Description:
FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
A UTILITY POLYMER BODY AND METHOD OF MANUFACTURING THE SAME

2. APPLICANTS

NAME : ALP Aeroflex India Private Limited
NATIONALITY : IN
ADDRESS : Plot No. 32 (HUDA), Sector-18, Gurugram-122015, Haryana, India

2. PREAMBLE TO THE DESCRIPTION

COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD

[0001] The present invention relates to the field of polymer-based structure, and more specifically, to a utility polymer body and a method for manufacturing the same using polymer sheet extrusion, precision cutting, and molecular-level welding, wherein the polymer sheet is made of a modified thermoplastic material.

BACKGROUND
[0002] With the advancements in material technologies, the demand for lightweight, corrosion-resistant, and maintenance-free structural components has increased significantly. Traditionally, the structural components, such as utility bodies, which are used in industries such as transportation, logistics, marine, and engineering applications, have been manufactured using materials such as metal, aluminum, or fiberglass. These materials generally provide structural strength, however, they have some drawbacks such as higher weight, corrosion susceptibility, complex manufacturing process, and post-processing requirements such as painting. Further, material wastes cause environmental concerns.
[0003] Accordingly, there exists a need for an improved utility polymer body that are lightweight, strong, and corrosion-resistant, while ensuring a high degree of precision and minimal material waste.
[0004] At present, there exist many alternatives materials such as Polymers, particularly those made from thermoplastic materials have gained attention due to their favorable mechanical properties, recyclability, chemical resistance, and cost-effectiveness. However, the fabrication of large structural polymer bodies remains a challenge, especially when ensuring dimensional stability, load-bearing capacity, and durable assembly using thermoplastic welding.
[0005] Conventional polymer body manufacturing processes often involve molding or thermoforming, which may limit flexibility in customization or create material waste.
[0006] In light of the foregoing discussion, there exists a need to address this problem by providing a utility polymer body made of a modified thermoplastic material and a method for manufacturing the same.

