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FRP (Fiberglass Reinforced Plastic) sandwich panels are a high-performance material widely used in modern yacht construction. They are composed of two thin, strong FRP skins bonded to a lightweight core material, creating a structure that is both exceptionally strong and rigid while remaining lightweight.
The table below compares the two main types of sandwich cores and traditional single-skin FRP based on research data.
| Feature/Material | Nomex Honeycomb Sandwich | Foam Sandwich (e.g., Corecell) | Traditional Single-Skin FRP |
| Primary Advantage | Highest strength-to-weight and stiffness-to-weight ratios | Good balance of strength, stability, and impact resistance | High tensile and compressive strength |
| Key Characteristics | Highest(Bending Strength) & stiffness- Larger deformation under load | – Better stability than honeycomb- Smaller deformation under load | Heavier and less rigid than sandwich panels- Prone to larger stress and deformation |
| Typical Yacht Applications | Yacht bow bottom (high stress area)- Interior structures (vibration damping, sound/heat insulation) | Sides (gunwales), deck, and bilge (requiring good stability)- Keel (provides stable support) | – Less common in modern performance yachts due to weight and rigidity limitations |
Material Improvements and Applications
Modern FRP sandwich panels for yachts incorporate several advanced technologies:
Enhanced Core Materials: New materials like polypropylene honeycomb offer superior bending and impact strength, flame retardancy, and easier installation compared to other core materials.
Advanced Resins and Fibers: Using a Barrier Coat resin between the gelcoat and the laminate layer reduces gelcoat cracking and improves impermeability. Hybrid reinforcements like Kevlar mixed with fiberglass can reduce hull weight by about 12% while meeting strength requirements for high-speed yachts.
Innovative Construction Methods: Techniques like Resin Transfer Molding (RTM) and mold-free methods using FRP panels with interlocking “S”-type hidden joints are used to build yacht hulls without expensive molds, reducing costs and increasing design flexibility.
Key Considerations for Selection
When planning to use FRP sandwich panels for a yacht, focus on these aspects:
Prioritize Performance Needs: The choice between honeycomb and foam cores should be based on the specific structural demands of each part of the yacht.
Consider Professional Analysis: For critical or custom projects, employing Finite Element Analysis (FEA) is a standard practice to simulate structural strength under various loads and ensure the design’s safety and performance.
Focus on Quality Control: The performance of a sandwich structure heavily depends on manufacturing quality. Ensure the lamination process and bonding between the skins and core are executed to high standards.