Hall Composite Batten's Flex range is specially built for long intermediate battens in mainsails. When choosing battens for a mainsail, these are the long intermediate battens that go between the full-length compression battens.
Flex battens have the biggest difference in stiffness between the inboard and outboard ends.
These battens are for use on all yachts from 12-foot skiffs to 100-foot Supermaxis and Superyachts.
Our Flex battens have a hollow section at the outboard end to give extra stiffness and taper down to a solid section at the inboard end to give ultimate flexibility.
The taper is specially engineered to match the desired draft profile of the sail and ensure your sail is always producing the best aerofoil shape.
The unique honey-comb shape of the hollow section makes the battens better at resisting impact with running backstays, spreading the load across a flat space instead of point-loading on a round section.
When building anything from carbon, the quality of the mould dictates the quality of the finished product. so at Hall Spars, we use the highest quality polished aluminium moulds on all of our Hall Composite Battens.
Our Flex range is made by cutting long strips of pre-preg carbon fibre using a precision computer-driven cutting machine and laying these onto two flat aluminium plates. Each plate has a row of half honey-comb shaped channels carved into them. Once the fibre is laid down, the stack of carbon is vacuum bagged and put into our autoclave and cooked at 85psi or six times the normal atmospheric pressure. This ensures that we get a very dense laminate and that the fibre makes its way into the corners of the channels to create the desired shape. The cooking cycle varies in length depends on the thickness of the laminate so that the resin flows between layers and gives a consolidated laminate.
Once cooking is complete and the plates have been cooled, the corrugated sheets of carbon are joined together so that the corrugations form the honey-comb shaped cross-section. They are bonded using an extremely strong rubber-toughened-epoxy adhesive. Once the adhesive has cured, the sheet is precision water cut lengthways between each corrugation to form each batten.