SUMMARY

[0007] The present invention provides a method for manufacturing a utility polymer body. The method is performed in steps that include extruding at least one polymer sheet. In an embodiment, the polymer sheet is made of modified thermoplastic material. The modified thermoplastic material includes, but is not limited to, polyolefin-based polymers such as Polyethylene (PE) and Polypropylene (PP) and exhibits a low lay-flat tolerance, a coefficient of friction ranging from 0.25 to 0.35, and a specific gravity of less than 1.
[0008] The steps further include cutting the polymer sheet to predefined dimensions corresponding to required shape of utility body. In an embodiment, excess cut-off polymer is reused to form the welding rod or re-extruded into the polymer sheet. The steps further include mounting the cut polymer sheet on a support structure. The steps further include preparing edges of the polymer sheet for welding. Thereafter, the steps include performing molecular-level welding to connect the edges of the polymer sheet to form the utility polymer body. In an embodiment, the molecular-level welding is performed using a handheld polymer extruder and a welding rod made of the same thermoplastic material. The polymer sheet and the welding rod are pre-colored and color-matched to eliminate the need for painting.
[0009] In an embodiment, the utility polymer body is mounted on a metal subframe for high load-bearing applications or an aluminum subframe for lightweight or corrosion-resistant applications. In an embodiment, UV stabilizers and flame retardants are incorporated into the polymer sheet to enhance durability and environmental performance.
[0010] In an another embodiment, the present invention discloses a utility polymer body. The utility polymer body includes a welded structure formed from at least one polymer sheet. The polymer sheet, cut to a required dimension, is mounted on a support structure, and edges of the sheet are connected via molecular-level welding along with insert nuts during manufacturing.
[0011] In an embodiment, the subframe is mounted on a vehicle chassis when the utility polymer body is configured for use in a utility vehicle.
[0012] A primary objective of the present invention is to provide a method for manufacturing a utility polymer body that is 50~60% lighter than conventional sheet metal body, corrosion-resistant, durable, and suitable for a range of applications, including logistics, transportation, marine, and engineering.
[0013] A further objective of the present invention is to provide the method for manufacturing the utility polymer body using modified thermoplastic materials, including polyolefin-based polymers such as Polyethylene (PE) and Polypropylene.
[0014] Yet another objective of the present invention is to eliminate the need for post-manufacturing painting by using pre-colored and color-matched polymer sheets and welding rods.
[0015] Yet another objective of the present invention is to integrate additives such as UV stabilizers and flame retardants into the polymer sheet, enhancing its durability and environmental performance while ensuring compliance with safety standards.
[0016] Yet another objective of the present invention is to provide a zero waste manufacturing method by enabling the reuse of excess polymer material, either by creating welding rods or re-extruding it into new polymer sheets. Yet another objective of the present invention is to manufacture the utility polymer body using polymer sheets having low lay-flat tolerance to achieve flat surface and avoid surface deformation and bulge on the polymer body, a specific gravity of less than 1, and a coefficient of friction ranging from 0.25 to 0.35, which results in less drag, and surface resistance, thereby offering excellent dimensional stability and performance.
[0017] Yet another objective of the present invention is to provide the manufacturing method that avoids hazardous emissions associated with traditional metal fabrication, thereby contributing to a more sustainable and environmentally friendly production approach.
[0018] Yet another objective of the present innovation is to provide a safe and easy working environment for fabricators. The Polymer sheet (S.G.0.96) is 7~8 times lighter than the standard Sheet-metal (S.G. 7.8), approx. 7 times lighter than stainless steel (S.G. 7.8), which make material handling and fabrication less stressful and safer from sudden accidents at work for fabricators.
[0019] Yet another objective of the present innovation is to improve health and safety for fabricators by minimizing exposure to risks commonly associated with traditional metal fabrication, such as cuts, abrasions, and infections, including tetanus, which can occur due to handling rusted or corroded metal components. Polymer, being an inert material with a fully saturated molecular structure, does not rust, rot, corrode, or suffer from osmosis or electrolysis. This significantly reduces the chances of injury and infection during fabrication and handling. Its chemical stability and durability further enhance workplace safety by eliminating sharp corrosion byproducts and ensuring long-term structural integrity, even in harsh environmental conditions.
[0020] The foregoing summary is provided for illustrative purposes only and is not intended to limit the scope of the invention in any way. In addition to the illustrative aspects, embodiments, and features described earlier, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings, which are incorporated herein and constitute a part of this disclosure, illustrate exemplary embodiments, and together with the description, serve to explain the disclosed principles. The same numbers are used throughout the figures to reference like features and components, wherein:
[0022] FIG. 1 depicts a flow diagram showing a method for manufacturing a utility polymer body, in accordance with one or more exemplary embodiments of the present disclosure;
[0023] FIG. 2 depicts a first use case of the utility polymer body with functional components, in accordance with one or more exemplary embodiments of the present disclosure;
[0024] FIG. 3A depicts a second use case of the utility polymer body, in accordance with one or more exemplary embodiments of the present disclosure;
[0025] FIG. 3B depicts implementation of the utility polymer body in a tipper application, in accordance with one or more exemplary embodiments of the present disclosure;
[0026] FIG. 4A depicts a third use case of the utility polymer body, in accordance with one or more exemplary embodiments of the present disclosure; and
[0027] FIG. 4B depicts implementation of the utility polymer body in a water tanker application, in accordance with one or more exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

