METHOD OF THERMOFORMING FRTP SANDWICH PANELS, THERMOFORMED ARTICLES, MODULAR CONTAINER

摘要

A method is disclosed utilizing off the shelf constant cross section thickness sandwich panels comprised of Fiber Reinforced Thermoplastic (FRTP) resin skins (23, 33) and low density thermoplastic (TP) resin core (27) wherein the steps of selectively and controllably exposing the panels to heat and incrementally thermoforming the core-skin into an integral consolidated composite edge or intra-panel area in consideration of subsequent mating and attachment of the FRTP sandwich panel to other structures is achieved. The exact configuration of articles so thermoformed is design optimized for an application for ease of manufacture, assembly, weight savings, and in-service structural performance. Further disclosed is a load bearing modular designed cargo container (1) assembled from such thermoformed FRTP sandwich panels (1, 5, 7) in which the integral core-skin consolidated composite edge configuration accounts for applied load transfer, useful container load volume, impact and damage tolerance, and repair and replace issues.