During the 2020 pandemic, people from all over the world started looking for portable living spaces because they offered a unique combination of social isolation, travel freedom, and a remote-work-friendly lifestyle. The pandemic created a situation where people wanted to escape densely populated cities, travel safely without flying, and work from anywhere, making #vanlife an ideal, self-contained solution.

A new entrepreneurial company approached Dal-Bac looking to create wall coverings that would insulate noise, weather and create a cozy area for living, working out, and traveling safely. He already had picked up the cotton canvas fabrics he wanted to use on his conversions. He also knew he wanted the complete lamination to be ½” thick and as wide as possible. He also knew the backing fabric was very important to prevent damage done to the lamination during installation. And he knew the laminate would need to be firm but flexible enough to be installed on the walls of the vans.

It was up to our engineering team to determine the foam grade to be used for this application, giving the customer a range of foams that would be flexible but also firm and light / breathable to help on the summer hot days. Our engineering team worked directly with the new customer to sample the different foam grades and the different backing fabrics for the customer to test and install on a van. The customer installed the samples and noticed a polyester foam grade had a better consistency of the lamination and ease during the installation. Cotton canvas fabrics have a better affinity to polyester foams, which makes the results from the customer testing make more sense.

After trying different backing fabrics, the customer made up his mind with a polyester warp knit.

The durability and low cost of our flame lamination made this idea into a multimillion-dollar industry, it innovated an area of the industry untouched for the longest time.

Our team at Dalbac Manufacturing Company is willing to make your idea or project into a multi-million-dollar application. Our experts on lamination are here to help you develop your ideas / application.