[0028] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that these specific details are only exemplary and not intended to be limiting.
[0029] It is to be understood that various omissions and substitutions of equivalents may be made as circumstances may suggest or render expedient to cover various applications or implementations without departing from the scope of the present disclosure.
[0030] Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of clarity of the description and should not be regarded as limiting.
[0031] Furthermore, in the present description, references to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification does not necessarily refer to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
[0032] Further, the terms “a” and “an” used herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described, which may be requirements for some embodiments but not for other embodiments.
[0033] Referring to FIG. 1, a flow diagram showing a method for manufacturing a utility polymer body is disclosed. The utility polymer body is a strong, lightweight structure that can be used in applications that demand lightweight, corrosion-resistant, and low-maintenance structural solutions. It is particularly effective in cases such as dry goods transport, cold storage compartments, and high-deck vehicle bodies, where weight reduction enhances fuel efficiency and payload capacity. Designed using polymer, its inherent corrosion resistance makes it ideal for moisture-sensitive environments, including refrigerated and marine applications.
[0034] Traditionally metal or fiberglass structures used in vehicles and industrial applications. Metal bodies, while strong, are heavy, prone to rust, and require complex fabrication and regular maintenance. Fiberglass, though lighter, can be brittle and non-recyclable, and infuse with chemicals that may pose health hazards with prolonged exposure as well as may impact the environment which makes it unsustainable. Therefore, a novel method for manufacturing a utility polymer body has been developed, offering numerous advantages such as reduced (50~60%) weight for improved fuel efficiency and increased payload capacity, zero corrosion, chemical resistance and cost-effectiveness through streamlined processes including extrusion, precision cutting, and thermoplastic welding. Moreover, polymer bodies support zero-waste production and provide design flexibility. These advantages make manufacturing utility polymer bodies highly suitable for modern applications in transportation, logistics, marine, and engineering sectors where performance, efficiency, and sustainability are of critical importance.
[0035] In the flow diagram, each block may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the drawings. For example, two blocks shown in succession in FIG. 1 may be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. Any process descriptions or blocks in flowcharts should be understood as representing modules, segments, or portions of code that include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included within the scope of the example embodiments in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved. In addition, the process descriptions or blocks in flow charts should be understood as representing decisions made by a hardware structure, such as a state machine. The flow diagram starts at step (102) and proceeds to step (110).
[0036] At step 102, at least one polymer sheet is formed through an extrusion process. In one embodiment, the polymer sheet is made of a modified thermoplastic material to provide optimal mechanical strength, flexibility, and resistance to environmental degradation. The thermoplastic material includes, but is not limited to, polyolefin-based polymers such as polyethylene (PE) and polypropylene (PP). In one exemplary embodiment, the polymer sheet is made of modified polyethylene (PE), which may comprise one or more materials such as Linear Low-Density Polyethylene (LLDPE), Low-Density Polyethylene (LDPE), Medium-Density Polyethylene (MDPE), High-Density Polyethylene (HDPE), High-Molecular-Weight Polyethylene (HMWPE), and Ultra-High-Molecular-Weight Polyethylene (UHMWPE). These grades of polyethylene are selected based on application-specific requirements such as impact resistance, flexibility, toughness, and ease of welding. It is important to note that the modified PE is a pre-colored extrusion sheet and thereby eliminates the need for painting after manufacturing the utility body. In terms of temperature tolerance, the modified PE operates effectively between -55°C to 85°C, making it suitable for colder environments. In another exemplary embodiment, the polymer sheet is made of modified polypropylene (PP), which may include one or more materials such as Polypropylene Homopolymer (PPH) and Polypropylene Copolymer (PPC). The Modified PP is easy to paint post-process, offering flexibility in finishing. In terms of temperature tolerance, the modified PP supports a broader temperature range from 0°C to 100°C, offering advantages in high-heat applications. The modified PP uses PPH (Polypropylene Homopolymer) for tank applications due to its chemical resistance. It is important to note that these modified sheets have been designed as an alternative to steel, stainless steel, aluminum, and fiberglass in a wide range of marine applications.
[0037] These polymer sheets generally offer enhanced chemical resistance, better thermal stability, and good weldability, making them particularly suitable for manufacturing the utility polymer body. Further, the polymer sheet exhibits a strong balance of stiffness and toughness, along with good mechanical damping ability, which helps in absorbing vibrations and reducing operational noise. A low lay-flat tolerance avoids waviness and ensures dimensional stability during handling and assembly. The polymer sheet also reduces wear and tear, enabling long services life even in harsh working conditions.
