LIGHTWEIGHT UNIT LOAD DEVICE

• US 20110247958A1
• Filed: 10/16/2009
• Published: 10/13/2011
• Est. Priority Date: 10/16/2008
• Status: Abandoned Application

• Current Assignee: Composite Transport Technologies, Inc.
• Original Assignee: Composite Transport Technologies, Inc.
• Inventors: Merriman, Douglas, Lucas, Rick, Tweddle, Allan, McDonough, Saundra
• Application Number:
  US13/124,447
• Publication Number:
  US 20110247958A1
• Time in Patent Office: Days
• US Class Current: 206/524.6
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 66/12441 being a single wall
• CPC Class Codes: B29C 66/4326 for making hollow articles or hollow-preforms, e.g. half-shells
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/72143 Fibres of discontinuous lengths
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 70/521 and impregnating the reinforcement before the die
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/0683 UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B29K 2023/10 Polymers of propylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/10 Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2081/04 : Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof
• CPC Class Codes: B29K 2277/10 : Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2875/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as mould material
• CPC Class Codes: B29L 2031/7126 : large, e.g. for bulk storage
• CPC Class Codes: B32B 2250/20 : All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/42 : Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2260/021 : Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0269 : Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 : Glass fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/308 : Heat stability dimensional stability B32B2307/734
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/714 : Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2439/62 : Boxes, cartons, cases
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: B65D 88/14 : by air
• CPC Class Codes: B65D 90/022 : Laminated structures B65D90/029 takes precedence
• CPC Class Codes: B65D 90/08 : Interconnections of wall parts; Sealing means therefor
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree

Abstract

A unit load device constructed from fiber reinforced polymer matrix composite materials is described. Individual panels of the unit load device may be customized with composite materials and patterns. The joints are adapted to receive the ends of the panels of the unit load device and may further be customized with fiber reinforced composite materials to strengthen the joint. Some embodiments provide for construction of a unit load device from a variety of fiber reinforcing materials utilizing a matrix of thermoplastic polymers with similar softening temperatures. Each component part within the container was designed and/or created to address the specific needs of the particular part. The unit load devices described herein provide for all composite containers with a significant weight savings from conventional unit load devices.

Claims

1. A container comprising:

a plurality of polymer composite wall panels connected together by a plurality of polymer composite joints and defining at least a partially enclosed volume, wherein the plurality of polymer composite wall panels comprise a core of a first polymer composite material and a polymer composite surface layer of a second polymer composite material bonded to opposing surfaces of the core, and wherein the second polymer composite material exhibits an elastic modulus lower than that for the first polymer composite material.

2. The container of claim 1 wherein the first polymer composite material is selected from the group consisting of a carbon fiber reinforced composite material and a glass fiber reinforced composite material.

3. The container of claim 1 wherein the second polymer composite material is a polymer fiber reinforced composite material having reinforcing fibers selected from the group consisting of polyethylene, polypropylene, aramid, TEGRIS, and KEVLAR.

4. The container of claim 1 wherein the first polymer composite material is a carbon fiber reinforced composite material and the second polymer composite material is a polymer fiber reinforced composite with polypropylene reinforcing fibers.

5. The container or claim 1 wherein the first polymer composite material is a carbon fiber reinforced composite material and the second polymer composite material is a polymer fiber reinforced composite with KEVLAR reinforcing fibers.

6. The container or claim 1 wherein the first polymer composite material is a carbon fiber reinforced composite material and the second polymer composite material is TEGRIS.

7. The container of claim 1 wherein the container exhibits a weight to volume ratio ranging from about 0.6 lbs/ft³ to about 0.8 lbs/ft³.

8. The container of claim 1 wherein the container is aircraft cargo LD-3 container and exhibits a ratio of container tare weight to FAA certification load of 0.02 to about 0.03 relative to the IATA, 23rd Edition, Effective Jul. 1, 2008.

9. The container of claim 8 wherein the container exhibits a weight to volume ratio ranging from about 0.6 lbs/ft³ to about 0.8 lbs/ft³.

10. The container of claim 1 wherein the polymer composite wall panel exhibits weight ranging from about 0.1 to about 0.2 lbs/ft².

11. The container of claim 1 wherein the composite joints comprise a fiber reinforced composite material having reinforcing fibers selected from the group consisting of carbon fibers aramid fibers, KEVLAR, and glass fibers.

12. The container of claim 1 wherein the wherein the first polymer composite material is a carbon fiber reinforced composite material and the second polymer composite material is a polymer fiber reinforced composite with polypropylene reinforcing fibers, wherein the composite joints comprise carbon fiber reinforce composite material, and wherein the composite joint exhibits a fiber volume fraction ranging from about 60% to about 70%.

13. A polymer composite wall panel comprising:

a core of a first polymer composite material and a polymer composite surface layer of a second polymer composite material bonded to opposing surfaces of the core, and wherein the second polymer composite material exhibits an elastic modulus lower than that for the first composite material.

14. The polymer composite wall panel of claim 13 wherein the first polymer composite material is selected from the group consisting of a carbon fiber reinforced composite material and a glass fiber reinforced composite material.

15. The polymer composite wall panel of claim 13 wherein the second polymer composite material is a polymer fiber reinforced composite material having reinforcing fibers selected from the group consisting of polyethylene, polypropylene, aramid, TEGRIS, and KEVLAR.

16. The polymer composite wall panel of claim 13 wherein the first polymer composite material is a carbon fiber reinforced composite material and the second polymer composite material is a polymer fiber reinforced composite with polypropylene reinforcing fibers.

17. The polymer composite wall panel of claim 13 wherein the polymer composite wall panel exhibits weight ranging from about 0.1 to about 0.2 lbs/ft².

18. The polymer composite wall panel of claim 13 wherein the configuration of core composite material is a carbon fiber reinforced composite material and is bonded on both sides by the second composite material is a polymer fiber reinforced composite with polypropylene reinforcing fibers has higher impact strength than a aluminum sheet of similar weight.

19. The polymer composite wall panel of claim 13 wherein the first composite material is a carbon fiber reinforced composite material and the second composite material is a polymer fiber reinforced composite with KEVLAR reinforcing fibers.

20. The polymer composite wall panel of claim 13 further comprising alternating layers of first polymer composite material and second polymer composite material.

21. A method for making a composite part comprising the steps of:

in a continuous process, pulling carbon fibers coated with polyether soft segment aliphatic isocyanate sizing through a supply of polyurethane to provide polyurethane impregnated carbon fibers; and

shaping the polyurethane impregnated carbon fibers to a predetermined size and forming a carbon fiber reinforced polyurethane material, wherein the fiber volume fraction ranges from about 60% to about 70%.

22. A substantially polymer composite container comprising:

a plurality of polymer composite wall panels comprising carbon fibers joined together by a plurality of polymer composite joints comprising carbon fibers and defining at least a partially enclosed volume, the polymer composite wall panels and joints being positioned on a polymer composite base; and

one or more mechanical fasteners to retain the wall panels to the joints and the joints to the base,

wherein the substantially polymer composite container has a weight reduction of at least 50% in comparison to an aluminum container of a similar dimension and volume.

23. The substantially polymer composite container of claim 22, wherein the mechanical fasteners comprise one or more of bolts, screws and rivets.

24. The substantially polymer composite container of claim 22, wherein the mechanical fasteners comprise a metal material.