Abstract: A lightweight flame-resistant composite panel is provided including a body portion and a side portion folded over the body portion. The side portion includes a channel segment adjacent to the body portion, and an overlapping segment adjacent to the channel segment. One or more panel apertures are located in the body portion and the channel segment for receiving bolts through the side of the panel. An edge reinforcement insert can be inserted underneath the channel segment in a channel defined by the folded side portion along an edge of the body portion. The edge reinforcement insert includes one or more insert apertures for receiving the one or more bolts through the panel, thereby increasing the bolt bearing strength of the panel along its edge. The edge reinforcement insert may comprise an elongated strip, a plurality of separated tabs, or an end cap, or may alternatively be contained within the panel.

Abstract: The multi-layered ballistics armor includes one or more containment layers covering at least a portion of an impact absorbing layer formed of a fragmenting material to minimize and contain fragmentation of the impact absorbing layer. The one or more containment layers may include one or more primary containment envelopes, and the fragmenting material may be a ceramic such as silicon carbide, carbon/carbon composites, carbon/carbon/silicon carbide composites, boron carbide, aluminum oxide, silicon carbide particulate/aluminum metal matrix composites, or combinations thereof. The multi-layered armor may include one or more adhesive layers over the impact absorbing layer, one or more composite backing layers, an energy absorbing layer, and a flame resistant layer. A secondary containment envelope can be provided over the one or more primary containment envelopes, composite backing layers, and energy absorbing layer.

Abstract: Provided herein is a blast resistant cargo container sufficiently lightweight to be practical for aircraft transport. The container includes a frame assembly and a plurality of panels. Innovative panel connections between side panels and a unique door latching system improve the weakest links of the container. The plurality of panels includes a top panel, a bottom panel, a plurality of side panels and a flexible door. The side panels and the flexible door are formed of at least one explosion resistant sheet of a flexible, high tensile strength material. Edges of the sheets are wrapped around and secured to a rod. An edge capturing rail is wrapped around the sheets over each rod. The latching mechanism involves retaining a locking rail extending from the door panel in a groove of a doorpost or door sill with a detent bar.

Abstract: A process for making a lightweight laminated panel material for construction of cargo containers includes providing a high performance fabric layer, placing film adhesive layers over both sides of the high performance fabric layer, placing protective surface film layers over the film adhesive layers to form a pre-lamination stack, and placing release layers over the protective surface film layers. The pre-lamination stack is heated, compressed, and maintained at the temperature and under pressure to form a lamination stack. The lamination stack is cooled to an intermediate temperature and released from pressure, cooled further, and the release layers are removed.

Abstract: Provided herein is a blast resistant cargo container sufficiently lightweight to be practical for aircraft transport. The container includes a frame assembly and a plurality of panels. Innovative panel connections between side panels and a unique door latching system improve the weakest links of the container. The plurality of panels includes a top panel, a bottom panel, a plurality of side panels and a flexible door. The side panels and the flexible door are formed of at least one explosion resistant sheet of a flexible, high tensile strength material. Edges of the sheets are wrapped around and secured to a rod. An edge capturing rail is wrapped around the sheets over each rod. The latching mechanism involves retaining a locking rail extending from the door panel in a groove of a doorpost or door sill with a detent bar.

Abstract: The method and system for rapid press forming and consolidation of a sheet of thermoformable material provides for molding of articles with complex shapes. The sheet of thermoformable material is suspended on a movable frame and transferred on a track to a preheating and preconsolidation station, where it is heated, and rapidly transferred suspended on the movable frame via the track to a molding and consolidation station for rapid press forming and consolidation with a hydraulic punch that applies pressure uniformly in all directions, to substantially eliminate wrinkles in the formed product.

Abstract: A process for making a lightweight laminated panel material for construction of cargo containers includes providing a high performance fabric layer, placing film adhesive layers over both sides of the high performance fabric layer, placing protective surface film layers over the film adhesive layers to form a pre-lamination stack, and placing release layers over the protective surface film layers. The pre-lamination stack is heated, compressed, and maintained at the temperature and under pressure to form a lamination stack. The lamination stack is cooled to an intermediate temperature and released from pressure, cooled further, and the release layers are removed.

