COMPOSITE WELDABLE PANEL WITH EMBEDDED DEVICES

• US 20080211669A1
• Filed: 10/03/2007
• Published: 09/04/2008
• Est. Priority Date: 10/06/2006
• Status: Active Grant

• Current Assignee: University of Maine System Board of Trustees
• Original Assignee: Maine Secure Composites LLC
• Inventors: Dagher, Habib J., Smith, Fred Hewitt, Viselli, Anthony M., Cassidy, Eric D., Segee, Bruce
• Granted Patent: US 8,865,285 B2
• Time in Patent Office: Days
• US Class Current: 340/561
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2439/40 Closed containers
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B65D 2211/00 Anti-theft means
• CPC Class Codes: B65D 2401/00 Tamper-indicating means relating to aerosol containers B65D83/224
• CPC Class Codes: B65D 88/12 specially adapted for transport associated with vehicles, see the relevant subclasses of B60 - B64
• CPC Class Codes: B65D 90/022 Laminated structures B65D90/029 takes precedence
• CPC Class Codes: B65D 90/023 Modular panels
• CPC Class Codes: B65D 90/08 Interconnections of wall parts; Sealing means therefor
• CPC Class Codes: B65D 90/22 Safety features floating covers B65D88/34; arrangements of indicating or measuring devices B65D90/48; fire-fighting A62C
• CPC Class Codes: B65D 90/48 Arrangements of indicating or measuring devices
• CPC Class Codes: G01D 5/16 by varying resistance
• CPC Class Codes: G01M 11/332 using discrete input signals G01M11/333 takes precedence
• CPC Class Codes: G01R 31/50 Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections testing of sparking plugs H01T13/58
• CPC Class Codes: G01R 31/58 Testing of lines, cables or conductors testing of electric windings G01R31/72
• CPC Class Codes: G08B 13/26 by proximity of an intruder causing variation in capacitance or inductance of a circuit
• CPC Class Codes: Y10T 428/16 Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/161 with frame, casing, or perimeter structure
• CPC Class Codes: Y10T 428/18 Longitudinally sectional layer of three or more sections
• CPC Class Codes: Y10T 428/183 : Next to unitary sheet of equal or greater extent
• CPC Class Codes: Y10T 428/187 : Continuous sectional layer
• CPC Class Codes: Y10T 428/24995 : Two or more layers

Abstract

A panel having a central panel element formed of a composite material, having peripheral edges formed of a weldable material, such as steel. In one form, the panel element is rectangular, and the panel element on two of its opposite edges have a corrugated profile, while the other two of its opposite edges have a linear profile. Multiple panels may be joined together by welding at the peripheral edges, to form a secure container. The composite material of the panel element in some forms, includes intrusion sensors, for example including optical fiber pathways at electrically conductive pathways, as well as processors for effecting data transfer and analyses and secure communications. In some embodiments, the electrically conductive pathways include one or more bypass resistors to produce a different circuit resistance upon interruption of one or more of the pathways.

Claims

1. A weldable hybrid composite panel comprising:

A. a panel element having a four sided rectangular peripheral edge PE, two of said four sides edges S1, S2 being mutually opposite and extending along a first axis A1 and having a length PE-L1, and two of said four sides edges S3, S4 being mutually opposite and extending along a second axis A2 and having a length PE-L2, wherein A1 is perpendicular to A2, said panel element having a substantially uniform thickness PE-L3 along a third axis A3,

wherein A3 is perpendicular to A1 and A2, and

wherein said panel element has a corrugated profile along A1, and has a linear profile along A2,

B. a first elongated edge element ME-1 affixed to, extending from and along said edge S1, wherein said edge element ME-1 has said corrugated profile along A1,

C. a second elongated edge element ME-2 affixed to and extending from and along side edge S2, wherein said edge element ME-2 has said corrugated profile along A1,

D a third elongated edge element ME-3 affixed to and extending from and along said side edge S3, and wherein said edge element ME-3 has said linear profile along A2,

E. a fourth elongated edge element ME-4 affixed to and extending from and along said side edge S4, and wherein said edge element ME-4 has said linear profile along A2,

wherein said panel element is composed of layered composite material, and wherein said first, second, third, and fourth edge elements are composed of weldable metal.

2. A panel according to claim 1, wherein said layered composite material has a layer profile:

M₂/0₃/90/0/90/0₃/M₂

wherein subscripts 2 and 3 denote two and three layers respectively, and wherein M denotes a mat fiber layer, 0 denotes a layer with longitudinal fiber orientation parallel to axis A2, and 90 denotes longitudinal fiber orientation perpendicular to said axis A2.

3. A panel according to claim 1, wherein said layered composite material has a layer profile:

M₂/90/0₃/0/0₃/90/M₂

wherein subscript 3 denotes three layers, and wherein M denotes a mat fiber layer, 0 denotes a layer with longitudinal fiber orientation parallel to axis A2 and 90 denotes longitudinal fiber orientation perpendicular to said corrugation.