[0038] Unlike metals or glass, which possess crystalline structures prone to denting or fracturing, these polymer sheets consist of long-chain molecules that provide the sheet with a form of material memory, resulting in high impact resistance.
[0039] The polymer sheet also exhibits a coefficient of friction ranging from 0.25 to 0.35, providing a suitable balance between surface smoothness and grip for assembly purposes. In an exemplary embodiment, the polymer sheet has a coefficient of friction around 0.29 which results in less drag, surface resistance, making for better performance.
[0040] Furthermore, the polymer sheet maintains a specific gravity (S.G.) of less than 1.00, contributing to the lightweight characteristics of the utility polymer body and thereby enhancing fuel efficiency when used in vehicle-based applications. In an exemplary embodiment, the polymer sheet is relatively light with S.G. of approximately 0.96, which is about one-third the weight of aluminum (S.G. 2.7) and fiberglass (S.G. 3) and approximately seven times lighter than stainless steel (S.G. 7.8) without compromising strength or durability.
[0041] In an embodiment, the polymer sheet is manufactured using a customized masterbatch, a concentrated formulation of polymers, colorants, and functional additives, tailored to meet specific requirements. This customization allows for the integration of desired properties such as UV protection, flame retardancy, and application-specific stabilizers. In one embodiment, ultraviolet (UV) stabilizers and flame retardants are incorporated into the polymer sheet to improve its environmental resistance, enhance fire safety, and ensure compliance with relevant safety and durability standards.
[0042] Additionally, the polymer sheet is chemically inert, which means its molecular structure is complete and stable, making it resistant to rust, rot, corrosion, osmosis, and electrolysis. Collectively, the polymer sheet improves the structural integrity and long-term performance of the utility polymer body.
[0043] Successively, the polymer sheet is cut, at step 104, to predefined dimensions corresponding to required shape of the utility body. This step ensures that the polymer sheet fits accurately within the overall structural framework of the utility body. To achieve high precision and consistency, the cutting process is performed using Computer Numerical Control (CNC) machines or power tools, depending on the complexity of the design and thickness of the polymer sheet. The CNC machine offers the advantage of automated, computer-guided cutting paths, which help maintain dimensional accuracy, reduce material waste, and enable repeatable fabrication of multiple components. The use of power tools, such as rotary saws or routers, may also be used for certain geometric profiles or when flexibility in manual handling is required.
[0044] It is important to note that any excess cut-off polymer may be reused either by converting it into welding rods for subsequent fabrication steps or by re-extruding it into new polymer sheets, thereby contributing to a zero-waste manufacturing process.
[0045] Successively, the polymer sheet is mounted on a support structure, at step 106. This support structure serves as a temporary holding or alignment frame during fabrication. Its primary purpose is to ensure that the polymer sheet remains properly positioned, level, and stationary during the welding process. The support structure can be a jig, fixture, or a customized assembly platform designed to accommodate the shape and size of the utility body. Accurate placement on the support structure is crucial to avoid misalignment or deformation during welding, especially in applications requiring high structural integrity.
[0046] Successively, edges of the polymer sheet are prepared, at step 108, for welding. In an embodiment, the edges are prepared by performing at least one of mechanical scraping, trimming, or beveling, depending on the application and thickness of the polymer sheet. This preparation is critical to remove surface contaminants, such as dust, dirt, oils, or oxidized layers, and to eliminate any geometric irregularities that may hinder proper bonding. These imperfections can prevent the polymer chains from fully interfacing during welding, leading to weak or incomplete joints. Therefore, edge preparation is essential for achieving strong molecular bonding between adjoining polymer sheets.
[0047] Once the edges are prepared, molecular-level welding is performed, at step 110, to connect the edges of the polymer sheet. In an embodiment, the welding is performed using a handheld polymer extruder gun equipped with a polymer welding rod, which is made of the same thermoplastic material as the polymer sheets to ensure material compatibility. During the welding process, both the welding rod and the prepared sheet edges are simultaneously melted, allowing the polymer chains from both components to intermingle and fuse at a molecular level. As the molten material cools and solidifies, it forms a homogeneous, continuous weld joint that maintains the mechanical integrity and structural performance of the original material. This molecular-level welding results in seamless, high-strength bonds that contribute to the formation of the unified utility polymer body capable of withstanding various mechanical and environmental stresses.
