A method is disclosed utilizing
off the shelf constant cross section thickness sandwich panels comprised of
Fiber Reinforced
Thermoplastic (FRTP) resin skins and
low density thermoplastic (TP) core material wherein the steps of selectively and controllably exposing the panels to heat and incrementally
thermoforming the
skin-core into a 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 to overcome manufacturing,
assembly, weight, in-service and structural performance shortcomings of prior art and FRP
sandwich panel structures. Further disclosed is an improved, load-bearing,
modular design container structure assembled from such thermoformed FRTP sandwich panels in which is utilized the unique core-
skin edge configuration of the present invention in consideration of improved:
load bearing performance, useful load volume, reduced manufacturing costs, structural weight savings,
impact and
damage tolerance and repair and replace issues.