4. A panel according to claim 1, wherein said layered composite material has a layer profile:

M₃/0₃/0/0₃/M₃

wherein subscript 3 denotes three layers, and wherein M denotes a mat fiber layer, 0 denotes a layer with longitudinal fiber orientation parallel to axis A2, and 90 denotes longitudinal fiber orientation perpendicular to said axis A2.

5. A panel according to claim 1, wherein said weldable metal is steel.

6. A panel according to claim 1, wherein said corrugation profile is symmetrical about an axis A11 parallel to A1.

7. A panel according to claim 6, wherein said corrugation profile has a piecewise linear repeating pattern X1-X2-X3-X4-X5, wherein:

X1 extends D1 at a positive non-zero angle P1 from A11,

X2 extends D2 parallel to A11,

X3 extends D3 at a negative non-zero angle P2,

X4 extends D4 parallel to A11, and

X5 extends D5 at a positive non-zero angle P3 to A11.

8. A panel according to claim 7, wherein

D2=D4

D1=D5= 1/2 D3

P1=P3=−

P2

9. A panel according to claim 8, wherein

D1 sin P1 is in the range 0.25 in to 4 in.,

D2 and D4 are in the range 1.5 in to 8.5 in, and

P1 is in the range 20°

to 90°

.

10. A panel according to claim 8, wherein

D1 sin P1=1.42 in.,

D2=2.75 in, and

P1=27.9°

.

11. A panel according to claim 8, wherein

D1 sin P1=1.80 in.,

D2=4.33 in., and

P1=68.5°

.

12. A panel according to claim 8, wherein

D1 sin P1=0.79 in,

D2=6.00 in, and

P1=57°

.

13. A panel according to claim 1, wherein said panel element includes a sensor system embedded therein.

14. A panel according to claim 13, wherein said sensor system includes an array of optical fibers.

15. A panel according to claim 14, wherein said array of optical fibers includes at least one fiber extending between two ends thereof, and arranged in a serpentine configuration.

16. A panel according to claim 15, wherein one of said ends is adapted to receive an optical signal whereby said optical signal propagates on said optical fiber toward to the other of said ends.

17. A panel according to claim 15, wherein said sensor system further includes an optical signal generator coupled to said one end for generating said optical signal and an optical signal detector coupled to said other end for detecting said optical signal.

18. A panel according to claim 17, wherein said optical signal generator is adapted for remote activation.

19. A panel according to claim 17, wherein said detector is adapted for remote interrogation.

20. A panel according to claim 13, wherein said sensor system includes an array electrical conductors.

21. A panel according to claim 20, wherein said array of electrical conductors includes at least one electrical conductor extending between two ends thereof and arranged in a serpentine configuration.

22. A panel according to claim 21, wherein said serpentine configuration includes at least one resistive bypass path interconnecting two points along said serpentine configuration.

23. A panel according to claim 22, wherein one of said ends is adapted to receive an electrical signal.

24. A panel according to claim 23, wherein said sensor system includes an electrical signal generator coupled to said one end for generating said electrical signal and an electrical signal generator coupled to said other end for detecting said electrical signal.

25. A panel according to claim 24, wherein said electrical signal generator is adapted for remote activation.

26. A panel according to claim 24, wherein said detector is adapted for remote interrogation.

43. A container comprising:

A. a rectangular parallelepiped frame composed of a weldable metal, and having;

i. four equal length parallel rails RX1, RX2, RX3 and RX4 extending along an X axis

ii. four equal length parallel rails RY1, RY2, RY3 and RY4 extending along a Y axis

iii. four equal length parallel rails RZ1, RZ2, RZ3 and RZ4 extending along a Z axis

wherein said X, Y, and Z axis are mutually orthogonal, and

wherein RX1, RX2, RY1 and RY2 define a first side panel locus,

wherein RX3, RX4, RY3 and RY4 define a second side panel locus,

wherein RY1, RY3, RZ1 and RZ2 define a first end panel locus,

wherein RY2, RY4, RZ3 and RZ4 define a second end panel locus,

wherein RX2, RX4, RZ2 and RZ4 define a top panel locus, and

wherein RX1, RX3, RZ1 and RZ3 define a bottom panel locus,

B. a weldable panel of claims 1-26 disposed in said first side panel locus and welded at its peripheral edge elements ME to said rails RX1, RX2, RY1, RY2,

C. a weldable panel of claims 1-26 disposed in said second side panel locus and welded at its peripheral edge elements ME to said rails RX3, RX4 RY3, RY4,

D. a weldable panel of claims 1-26 disposed in said first end panel locus and welded at its peripheral edge elements ME to said rails RY1, RY3, RZ1, RZ2, and

E. a weldable panel of claims 1-26 disposed in said top panel locus and welded at its peripheral edge elements ME to said rails RX1, RX4, RZ2, RZ4.

44. A container according to claim 43, further comprising:

a weldable panel of claims 1-26 disposed in said bottom panel locus, and welded at its peripheral edge elements ME to said rails RX1, RX3, RZ1, RZ3.

46. A container of claim 43, further comprising:

a weldable panel of claims 1-26 disposed in said second end panel locus, and welded at its peripheral edge elements ME to said rails RY2, RY4, RZ3, RZ4.

