Structural panel, and pallet formed thereby

Claim 2

A cargo pallet for aircraft and the like, which comprises: a structural panel adapted to support cargo, said panel comprising a multiplicity of elongated parallel core elements inserted, respectively, into openings between the webs of an integrally woven three-dimensional fabric, said core elements being formed of a high-strength partially expanded thermoplastic polymer, said polymer forming said core elements being partially expanded acrylonitrile butadiene styrene, the density of said partially expanded acrylonitrile butadiene styrene polymer being approximately 23-24 pounds per cubic foot, said panel further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edges of said panel and forming a frame therearound; and connector means secured to the edges of said panel for connection thereof to a cargo-retaining means.

Claim 3

A cargo pallet for aircraft and the like, which comprises: a structural panel adapted to support cargo, said panel comprising a multiplicity of elongated parallel core elements inserted respectively, into openings between the webs of an integrally woven three-dimensional fabric, said core elements being formed of a high-strength partially expanded thermoplastic polymer, said panel further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edges of said panel and forming a frame therearound; and connector means secured to the edges of said panel for connection thereof to a cargo-retaining means, said connector means including a portion recessed into an edge of said panel and secured to said edge by fastener means, said connector means further including a hard insert in said panel edge for reception of said connector portion and said fastener means, said connector means further including a connector element removably secured to said connector portion.

Claim 4

A cargo pallet for aircraft and the like, which comprises: a structural panel adapted to support cargo, said panel comprising a multiplicity of elongated parallel core elements inserted respectively, into openings between the webs of an integrally woven three-dimensional fabric, said core elements being formed of a high-strength partially expanded thermoplastic polymer, said panel further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edges of said panel and forming a frame therearound; and connector means secured to the edges of said panel for connection thereof to a cargo-retaining means, said connector means including a portion recessed into an edge of said panel and secured to said edge by fastener means, said connector means further including a hard insert in said panel edge for reception of said connector portion and said fastener means, said connector means further including a connector element removably secured to said connector portion.

Claim 5

The invention as claimed in claim 2, in which said edge means comprises channel-sectioned aluminum extrusions mounted over the edges of said panel and secured thereto, said extrusions having openings therethrough registered with said connector portions.

Claim 6

The invention as claimed in claim 2, in which said insert is formed of chopped fiberglass and synthetic bonding resin.

Claim 7

The invention as claimed in claim 2, in which said polymer forming said core elements is expanded acrylonitrile butadiene styrene, in which said core elements are triangular in section, in which said fabric is an integrally woven fiberglass fabric having flutes or webs which define triangularly sectioned passages for reception of said core elements, and in which said synthetic bonding resin is selected from a group consisting of epoxy resins and polyester resins.

Claim 8

A cargo pallet for aircraft and the like, which comprises: a structural panel adapted to support cargo: said panel comprising a multiplicity of elongated parallel core elements inserted, respectively, into openings between the webs of an integrally woven three-dimensional fabric, each of said core elements being an extrusion formed of a high-strength partially expanded thermoplastic polymer, said polymer being acrylonitrile butadiene styrene, said extrusion having an axial passage therethrough, said panEl further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edges of said panel and forming a frame therearound; and connector means secured to the edges of said panel for connection thereof to a cargo-retaining means.

Claim 9

A cargo pallet for aircraft and the like, which comprises: a structural panel adapted to support cargo: said panel comprising a multiplicity of elongated parallel core elements inserted, respectively, into openings between the webs of an integrally woven three-dimensional fabric, each of said core elements being an extrusion formed of a high-strength partially expanded thermoplastic polymer, said polymer being acrylonitrile butadiene styrene, said extrusion having an axial passage therethrough, said panEl further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edges of said panel and forming a frame therearound; and connector means secured to the edges of said panel for connection thereof to a cargo-retaining means.

Claim 10

The invention as claimed in claim 6, in which said axial passage is filled with a very low-density insulating foam plastic.

Claim 11

The invention as claimed in claim 7, in which said foam plastic is polyurethane foam.