[0048] This welding method ensures that the final assembly is rigid, leak-proof, corrosion-resistant, and structurally robust, making it suitable for a variety of utility applications such as transportation, logistics, marine, and engineering environments where durability and reliability are essential.
[0049] After the utility polymer body is manufactured, the polymer body is mounted on a subframe. In one embodiment, the utility polymer body is mounted on a metal subframe, which is particularly suitable for high load-bearing applications such as water tankers, tipper bodies, and dry goods transport boxes. The metal subframe acts as a rigid intermediary between the polymer body and the vehicle chassis, enhancing load distribution and improving structural durability. Additionally, the metal subframe allows for the integration of hydraulic systems, including lifting pistons and pressure pumps, and supports mounting of critical components such as platforms, reverse osmosis (RO) units, and water pumps in case of water tankers and hydraulic actuators and pivot hinges in case of tipper bodies. This configuration is especially beneficial for heavy-duty applications in sectors such as construction, mining, and waste management, where high structural strength and robustness are required.
[0050] In another embodiment, the utility polymer body is mounted on an aluminum subframe, which is preferable for lightweight and corrosion-resistant applications. This includes use cases such as cold storage compartments, high-deck vehicle bodies, and dry goods carriers, where weight reduction improves fuel efficiency and increases payload capacity. The aluminum subframe supports uni-body construction, enabling the polymer body to be mounted directly onto the vehicle chassis without the need for the metal subframe. Since aluminum is naturally corrosion-resistant, making it ideal for moisture-sensitive environments, such as refrigerated transport and marine applications. Furthermore, the aluminum subframe can be designed as a single integrated unit with fewer joints, bolts, and welding points, simplifying assembly and reducing maintenance.
[0051] In an additional embodiment, the polymer sheet may be wrapped around the metal subframe to enhance its weatherability, chemical resistance, and operational longevity. This polymer wrapping reduces wear and tear, provides protection against corrosion, degradation of metal, shields against UV exposure, moisture ingress, and extreme temperatures, chemical resistance, protection from road salts, oils, and other chemicals. As a result, it extends the lifespan of the subframe and reduces long-term maintenance requirements.
[0052] It is important to note that the selection of the subframe material and wrapping configuration depends on the intended utility vehicle application. For instance, a water tanker may require a metal subframe due to its heavy load demands and need for hydraulic equipment, whereas a cold goods transport body may be better suited to an aluminum subframe for its lightweight and corrosion-resistant properties.
[0053] It is important to note that the utility polymer body is mounted on the subframe to provide additional structural support and facilitate installation on a vehicle chassis or other platform.
[0054] Applications:
[0055] The utility polymer body is suitable for use in both internal combustion engine (ICE) vehicles and electric vehicles (EVs). When implemented in the EVs, the polymer sheet used in manufacturing the utility body offers multiple advantages in terms of performance, efficiency, and durability, making it an ideal choice for constructing lightweight EV utility bodies. The reduced weight of the polymer body contributes to greater driving range and improved energy efficiency, which are critical performance metrics for EV platforms.
[0056] Additionally, the polymer sheet is highly durable and corrosion-resistant, resulting in longer service life and reduced maintenance requirements. The polymer sheet also supports environmentally sustainable manufacturing practices, and its impact-absorbing properties enhance vehicle safety. Beyond automotive utility applications, the utility polymer body is suitable for a wide variety of end uses. In transportation, it can be applied to water tankers, fire trucks, liquid fertilizer spray tank, ISO tanks, waste truck bodies, trailers, truck or van floors and liners, double wall dry truck body, vehicle control panel battery boxes, vehicle air ducts, and vehicle toolboxes.
[0057] In the marine sector, applications include floating houses, floating solar walkways, aquarium touch pool, pontoons, docks, walkways, jettys, and boats.
[0058] In engineering and industrial settings, it is suitable for fabricating closed or open tanks, electrode tanks, water/wastewater storage units, chemical/process tanks, polymer hoppers, and cool boxes for food products.
[0059] Additional applications include road safety barriers, drainage covers, and piping connections. These diverse uses demonstrate the polymer sheet's versatility, reliability, and relevance across multiple industries.
[0060] Referring to FIG. 2, a first use case of the polymer utility body (200) with functional components is disclosed, in accordance with one or more exemplary embodiments of the present disclosure. As depicted, the utility polymer body (200) is configured as a dry box polymer utility body, which is commonly used for the secure and weather-resistant transportation or storage of non-perishable goods, tools, or equipment. Further, FIG. 2 discloses the structural elements, functional components, and dimensions that make up the body. The polymer body (200) is formed by cutting extruded polymer sheets in dimensions as indicated: 2200 mm x 1562 mm x 1600 mm, mounting them on a support structure, and welding the sheet edges using a handheld polymer extruder for molecular-level bonding.
