Lightweight blast resistant container

Abstract

This invention is a novel lightweight blast resistant container. It consists of containers made of a blast resistant fiber reinforced polymer resin matrix composite. The invention employs a novel construction configuration whereby the container is created by the appropriate nesting of composite parts to create a cube, box or multi-faceted geometry. As a result of the nesting, the box like geometry exhibits characteristics that cause the geometry to behave more like a sphere than a box when subjected to internal blast pressures. Such an approach provides an optimized minimum weight solution by fully utilizing the entire material volume, whereby ultimate tensile strength can be simultaneously developed everywhere in the container.

1 . A blast resistant container, constructed entirely or in part of a blast resistant composite material.  
   
   
       2 . The container of  claim 1  wherein the composite material is a fiber reinforcement in a polymer resin matrix.  
   
   
       3 . The polymer resin matrix of  claim 2  wherein the polymer resin matrix is resistant to galvanic corrosion, solvents and chemical agents and exhibits a high specific strength, high specific modulus, high strain to failure, high fracture toughness and is not hygroscopic.  
   
   
       4 . The fiber reinforcement of  claim 2  wherein the fiber reinforcement is treated with a special resin compatible sizing which develops a high specific laminate strength, high specific Laminate modulus, high laminate strain to failure and a high laminate fracture toughness.  
   
   
       5 . The container of  claim 2 , wherein the composite material is layered to form a laminate.  
   
   
       6 . The container of  claim 2  wherein the container is constructed of three nested parts, such that circumferential hoop stresses are developed in the winding direction of the broadgoods associated with each part's geometry.  
   
   
       7 . The container of  claim 6  wherein when exposed to an internal blast, each part, within the nested assembly, tends to dilate into a cylindrical shape, reducing the high stresses normally developed at the corners of a rigid box where three edges intersect  
   
   
       8 . The container of  claim 7  wherein the device is closed by installing the third part, and in the event of the blast the expansion of the inner parts to the outer parts seal with a gasket.  
   
   
       9 . The container of  claim 1  wherein the container is a Unit Load Device.  
   
   
       10 . The container of  claim 1  wherein the container is a mailbox.  
   
   
       11 . The container of  claim 1  wherein the container is a containerized shipping container.  
   
   
       12 . The container of  claim 1  wherein the container is a storage unit for explosive materials in order to protect the surroundings from an accidental or unanticipated detonation of the explosives stored within the container.  
   
   
       13 . The container of  claim 1  wherein the container is a portable container to safely detonate bombs.  
   
   
       14 . The container of  claim 6  wherein core materials are placed adjacent or bonded to at least one side of at least one of the nested parts.  
   
   
       15 . The container of  claim 14  wherein, when assembled, the core material forms a sandwich consisting of an inner part wall, the core material and the adjoining next outer part wall.  
   
   
       16 . The container of  claim 14  wherein the possible core materials include opened or closed cell foam, a honeycomb material, nomex, metal foam, or balsa wood.  
   
   
       17 . The container of  claim 14  wherein the nested part assembly is bonded to a base plate.  
   
   
       18 . The container of  claim 17  wherein the base plate footprint is equal to or greater than the nested part assembly footprint.  
   
   
       19 . The container of  claim 6  wherein a non-circular opening is cut into one side wall, and an oversized composite door is made to seal the opening from the inside.  
   
   
       20 . The container of  claim 15  further comprising; 
 at least one wall with a portion of empty space instead of core material,    a door cutout through one entire side of the container; and,    an internal door in the empty space which seals the door opening when in the closed position.    
   
   
       21 . The container of  claim 20  where the door is a guillotine door.  
   
   
       22 . The container of  claim 21  wherein the guillotine door bottoms out on a base plate by gravity  
   
   
       23 . The container of  claim 20  wherein the door is a sliding door.  
   
   
       24 . The container of  claim 20  including door stops to prevent movement of the door.  
   
   
       25 . A method of constructing a blast resistant container, comprising: 
 providing a tool which allows for forming of three nested parts,    fabricating and curing the nested parts; and,    assembling the container from the three nested parts, such that circumferential hoop constraint is achieved about three orthogonal axes.    
   
   
       26 . The method of  claim 25  wherein the containers are constructed at least in part using a fiber reinforced, polymer resin matrix, composite.  
   
   
       27 . The method of  claim 26  wherein resin is introduced using a vacuum infusion process.  
   
   
       28 . The method of  claim 26  wherein resin is introduced by pre-impregnating the reinforcement broadgoods.  
   
   
       29 . The method of  claim 25  further comprising; 
 placing adjacent or bonding core materials to at least one side of one of at least one of the nested parts such that when assembled,    the core material forms a sandwich consisting of an inner part wall, the core material and the adjoining next outer part wall