Abstract: The multi-layered ballistics armor includes one or more containment layers covering at least a portion of an impact absorbing layer formed of a fragmenting material to minimize and contain fragmentation of the impact absorbing layer. The one or more containment layers may include one or more primary containment envelopes, and the fragmenting material may be a ceramic such as silicon carbide, carbon/carbon composites, carbon/carbon/silicon carbide composites, boron carbide, aluminum oxide, silicon carbide particulate/aluminum metal matrix composites, or combinations thereof. The multi-layered armor may include one or more adhesive layers over the impact absorbing layer, one or more composite backing layers, an energy absorbing layer, and a flame resistant layer. A secondary containment envelope can be provided over the one or more primary containment envelopes, composite backing layers, and energy absorbing layer.

Abstract: The method and system for rapid press forming and consolidation of a sheet of thermoformable material provides for molding of articles with complex shapes. The sheet of thermoformable material is suspended on a movable frame and transferred on a track to a preheating and preconsolidation station, where it is heated, and rapidly transferred suspended on the movable frame via the track to a molding and consolidation station for rapid press forming and consolidation with a hydraulic punch that applies pressure uniformly in all directions, to substantially eliminate wrinkles in the formed product.

Abstract: The explosion resistant cargo container includes a frame including a main section and an angled projecting section, and is formed from a plurality of support members. The frame is covered with one or more explosion resistant sheets to form the explosion resistant side panels. The explosion resistant panels comprise a plurality of layers of explosion resistant sheets. The explosion resistant panels may also include a sheet of polycarbonate, and may also include padding or insulation placed between layers of the explosion resistant sheets. The side panels and flexible door comprise one or more of explosion resistant sheets, with one or more of the sheets of the plurality of explosion resistant sheets have edges wrapped around and secured to one or more mounting strips, with the edges of the plurality of explosion resistant sheets and mounting strips being bonded together. The mounting strips are currently preferably formed of metal, such as aluminum.

Abstract: The explosion resistant cargo container includes a frame including a main section and an angled projecting section, and is formed from a plurality of support members. The frame is covered with one or more explosion resistant sheets to form the explosion resistant side panels. The explosion resistant panels comprise a plurality of layers of explosion resistant sheets. The explosion resistant panels may also include a sheet of polycarbonate, and may also include padding or insulation placed between layers of the explosion resistant sheets. The side panels and flexible door comprise one or more of explosion resistant sheets, with one or more of the sheets of the plurality of explosion resistant sheets have edges wrapped around and secured to one or more mounting strips, with the edges of the plurality of explosion resistant sheets and mounting strips being bonded together. The mounting strips are currently preferably formed of metal, such as aluminum.

Abstract: The explosion resistant cargo container includes a frame including a main section and an angled projecting section, and is formed from a plurality of support members. The frame is covered with one or more explosion resistant sheets to form the explosion resistant side panels. The explosion resistant panels comprise a plurality of layers of explosion resistant sheets. The explosion resistant panels may also include a sheet of polycarbonate, and may also include padding or insulation placed between layers of the explosion resistant sheets. The side panels and flexible door comprise one or more of explosion resistant sheets, with one or more of the sheets of the plurality of explosion resistant sheets have edges wrapped around and secured to one or more mounting strips, with the edges of the plurality of explosion resistant sheets and mounting strips being bonded together. The mounting strips are currently preferably formed of metal, such as aluminum.

Abstract: The explosion resistant cargo container includes a frame including a main section and an angled projecting section, and is formed from a plurality of support members. The frame is covered with one or more explosion resistant sheets to form the explosion resistant side panels. The explosion resistant panels comprise a plurality of layers of explosion resistant sheets. The explosion resistant panels may also include a sheet of polycarbonate, and may also include padding or insulation placed between layers of the explosion resistant sheets. The side panels and flexible door comprise one or more of explosion resistant sheets, with one or more of the sheets of the plurality of explosion resistant sheets have edges wrapped around and secured to one or more mounting strips, with the edges of the plurality of explosion resistant sheets and mounting strips being bonded together. The mounting strips are currently preferably formed of metal, such as aluminum.

Abstract: The explosion resistant cargo container includes a frame including a main section and an angled projecting section, and is formed from a plurality of support members. The frame is covered with one or more explosion resistant sheets to form the explosion resistant side panels. The explosion resistant panels comprise a plurality of layers of explosion resistant sheets. The explosion resistant panels may also include a sheet of polycarbonate, and may also include padding or insulation placed between layers of the explosion resistant sheets. The side panels and flexible door comprise one or more of explosion resistant sheets, with one or more of the sheets of the plurality of explosion resistant sheets have edges wrapped around and secured to one or more mounting strips, with the edges of the plurality of explosion resistant sheets and mounting strips being bonded together. The mounting strips are currently preferably formed of metal, such as aluminum.