poor ventilation...
Humidity is a killer for marine upholstery. It generates stains, mold, bad smells, damages fabric and foam.
Solution: an insulating layer below seats and mattresses. A material that is light, resistant, easy to wash, and easy to cut at the shape of a boat's seats, berths and beds.
Flexible cellular polycarbonate
Polycarbonate (PC) is one of the most resistant thermoplastics (it is a component of armored glasses, helmet windshields, etc.). It resists to compression, impacts, and heat. Polycarbonate comes in two forms: compact and cellular ("honeycomb-like"). Problem: polycarbonate plaques are generally rigid, therefore unpractical for boats.
D4S developed insulating layers for upholstery made of flexible, incompressible cellular polycarbonate. This is obtained by a combination of 3 parameters: diameter of the cells, thickness of the cell walls and thickness of the layer.
The raw material is a low density Tubus Core(r) (48kg/m3), with 6mm diameter cells, thickness ~8mm (6mm to 10mm). The plaques are flexible, rollable and at the same time incompressible.
Figure 2. The car test. Rolling and stationing for 1 minute over a PC insulating layer (car: Opel Vectra). No damage
Of special interest for boat upholstery:
- flexible and rollable
- high mechanical resistance (pressure, torsion)
- anti-slip (the cell walls are blocked in the soft material of upholstery)
- thermally insulating (the alveolar material creates a insulating layer of air)
- water insulating (the layer separates the upholstery from the underlying surface that can be wet)
- anti-condensation (the air circulates between the cells and the lower face of the upholstery, which is normally porous)
Production & installation
Tools
Ruler, soldering iron with a cutting tip and/or sissors.
Figure 3. Tools to cut PC insulating layer
Preparation
Cut one or several pieces of insulating layer to cover the shape of the upholstery (transversal or longitudinal, no problem).
Place the pieces of insulating layer on surface underneath.
Fixation
The material is anti-slip. For normal cases (mattresses, seats) further securing is not needed.
In case the upholstery requires fixation (e.g., a watch table seat that will slip when the boat is heeling), use scratch bands (e.g. Velcro One Wrap (r)) to secure on seat and on underneath surface.
Cut slots with soldering iron.
Figure 4. PC insulating layer with scratch
Bonding
Polyurethane glue, hot glue.
Examples
Cabin bed
The PC insulating layer is cut in two pieces one per half-mattress.
Figure 5. Cabin bed
Access to hatches
Figure 6. Access to hatches
Shelves and open storage
The PC insulating layer is used to prevent dampness, e.g., in clothes.
Figure 7. Shelf
Figure 8. Lateral shelf
Features and properties
Compressive strength : 0.5 mPa, i.e., resistant to pressures above 49 tons/m2.
Weight: ~384 g/m2
Flexibility: in both directions. Minimum radius of curvature ~2cm (i.e., rolls of ~6cm)
Cleaning: rinse with fresh water.
Dimensions & color
Standard plaques: 2m x 1m x 8mm, translucent, W~770g (385g/m2)
Maximal dimensions: 3.05m x 1.38m
Thickness: between 5mm & 12mm (standard: 8mm)
Cell diameter: 6mm (standard) or 4mm (higher compressive strength and density).
Site design: Copyright: (c) 2012 Eric Jacques