# US 11,305,478 B2 · Door assembly for use on a utility truck

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- Number: US 11,305,478 B2
- Document ID: US11305478B2
- Status: Granted
- Kind: B2
- Application number: 15/803,525
- Filed: 2017-11-03
- Published: 2018-05-10
- Granted: 2022-04-19
- Earliest claimed: 2016-11-08
- Assignees: Altec Industries, Inc.
- Applicants: Altec Industries, Inc.
- Inventors: Ryan J. McKinney; Brad Harju
- Web page: https://patentgrep.com/patent/US11305478B2

## CPC

- B29C 51/267: {Two sheets being thermoformed in separate mould parts and joined together while still in the mould (B29C49/0691 takes precedence)}
- B29C 48/0017: {combined with blow-moulding or thermoforming}
- B29C 48/0022: {combined with cutting}
- B29C 48/07: Flat, e.g. panels
- B29C 51/10: Forming by pressure difference, e.g. vacuum
- B29C 64/00: Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 7/08: by mechanical means
- B33Y 80/00: Products made by additive manufacturing
- B66F 11/044: {Working platforms suspended from booms}
- F25D 23/082: {Strips}
- B29C 2791/006: Using vacuum
- B29L 2031/724: {Doors}
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B66F: HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD ({invalid lifting devices A61G7/10; } mounting artificial islands on piles or like supports E02B17/00; scaffolding combined with lifting devices E04G1/22; lifting devices for sliding forms E04G11/24; lifting of buildings E04G23/06; shores or struts E04G25/00; lifts or other hoisting devices on ladders E06C7/12; props for mining E21D15/00)
- F25D: REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR (refrigerated showcases A47F3/04; thermally-insulated vessels for domestic use A47J41/00; refrigerated vehicles, see the appropriate subclasses of classes B60 - B64; containers with thermal insulation in general B65D81/38; heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants, or materials for the production of heat or cold by chemical reactions other than by combustion C09K5/00; thermally-insulated vessels for liquefied or solidified gases F17C; air-conditioning or air-humidification F24F; refrigeration machines, plants, or systems F25B; cooling of instruments or comparable apparatus without refrigeration G12B)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A multi-sheet component for a utility vehicle that includes at least one gap between at least two of the sheets, thereby providing a component that enhances worker safety by increasing component stiffness and reducing component thickness. The component is manufactured through multi-sheet thermoforming and uses a conical frustum corrugation to increase stiffness.

## Claims

### Claim 1

A method for manufacturing a multi-sheet component consisting of a first sheet and a second sheet for a utility vehicle, comprising:
thermoforming the first sheet;
inserting a core material between the first sheet and the second sheet; and
manufacturing the second sheet onto the first sheet and the core material using lamination and/or 3D printing;
wherein the multi-sheet component is a hinged door;
wherein the core material is removed after manufacturing the second sheet;
wherein the first sheet and the second sheet are separated by at least one gap;
wherein a corrugation on the first sheet extends into the component to meet the second sheet, thereby creating a mounting location on the first sheet to mount conductive hardware through;
wherein the mounting location is recessed into the first sheet, thereby shielding the conductive hardware from contacting a conductor greater than the width of the corrugation on the first sheet; and
wherein the first sheet and/or the second sheet is made from dielectric materials including reinforced thermosets, unreinforced thermosets, reinforced thermoplastics, and/or unreinforced thermoplastics.

### Claim 2 (depends on 1)

The method of claim 1, wherein the corrugation includes a conical frustum corrugation, and further including the step of forming the conical frustum corrugation in the first sheet when forming the first sheet; and
wherein the frusta have base diameters of between about 2 and about 4 inches.

### Claim 3 (depends on 1)

The method of claim 1, further comprising filling the gap with pressurized or non-pressurized air after manufacturing the second sheet.

### Claim 4 (depends on 1)

The method of claim 1, wherein the corrugation on the first sheet includes a frustum corrugation, and wherein the first sheet is thermoformed to include the frustum corrugation.