# US 9,517,586 B2 · Method for making an enclosure

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- Number: US 9,517,586 B2
- Document ID: US9517586B2
- Status: Granted
- Kind: B2
- Application number: 13/890,003
- Filed: 2013-05-08
- Published: 2014-11-13
- Granted: 2016-12-13
- Earliest claimed: 2013-05-08
- Assignees: Extenet Systems, Inc.
- Applicants: Extenet Systems, Inc.
- Inventors: Gary D. Stahl; Gregory L. Klosowski; Rick Conklin
- Web page: https://patentgrep.com/patent/US9517586B2

## 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 51/10: Forming by pressure difference, e.g. vacuum
- B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding}
- B29C 65/562: {using extra joining elements, i.e. which are not integral with the parts to be joined (using plastic snap elements B29C65/58; using plastic rivets B29C65/601)}
- B29C 66/543: {joining more than two hollow-preforms to form said hollow articles}
- B29C 66/545: {one hollow-preform being placed inside the other}
- B29C 2791/006: Using vacuum
- B29K 2995/0003: having particular electrical or magnetic properties, e.g. piezoelectric
- B29L 2031/3481: {Housings or casings incorporating or embedding electric or electronic elements}
- 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)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

An enclosure for housing electrical equipment is disclosed. The enclosure is produced by thermoforming four separate pieces or bodies together to form the top and bottom of the enclosure. The enclosure is made of a moldable material, such as plastic or fiberglass.

## Claims

### Claim 1

A method of making an enclosure for housing at least one electrical component, the method comprising:
thermoforming a first outer shell from a moldable material;
thermoforming a second outer shell from the moldable material;
thermoforming a first inner body from the moldable material;
thermoforming a second inner body from the moldable material;
securing the first inner body within the first inner shell to create a first part of the enclosure;
securing the second inner body within the second outer shell to create a second part of the enclosure; and
wherein the second inner body comprises a base with upwardly extending side walls and the second outer shell comprises a base with upwardly extending side walls;
wherein the second inner body is positioned within the second outer shell such that the side walls of the second inner body are positioned within the side walls of the second outer shell; and
wherein the second inner body includes a lip that extends downwardly from the upwardly extending side walls and the lip is positioned within the upwardly extending side walls of the base of the second outer shell.

### Claim 2 (depends on 1)

The method of claim 1 further comprising vacuum forming the first outer shell, the second outer shell, the first inner body, and the second inner body.

### Claim 3 (depends on 1)

The method of claim 1 wherein the moldable material comprises plastic or fiberglass.

### Claim 4 (depends on 1)

The method of claim 1 wherein the moldable material comprises a radio-frequency (RF) transparent material.

### Claim 5 (depends on 1)

The method of claim 1 wherein the first inner body is secured within the first outer shell by adhesive, and wherein the second inner body is secured within the second outer shell by adhesive.

### Claim 6 (depends on 1)

The method of claim 1 wherein the first inner body comprises a base with downwardly extending side walls and the first outer shell comprises a base with downwardly extending side walls, and wherein the first inner body is positioned within the first outer shell such that the walls of the first inner body are positioned within the walls of the first outer shell.

### Claim 7 (depends on 6)

The method of claim 6 wherein the lip is also positioned within the downwardly extending walls of the first outer shell when the first outer shell is in a closed position with respect to the second outer shell.

### Claim 8 (depends on 1)

The method of claim 1 further comprising securing the first part of the enclosure to the second part of the enclosure.

### Claim 9 (depends on 8)

The method of claim 8 further comprising locking the first part of the enclosure to the second part of the enclosure with a locking mechanism.

### Claim 10 (depends on 1)

The method of claim 1 wherein the at least one electrical component comprises a telecommunications antenna.

### Claim 11

A method of making and assembling an enclosure for housing at least one electrical component, the method comprising:
vacuum forming a first outer shell from a plastic material;
vacuum forming a second outer shell from the plastic material;
vacuum forming a first inner body from the plastic material;
vacuum forming a second inner body from the plastic material;
securing the first inner body within the first outer shell to create a first double-walled part of the enclosure;
securing the second inner body within the second outer shell to create a second double-walled part of the enclosure; and
securing the first part to the second part.

### Claim 12 (depends on 11)

The method of claim 11 wherein the first part is secured to the second part via a hinge.

### Claim 13 (depends on 11)

The method of claim 11 wherein the first inner body is secured within the first outer shell by adhesive.

### Claim 14 (depends on 11)

The method of claim 11 wherein the second inner body is secured within the second outer shell by adhesive.

### Claim 15 (depends on 11)

The method of claim 11 further comprising locking the first part of the enclosure to the second part of the enclosure with a locking mechanism.

### Claim 16 (depends on 7)

The method of claim 7, wherein the lip is exposed to an exterior of the enclosure when the when the first outer shell is in a closed position with respect to the second outer shell.