[0061] Referring to FIG. 3A, a second use case of the polymer utility body (200) is disclosed, in accordance with one or more exemplary embodiments of the present disclosure. This embodiment demonstrates a compact, rugged, and lightweight utility polymer body (200) designed using the manufacturing method disclosed here in the disclosure. The structure is formed by cutting extruded polymer sheets to predefined dimensions as indicated: 2300 mm x 1500 mm x 1200 mm, mounting them on a support structure, and welding the sheet edges using a handheld polymer extruder for molecular-level bonding.
[0062] Referring to FIG. 3B, the polymer utility body is utilized in a tipper application, demonstrating the integration of the polymer utility body with the chassis. As depicted, the utility polymer body (200), which is manufactured using the method (100) of the present disclosure, mounted on the subframe (302), which provides intermediate structural support between the polymer utility body (200) and the vehicle chassis (304). The vehicle chassis (304) acts as the primary structural platform of the vehicle. Once the utility polymer body (200) is manufactured and attached to the subframe (302), the entire assembly is mounted onto the chassis (304), ensuring compatibility with standard commercial transport frameworks.
[0063] Referring to FIG. 4A, a third use case of the polymer utility body (200) is disclosed, in accordance with one or more exemplary embodiments of the present disclosure. This embodiment demonstrates a utility polymer body (200) designed using the manufacturing method disclosed in the present invention. The structure is formed by cutting extruded polymer sheets to predefined dimensions as indicated: 1900 mm x 1450 mm x 1000 mm, mounting them on a support structure, and welding the sheet edges using a handheld polymer extruder for molecular-level bonding.
[0064] Referring to FIG. 4B, demonstrating side view of the water tanker fitted with the polymer utility body. As depicted, the utility polymer body (200) is securely installed on the vehicle chassis using the subframe.
[0065] Advantages of the Invention:
[0066] Lightweight: The utility polymer body is made of the modified thermoplastic material that has a specific gravity < 1.0, making it significantly lighter than conventional materials such as metal, aluminum, or fiberglass. This reduction in weight contributes to improved fuel efficiency, increased payload capacity, and extended range.
[0067] Corrosion Resistance: The fabricated polymer body is inherently resistant to corrosion, rot, osmosis, and electrolysis. This makes it especially suitable for applications in humid, marine, or chemically aggressive environments, ensuring long-term durability and minimal material degradation.
[0068] Zero-Waste Manufacturing: The manufacturing method allows for the reuse of polymer cut-offs either to create welding rods or re-extruded into new sheets. This supports a sustainable, circular manufacturing process with minimal material waste.
[0069] No Painting Required: The use of pre-colored extrusion sheets and color-matched welding rods eliminates the need for post-processing paint applications. This not only reduces manufacturing time and cost but also avoids the emission of volatile organic compounds (VOCs), making the process more environmentally friendly.
[0070] Molecular-Level Welding: The polymer sheets are joined using a molecular-level welding process, resulting in strong, seamless bonds. This method provides superior structural integrity compared to mechanical fastening or chemical adhesives and ensures the joints are leak-proof and capable of withstanding mechanical stress and vibration.
[0071] Customization & Scalability: Precision cutting using CNC machines allows for accurate shaping of polymer sheets according to specific design requirements. This enables scalable manufacturing and modular integration across various vehicle platforms.
[0072] Thermal & Chemical Stability: Due to modified thermoplastic material, the utility polymer body is suitable for chemical or food-grade transport.
[0073] High Impact and Wear Resistance: The polymer body absorbs shock and vibration, which results in long life in construction, mining, or waste management vehicles.
[0074] Improved assembly and maintenance: The utility polymer body requires fewer fasteners and no painting, which reduces assembly time and cost.
[0075] Compatibility with electric vehicles (EVs) and internal combustion engine (ICE) Vehicles: The lightweight and modular design is particularly beneficial for EVs, where reduced weight improves energy efficiency. It is equally compatible with ICE vehicles.
[0076] Enhanced Safety: The polymer body absorbs impacts effectively, reducing the transmission of shock during collisions. Additionally, the absence of sharp metal edges or corrosion-prone surfaces enhances safety for both users and service personnel.
[0077] Environmental Sustainability and Design Flexibility: The polymer sheets are made from thermoplastics and do not release hazardous emissions during processing. This supports sustainable manufacturing practices and allows flexibility in color, finish, and structural design, enabling adaptation to diverse commercial applications.
[0078] It has thus been seen that the utility polymer body and method of manufacturing the same, according to the present invention, achieve the purposes highlighted earlier. Such a method and the polymer body can in any case undergo numerous modifications and variants, all of which are covered by the same innovative concept, moreover, all of the details may be replaced by elements that are technically equivalent. The scope of protection of the invention is therefore defined by the attached claims.

