FRP Composites Boost Efficiency in Delivery Van Bodies

Imagine a van body that combines steel-like strength with feather-light weight while effectively insulating against external temperatures to protect cargo freshness and safety. This is not science fiction but the remarkable performance enabled by FRP (Fiber Reinforced Plastic) composites in van body manufacturing.

Traditional metal bodies suffer from heavy weight, increasing fuel consumption and reducing transport efficiency. FRP composites, with their lightweight, high-strength, corrosion-resistant, and thermally insulating properties, have emerged as an ideal solution for van body lightweighting. Compared to all-metal panels and metal-faced sandwich panels, FRP sandwich panels offer superior weight savings and impact resistance, making them the representative material for lightweight van bodies.

FRP, or Fiberglass Reinforced Plastic (also called GFRP), is a composite material consisting of resin (such as unsaturated polyester, epoxy, or phenolic resin) as the matrix and glass fiber as reinforcement. It combines lightweight with rigidity, offers electrical insulation, stable performance, high mechanical strength, and excellent corrosion resistance.

Current FRP offerings for van bodies include two main types: thermoset FRP and thermoplastic FRP (CFRT, or Continuous Fiber Reinforced Thermoplastic). These differ in resin and fiber types, each with distinct characteristics and applications:

• Thermoset FRP panels: Feature mat or fabric glass fibers with a gel coat surface for smooth finish
• CFRT panels: Composed of multiple layers of continuous unidirectional glass fiber prepreg tapes, offering greater strength and elasticity while enabling thinner panel construction

FRP materials are compatible with various foam (XPS/PU/PET/PVC) and honeycomb (PP) systems. Selection depends on vehicle application, with three primary FRP sandwich panel types available: foam core, honeycomb core, and plywood core panels.

The FRP sandwich panel lineup addresses diverse transport requirements:

• FRP foam core panels: XPS/PU-core panels provide superior insulation for refrigerated vans transporting perishables like produce, meat, pharmaceuticals, and frozen goods
• FRP honeycomb panels: PVC/PET foam-core and PP honeycomb-core panels deliver high strength-to-weight ratios for dry freight vans
• FRP plywood panels: Combine FRP weather resistance with plywood structural strength for demanding applications

The transition to FRP van bodies offers multiple operational benefits:

• Lightweight design: Reduces vehicle weight, improves transport efficiency, and lowers fuel costs
• High-strength structure: Enables greater payload capacity while ensuring cargo safety
• Superior thermal insulation: Maintains precise temperature control for cold chain logistics
• Corrosion resistance: Withstands harsh environments, extending service life
• Easy maintenance: Smooth surfaces simplify cleaning and upkeep
• Design flexibility: Accommodates customized configurations for specialized applications

Specialized FRP refrigerated vans feature partitioned zones maintaining temperature differentials up to 20-30°C between sections. Constructed with 10cm-thick FRP PU foam core panels, these units demonstrate exceptional thermal performance, durability, and aesthetic finish with gel-coated surfaces. The design proves particularly effective in hot, humid climates for preserving food freshness and extending shelf life.

FRP van bodies serve critical roles across logistics sectors:

• Cold chain transport for temperature-sensitive goods
• E-commerce logistics supporting rapid delivery networks
• Urban distribution systems requiring maneuverability
• Specialized vehicle conversions including mobile clinics and service units

Future advancements are expected to focus on enhanced lightweighting through advanced materials, integration of smart monitoring systems, improved sustainability via recyclable components, and greater customization options to meet evolving market demands.