Door assembly for use on utility truck

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Solution Overview

Problem

Existing splicer platforms and doors for utility trucks face issues with dielectric hazards, weight, manufacturing costs, and operational range limitations, while lacking efficient manufacturing methods that enhance strength and reduce dielectric risks.

Innovation Solution

Incorporation of multi-sheet thermoforming and resin transfer molding (RTM) processes to create a splicer door and platform assembly with recessed mounting locations, corrugated structures, and non-conductive materials, reducing dielectric hazards and weight, while increasing strength and operational range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional single-sheet thermoforming or conventional manufacturing methods are used for splicer doors, then manufacturing simplicity is maintained, but the door strength, weight reduction, and dielectric hazard reduction are insufficient

Engineering Contradiction:

Improvedoor strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining multiple sheets of thermoplastic material with reinforcing elements to create a multi-layered splicer door structure. This composite construction enhances door strength and provides dielectric protection while managing the complexity through integrated manufacturing processes.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements nesting by forming recessed mounting locations and corrugated structures within the door body itself during the thermoforming process. These nested features integrate multiple functions (mounting, structural reinforcement) into the door structure, reducing the need for separate components and assemblies.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Length of moving object

If heavier materials and traditional construction methods are used for splicer doors, then manufacturing simplicity is maintained, but the operational range of the utility truck boom is limited

Engineering Contradiction:

Improveoperational rangeVSAvoiddoor weight

Core Design Contradiction:

Length of moving objectVSWeight of moving object

Solution Approach 1:

The patent applies parameter changes by utilizing thermoplastic materials with specific physical properties and controlling the thermoforming process parameters to create a door that achieves optimal strength-to-weight ratio. The multi-sheet construction with controlled thickness and integrated reinforcement allows weight reduction while maintaining structural integrity for extended operational range.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional manufacturing methods are used for splicer doors, then manufacturing costs are controlled, but dielectric hazards and safety risks are not sufficiently reduced

Engineering Contradiction:

Improveworker safetyVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by layering multiple sheets of dielectric thermoplastic material with appropriate spacing and reinforcement, creating a door structure that provides enhanced electrical insulation. This composite construction reduces dielectric hazards while the integrated thermoforming process maintains manufacturing efficiency.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by creating recessed mounting locations and varying material thickness in specific areas of the door to provide enhanced dielectric protection where needed, while maintaining overall manufacturing efficiency through the integrated thermoforming process.

Inventive Principle:

Principle #3Local quality

4Strength

If multi-sheet thermoforming and RTM processes are implemented, then door strength and safety are improved, but manufacturing costs and process complexity increase

Engineering Contradiction:

Improvedoor strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies merging by integrating the multi-sheet thermoforming process with resin transfer molding (RTM) to create a unified manufacturing process. This combination allows the door structure and reinforcement elements to be formed in an integrated manner, reducing assembly steps and potentially offsetting the increased process complexity through manufacturing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution results in a lighter, stronger, and safer splicer door and platform assembly with reduced manufacturing costs, enhanced operational range, and improved worker safety by minimizing dielectric hazards and tool storage capabilities.

Implementation Method 1

a thermoplastic sheet is heated and softened

Methodology Applied

Scientific EffectThermal softening: Heating

Implementation Method 2

formed under vacuum into a desired door configuration

Methodology Applied

Scientific EffectVacuum forming: Vacuum

Implementation Method 3

splicer platform that is molded using a resin transfer molding (RTM) process

Methodology Applied

Scientific EffectResin transfer molding:

Data Source

PatentUS20250332779A1Door assembly for use on utility truck

Publication Date: 2025.10.30 ALTEC INDS

AI summary

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.