Marine foam core is one of the essential materials for modern shipbuilding (yachts, cruise ships, sailboats, cargo ships, fishing boats, etc.). Traditional ship materials such as steel are prone to corrosion in seawater environments and require frequent maintenance and replacement, while foam core can effectively resist corrosion factors such as seawater and salt spray, extending the service life of the ship. This corrosion resistance not only reduces maintenance costs, but also ensures the safety and reliability of the ship.
Application of Foam Core in Marine
- Deck
- Bottom
- Side
- Bulkhead
- Internal rooms such as lounges, bedrooms, storage rooms, etc.
Suitable Processes
- Hand lay-up.
- Vacuum infusion.
- Compression molding.
Common Marine Foam Core Materials
Among marine foam core materials, PET foam, PVC foam and PMI foam are the three most common types, each of which has different performance characteristics and is suitable for different ship design requirements. These foams are all pore structures and are used in the construction of marine sandwich panels. The foam core plays a supporting role in the sandwich structure, and sometimes also makes the structure have heat insulation and sound insulation properties.
Performance Comparison
| Property/Material | PET Foam | PVC Foam | PMI Foam |
|---|---|---|---|
| Density | 60-300kg/m³ | 40-250 kg/m³ | 75-205 kg/m³ |
| Compressive Strength | Good | Moderate | Very high |
| Water Absorption | Low | Very low | Very low |
| Temperature Resistance | 120°C | 80°C | 200°C+ |
| Corrosion Resistance | Good | Excellent | Good |
| Applications | Mid-to-high-end vessels, high structural strength requirements | Widely used in hulls, decks, and lighter load areas | High-performance vessels, extreme requirement applications |
Processing of Marine Foam Core
Flat Foam
It is essentially a flat, uniform sheet of foam material that is further processed to enhance its properties or adapt it to a specific application. This base foam is often used as an initial form, followed by other processing such as perforations, slotting or cutting.
Perforated Foam
Perforated foam is made by adding small holes or perforations to the surface of the foam. These perforations help
prevent air pockets or bubbles from forming between the core and the skin, and improve the adhesion of the foam.
Grooved Foam
The surface of the foam has channels or grooves. These grooves provide flexibility to the foam material, making it easier to bend. Grooves are particularly useful when the foam is applied to curved surfaces or needs to be molded into specific shapes. The width and depth of the grooves can be customized to meet the functional requirements.
Grooved + Perforated Foam
Combining grooves and perforated foam into a foam core can create a hybrid structure that combines the advantages of both.
The various groove and perforation options can be combined with mesh cloth.