Dated 9th day of July, 2025
Ankush Mahajan
Agent for the Applicant (IN/PA-1523)
OF Global Institute of Intellectual Property Pvt. Ltd
, Claims:Claims
We Claim:
1. A method (100) for manufacturing a utility polymer body, the method (100) comprising:
extruding (102) at least one polymer sheet, wherein the polymer sheet is made of modified thermoplastic material;
cutting (104) the polymer sheet to predefined dimensions corresponding to required shape of utility body;
mounting (106) the cut polymer sheet on a support structure;
preparing (108) edges of the polymer sheet for welding; and
performing (110) molecular-level welding to connect the edges of the polymer sheet to form the utility polymer body.

2. The method (100) as claimed in claim 1, wherein the utility polymer body is mounted on
a metal subframe for high load-bearing applications; or
an aluminum subframe for lightweight or corrosion-resistant applications.

3. The method (100) as claimed in claim 1, wherein the thermoplastic material includes, but is not limited to, polyolefin-based polymers.

4. The method (100) as claimed in claim 1, wherein the polymer sheet exhibits a low lay-flat tolerance, a coefficient of friction ranging from 0.25 to 0.35, and a specific gravity of less than 1.

5. The method (100) as claimed in claim 1, wherein the molecular-level welding is performed using a handheld polymer extruder and a welding rod made of the same thermoplastic material.

6. The method (100) as claimed in claim 5, wherein the polymer sheet and the welding rod are pre-colored and color-matched to eliminate the need for painting.

7. The method (100) as claimed in claim 1, wherein excess cut-off polymer is reused to form the welding rod or re-extruded into the polymer sheet.

8. The method as claimed in claim 1, wherein ultraviolet (UV) stabilizers and flame retardants are incorporated into the polymer sheet to enhance durability and environmental performance.

9. A utility polymer body (200), comprising:
a welded structure (202) formed from at least one polymer sheet, wherein the polymer sheet, cut to a required dimension, is mounted on a support structure, and edges of the sheet are connected via molecular-level welding along with insert nuts during manufacturing.

10. The utility polymer body (200) as claimed in claim 9, wherein the polymer sheet is made of modified thermoplastic material, which includes, but is not limited to, polyolefin-based polymers.

11. The utility polymer body (200) as claimed in claim 9, wherein the utility polymer body is mounted on a subframe (302) made of metal or aluminum depending on load requirement.

12. The utility polymer body (200) as claimed in claim 11, wherein the subframe (302) is mounted on a vehicle chassis (304) when the utility polymer body (200) is configured for use in a utility vehicle.

Dated 9th day of July, 2025
Ankush Mahajan
Agent for the Applicant (IN/PA-1523)
OF Global Institute of Intellectual Property Pvt. Ltd.