71. A container of claim 43, wherein at least one of the first and second side panel loci, the first and second end panel loci, and the top and bottom panel loci comprises more than one of the weldable panels of claims 1-26, the more than one weldable panels being parallel within the respective locus, and welded together along an adjacent peripheral edge, the remaining peripheral edge elements of the more than one weldable panels being welded to adjacent rails, each of the more than one panels being individually replaceable as subpanel elements.

27. A hybrid panel comprising:

A. a wood layer preferably ¾

inch laminated plywood including hard and soft wood solid-sawn tongue-and-groove hardwood planks, and partially laminated solid-sawn hardwood,

B. a fiber-reinforced polymer composite layer wherein said composite layer includes a sensor system embedded therein.

30. A panel according to claim 27, wherein said sensor system includes an array of optical fibers.

31. A panel according to claim 30, wherein said array of optical fibers includes at least one fiber extending between two end thereof, and arranged in a serpentine configuration.

32. A panel according to claim 31, wherein one of said ends is adapted to receive an optical signal whereby said optical signal propagates on said optical fiber toward to the other of said ends.

33. A panel according to claim 32, wherein said sensor system further includes an optical signal generator coupled to said one end for generating said optical signal and an optical signal detector coupled to said other end for detecting said optical signal.

34. A panel according to claim 33, wherein said optical signal generator is adapted for remote activation.

35. A panel according to claim 33, wherein said detector is adapted for remote interrogation.

36. A panel according to claim 27, wherein said sensor system includes an array electrical conductors.

37. A panel according to claim 36, wherein said array of electrical conductors includes at least one electrical conductor extending between two ends thereof and arranged in a serpentine configuration

38. A panel according to claim 37, wherein said serpentine configuration includes at least one resistive bypass path interconnecting two points along said serpentine configuration.

39. A panel according to claim 38, wherein one of said ends is adapted to receive an electrical signal.

40. A panel according to claim 39, wherein said sensor system includes an electrical signal generator coupled to said one end for generating said electrical signal and an electrical signal generator coupled to said other end for detecting said electrical signal.

41. A panel according to claim 40, wherein said electrical signal generator is adapted for remote activation.

42. A panel according to claim 40, wherein said detector is adapted for remote interrogation.

28. A hybrid panel comprising:

A. a wood layer including apitong; and

B. a fiber-reinforced polymer composite layer wherein said composite layer includes a sensor system embedded therein.

29. A hybrid panel comprising:

A, a wood layer including a high-density plywood; and

B. a fiber-reinforced polymer composite layer wherein said composite layer includes a sensor system embedded therein.

45. A container according to claim 43, further comprising:

at least two cross members extending between said rails RX1, RX3, and a hybrid panel of claims 29-42 connected to said cross members.

47. A panel comprising:

an insulating planar member;

an electrically conductive path extending between two terminals and aligned with the insulating planar member;

a bypass resistor coupled between two different points along the electrically conductive path, the resulting combination providing an increased circuit resistance between the two terminals when the electrically conductive path is breached.

48. The panel of claim 47, wherein the insulating planar member is comprised of at least one resin-fiber layer.

49. The panel of claim 47, further comprising a weldable member coupled to the insulating planar member.

50. The panel of claim 47, wherein the electrically conductive path includes a wide-profile conductor.

51. The panel of claim 50, wherein the wide profile conductor is porous.

52. The panel of claim 47, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a serpentine configuration.

53. The panel of claim 47, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a spiral configuration.

54. The panel of claim 47, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a rectangular grid configuration.

55. The panel of claim 47, wherein one of the two terminals is adapted to receive an electrical signal.

56. The panel of claim 47, further comprising an electrical signal generator coupled to said one end for generating said electrical signal and detector coupled to said other end for detecting said electrical signal.

57. The panel of claim 47, wherein the planar member is corrugated.

58. The panel of claim 47, further comprising another insulating layer in planar alignment with the insulating planar member.

59. A panel comprising:

an insulating planar member;

an electrically conductive path extending between two terminals and aligned with the insulating planar member, the electrically conductive path including a wide-profile conductor.

60. The panel of claim 59, wherein the insulating planar member is comprised of at least one resin-fiber layer.

61. The panel of claim 59, further comprising a weldable member coupled to the insulating planar member.

62. The panel of claim 59, wherein the wide profile conductor is porous.

63. The panel of claim 59, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a serpentine configuration.

64. The panel of claim 59, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a spiral configuration.

65. The panel of claim 59, wherein the electrically conductive path includes at least one electrical conductor extending between two ends thereof and arranged in a rectangular grid configuration.

66. The panel of claim 59, further comprising at least one bypass resistor coupled between two different points along the electrically conductive path.

67. The panel of claim 59, wherein one of the two terminals is adapted to receive an electrical signal.

68. The panel of claim 59, further comprising an electrical signal generator coupled to said one end for generating said electrical signal and an electrical signal generator coupled to said other end for detecting said electrical signal.

69. The panel of claim 59, wherein the planar member is corrugated.

70. The panel of claim 59, further comprising another insulating layer in planar alignment with the insulating planar member.