Lightweight spherical blast resistant container

Abstract

This invention is a novel minimum weight and minimum volume blast resistant container. The container is made of a blast resistant, fiber reinforced, polymer resin matrix, composite material. The invention employs a novel construction configuration whereby the container is created by winding a collection of continuous reinforcing fiber filaments, called a tow, or winding a collection of tows called a tape, around a spherical tool or mandrel. Prior to winding, resin is applied to the tow or tape by immersion into a resin bath. Such an approach provides an optimized minimum weight and minimum volume solution by fully utilizing all the material in the part, whereby ultimate tensile strength can be simultaneously developed everywhere in the container.

1 . A spherically shaped 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 fiber reinforcement and polymer resin matrix of  claim 2  wherein the fiber reinforcement and the polymer resin matrix are resistant to galvanic corrosion, solvents and chemical agents and exhibit 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 1  wherein the container is used for robotic handling of explosives or improvised explosive devices (IED's).  
   
   
       7 . The container of  claim 1  wherein the container is a minimum weight, minimum volume explosives container for use where minimum weight and/or volume is essential.  
   
   
       8 . The container of  claim 1  wherein the container is a minimum weight, minimum volume explosives container for use in Military or commercial land, sea or air assets.  
   
   
       9 . The container of  claim 1  wherein the container is a storage unit for explosive materials in order to protect the surrounding personnel and property from an accidental or unanticipated detonation of the explosives stored within the container.  
   
   
       10 . The container of  claim 1  wherein the container is a portable container to safely detonate bombs or IED's.  
   
   
       11 . The container of  claim 1  wherein core materials are placed between inner and outer walls of the composite.  
   
   
       12 . The container of  claim 11  wherein, when assembled, the core material forms a sandwich consisting of an inner wall, the core material and an outer wall.  
   
   
       13 . The container of  claim 11  wherein the possible core materials include, opened or closed cell foam, a honeycomb material, nomex, metal foam, or balsa wood.  
   
   
       14 . The container of  claim 1  wherein a non-circular opening is cut into the container wall, and an oversized composite door is made to seal the opening from the inside.  
   
   
       15 . The container of  claim 11  further comprising; 
 at least one section of wall with a portion of empty space instead of core material,    a door cutout through the wall of the container in the region with no core material; and,    an internal door in the empty space which completely seals the door opening when in the closed position.    
   
   
       16 . The container of  claim 15  where the door is a guillotine door.  
   
   
       17 . The container of  claim 15  wherein the door is a sliding door.  
   
   
       18 . The container of  claim 15  including door retainers to prevent movement of the door.  
   
   
       19 . A method of constructing a spherical blast resistant container, comprising: 
 providing a collapsible and/or removable tool which allows for forming of a spherical shape made from a blast resistant composite material,    making a doorway in the container wall.    providing a tool for making a door of blast resistant composite material    fabricating and curing the sphere and hatch; and,    assembling the door and sphere into a completed container.    
   
   
       20 . The method of  claim 19  wherein the containers are constructed at least in part using a fiber reinforced, polymer resin matrix, composite.  
   
   
       21 . The method of  claim 20  wherein the reinforcement is a collection of fiber filaments, commonly referred to as fiber tow, whereby resin is applied to the fiber tow by immersion into a resin bath.  
   
   
       22 . The method of  claim 20  wherein the reinforcement is a collection of fiber tows comprising a tape or band of reinforcement fibers whereby resin is applied to the tape by immersion into a resin bath.  
   
   
       23 . The method of  claim 19  wherein the spherical tool is collapsible, and is removed through the door when the sphere is fully cured.  
   
   
       24 . The method of  claim 19  wherein the spherical tool is inflatable, and is deflated and removed through the door when the sphere is fully cured.  
   
   
       25 . The method of  claim 19  wherein the spherical tool is left in the container and becomes part of the structure.  
   
   
       26 . The method of  claim 19  wherein the spherical tool may be dissolved (using water or other agent) or melted at elevated temperature, and then removed via the cutout doorway, after the part is fully cured.