Claim 12

A cargo pallet for aircraft, which comprises: a structural panel adapted to support cargo, and adapted to be shifted along roller-type support means, said panel comprising an integrally woven three-dimensioned fabric having spaced-apart parallel faces integrally connected to each other by a multiplicity of webs, said panel further comprising a multiplicity of elongated extrusions of expanded acrylonitrile butadiene styrene polymer, said extrusions being snugly inserted in parallel relationship to each other and to said webs in the spaces formed between said faces and said webs, said panel further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edge portions of said panel and forming a frame therearound; and means to connect the edge portions of said panel to a cargo-retaining means.

Claim 13

A cargo pallet for aircraft, which comprises: a structural panel adapted to support cargo, and adapted to be shifted along roller-type support means, said panel comprising an integrally woven three-dimensioned fabric having spaced-apart parallel faces integrally connected to each other by a multiplicity of webs, said panel further comprising a multiplicity of elongated extrusions of expanded acrylonitrile butadiene styrene polymer, said extrusions being snugly inserted in parallel relationship to each other and to said webs in the spaces formed between said faces and said webs, said panel further comprising synthetic bonding resin impregnated into said fabric and enclosing said core elements; edge means mounted about the edge portions of said panel and forming a frame therearound; and means to connect the edge portions of said panel to a cargo-retaining means.

Claim 14

The invention as claimed in claim 9, in which said extrusions of acrylonitrile butadiene styrene polymer are only partially expanded.

Claim 15

The invention as claimed in claim 9, in which one of said impregnated panel faces is substantially thicker than the other, each of said faces being integral and nonlaminated.

Claim 16

The invention as claimed in claim 11, in which the thickness of said thicker impregnated face is about 0.050 inch.

Claim 17

The invention as claimed in claim 9, in which a tough and wear-resistant coating of unfoamed polyurethane is provided exteriorly on at least the lower one of said faces, thereby insuring that any exposed fibers from said faces may not enter the rollers of said support means.

Claim 18

A cargo pallet for aircraft, which comprises: a structural panel adapted to support cargo, and adapted to be shifted along roller-type support means, said panel comprising an integrally woven three-dimensional fiber glass fabric having spaced-apart parallel faces integrally connected to each other by a multiplicity of webs, said webs and faces defining triangularly-sectioned passages for snug reception of core elements, said panel further comprising a multiplicity of elongated extrusions of partially expanded acrylonitrile butadiene styrene polymer, each of said extrusions being triangular in section and being adapted to fit snugly into one of said triangularly sectioned passages, alternate ones of said extrusions being inverted whereby said extrusions nest together on opposite sides of said webs and between said faces, said panel further comprising synthetic bonding resin selected from a group consisting of epoxy resins and polyester resins, said bonding resin being impregnated into said fabric and enclosing said extrusions; edge means mounted around the edge portions of said panel and forming a frame therearound; and connector means to connect said edge portions of said panel to a cargo-retaining means.

Claim 19

A cargo pallet for aircraft, which comprises: a structural panel adapted to support cargo, and adapted to be shifted along roller-type support means, said panel comprising an integrally woven three-dimensional fiber glass fabric having spaced-apart parallel faces integrally connected to each other by a multiplicity of webs, said webs and faces defining triangularly-sectioned passages for snug reception of core elements, said panel further comprising a multiplicity of elongated extrusions of partially expanded acrylonitrile butadiene styrene polymer, each of said extrusions being triangular in section and being adapted to fit snugly into one of said triangularly sectioned passages, alternate ones of said extrusions being inverted whereby said extrusions nest together on opposite sides of said webs and between said faces, said panel further comprising synthetic bonding resin selected from a group consisting of epoxy resins and polyester resins, said bonding resin being impregnated into said fabric and enclosing said extrusions; edge means mounted around the edge portions of said panel and forming a frame therearound; and connector means to connect said edge portions of said panel to a cargo-retaining means.

Claim 20

The invention as claimed in claim 14, in which one of said faces is formed of integrally woven fabric which is more thick than the other of said faces, both of said faces being nonlaminated.

Claim 21

The invention as claimed in claim 14, in which an unfoamed polyurethane coating is provided exteriorly on at least one of said faces.