Quantum Mouldings incorporates recycled PET into camper van roofs

Quantum Mouldings, a British manufacturer of composites for automotive and industrial applications, has developed a range of pop-top roofs used to convert conventional vans into motorhomes.

At its Kidderminster plant, the company produces medium volumes of between 1,500 and 5,000 units a year, using a range of transformation processes including RTM, manual lamination and spray lamination. Roofing composites are designed to combine mechanical integrity, surface finish and quality colour.

To reduce the carbon footprint of these parts, Quantum Mouldings called on resin manufacturers AOC Formulations and Büfa Composites to incorporate a recycled thermoplastic, in this case PET (polyethylene terephthalate).

“During hot summers, parts can reach temperatures in excess of 80°C in service, particularly when they are dark in colour. It is therefore very important that they do not deform and retain their shape when exposed to heat. The gelcoat finish must also retain its colour and resist UV ageing so that the pop top retains its appearance year after year,” explains Mark Young, Managing Director of Quantum Mouldings.

Post-consumer recycled products

AOC and BÜFA supplied their new rPET-based products, respectively Synolite 4600-G-1, a formulation used in RTM and vacuum infusion, and Neogel 3000 series gelcoats.

“Synolite 4600-G-1 has a lower exotherm than the products we have used in the past. This means less stress on the moulds and longer tool life compared with using other resins. Compared with DCPD (dicyclopentadiene) polyester resins, parts can also be demoulded more easily and quickly, with less risk of sticking,” says Mark Young.

The products in the Synolite 4600 series are based on recycled PET, mainly from post-consumer waste.

Photos: Quantum Mouldings / AOC Formulations