15mm PET Foam Board for RV

The BIGBAHN 15mm PET Foam Board is a lightweight composite substrate developed for applications in the recreational vehicle (RV), marine, and construction sectors. The material is characterised by a formaldehyde‑free formulation, water resistance, high mechanical strength, and full recyclability (100 %).

Core Technical Specifications – 15 mm Thickness

Product Model: SLE30015
Standard Thickness: 15 mm
Standard Dimensions: 1220 × 2440 mm (48" × 96") or 1220 × 2500 mm; custom sizes available upon request
Thickness Tolerance: ±0.3 mm
Density Range: Available in multiple density grades; commonly used variants include 250–300 kg/m³

Screw Holding Force: Approx. 600 N

Mechanical Properties (Average Values):

• Compressive strength: 2.4–6.8 MPa

• Tensile strength: 2.5–4.5 MPa

• Shear strength: 1.25–2.3 MPa

Environmental Compliance & Safety:

• Formaldehyde emission: 0 mg/m³ (not detected / below detection limit)

• Odour: odourless

• Fire resistance classification: Class B (exhibits FST – Fire, Smoke, Toxicity – properties; flame‑retardant, low‑smoke, and non‑toxic characteristics)

Key Properties

• Weight reduction: Owing to its closed‑cell thermoplastic polymer foam structure, the product enables substantial weight reduction in assemblies and serves as an effective alternative to aluminium and plywood.

• Stability: The material exhibits high fatigue resistance, chemical stability, and low water absorption.

• Environmental compliance: The foam is 100 % recyclable and supports sustainable resource management.

• Thermal stability: High thermal stability is achieved, with minimal dimensional change under temperature variations.

• Processability: The board facilitates moulding and machining. Its smooth and rigid surface is suitable for lamination with various decorative finishes.

Classification 

Within the BIGBAHN product portfolio, the PET foam board is frequently employed as a core material in combination with various facing materials to produce composite panels with specific functional properties: 

Aluminium‑faced series (PET sandwich) The PET foam board serves as the core, with aluminium skins bonded to both faces. This construction provides high structural rigidity and impact resistance. It is commonly used for RV flooring, body panels, or as a substitute for aluminium honeycomb panels.

HPL‑faced series (HPL‑PET sandwich) The PET foam board is laminated with high‑pressure laminate (HPL) on the surface. The HPL layer is typically applied in a thickness range of 0.45–0.80 mm. This combination integrates the lightweight and waterproof characteristics of PET foam with the scratch‑resistance, heat‑resistance, and fire‑retardant properties of HPL, making it a suitable choice for RV countertops, kitchen, and bathroom furniture applications.

Application 

The PET foam board is utilised across a broad range of sectors, encompassing mobile living spaces, automotive engineering, and industrial construction:

• Recreational Vehicles (Caravans / RVs): Body structural panels, furniture boards, interior wall panels, bathroom partitions, flooring, and decorative grille panels (surface layer).

• Automotive: Boot side linings, roof headliners, spare wheel covers, sun visors, and carpet substrates.

• Rail Transport: Ceiling panels, door panels, flooring, and air‑conditioning ducting.

• Construction & Residential: Thermal insulation wall panels, shaped architectural structures, decorative cladding, and high‑end furniture boards.

• Wind Energy: Utilised as core material in wind turbine blades.

Handling Instructions

• Surface lamination: Bonding of decorative skins shall be carried out using PUR (polyurethane reactive) hot‑melt adhesive. This adhesive cures irreversibly and ensures delamination‑free bonding under temperature extremes up to 130 °C as well as in low‑temperature environments.

• Structural load‑bearing: Although the PET foam board exhibits adequate mechanical strength, load‑bearing structural designs shall reference its screw holding force (approx. 600 N) and incorporate composite constructions (e.g., sandwich panels) to enhance overall load capacity.

• Storage recommendations: Despite the material's low water absorption, storage in a flat, dry environment is recommended. Prolonged direct exposure to sunlight should be avoided in order to minimise colour degradation of surface decorative films.

• Machining tolerances: Given the thickness tolerance range (±5 % or –0.1 mm to +0.2 mm), CNC machining parameters shall be adjusted based on the actual measured thickness of each panel during large‑scale furniture assembly.