U.S. patent application number 11/264574 was filed with the patent office on 2007-05-17 for modular cupola assembly.
Invention is credited to Torrence Anderson, Jed Richardson, Michael Uffner.
Application Number | 20070107326 11/264574 |
Document ID | / |
Family ID | 38039295 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070107326 |
Kind Code |
A1 |
Uffner; Michael ; et
al. |
May 17, 2007 |
Modular cupola assembly
Abstract
The present invention relates to kit for a cupola assembly. The
cupola assembly utilizes injection molded plastic panels having
integrally formed connectors. The cupola is capable of being
packaged and shipped in a knocked-down state and constructed into a
secure cupola.
Inventors: |
Uffner; Michael;
(Naperville, IL) ; Richardson; Jed; (Batavia,
IL) ; Anderson; Torrence; (Overland Park,
IL) |
Correspondence
Address: |
MCHALE & SLAVIN, P.A.
2855 PGA BLVD
PALM BEACH GARDENS
FL
33410
US
|
Family ID: |
38039295 |
Appl. No.: |
11/264574 |
Filed: |
October 31, 2005 |
Current U.S.
Class: |
52/200 ;
52/72 |
Current CPC
Class: |
E04B 7/026 20130101;
E04B 7/028 20130101 |
Class at
Publication: |
052/200 ;
052/072 |
International
Class: |
E04B 7/16 20060101
E04B007/16 |
Claims
1. A kit for a cupola assembly comprising: a left side panel for
enclosing the left side of said cupola assembly, said left side
panel including a first edge and a second edge, said first and said
second edges including an integrally formed first means for
connecting to adjacently positioned panel members; a right side
panel for enclosing the right side of said cupola assembly, said
right side panel including a first edge and a second edge, said
first and said second edges including an integrally formed first
means for connecting to adjacently positioned panel members; a rear
side panel for enclosing the back of said cupola assembly, said
rear side panel including a first edge and a second edge, said
first and said second edges including an integrally formed first
means for connecting to adjacently positioned panel members; a
front panel for enclosing the front of said cupola assembly, said
front side panel including a first edge and a second edge, said
first and said second edges including an integrally formed first
means for connecting to adjacently positioned panel members; a
cover panel for enclosing the top of said cupola assembly; wherein
said cupola assembly can be shipped in a disassembled compact
configuration and assembled on a desired site.
2. The kit for a cupola assembly of claim 1 wherein said left and
said right side panel each include a top surface, each said top
surface having a second means of connecting for securing said cover
panel to said top surface.
3. The kit for a cupola assembly of claim 2 wherein said second
means of connecting includes at least one upwardly extending boss,
wherein said at least one boss is constructed and arranged to
cooperate with a socket integrally formed into a bottom surface of
said cover panel, wherein said cover panel is secured in
interlocking engagement with said left side panel and said right
side panel.
4. The kit for a cupola assembly of claim 1 wherein said left side
panel, said right side panel, said front side panel and said rear
side panel each include a top surface, each said top surface having
a second means of connecting for securing said cover panel to said
top surface.
5. The kit for a cupola assembly of claim 4 wherein said second
means of connecting includes at least one upwardly extending boss,
wherein a portion of said at least one boss is formed by said left
said panel, said right side panel, said front side panel and said
rear side panel, wherein said at least one boss constructed and
arranged to cooperate with a socket integrally formed into a bottom
surface of said cover panel, wherein said cover panel is secured in
interlocking engagement with said left side panel, said right side
panel, said front side panel and said rear side panel.
6. The kit for a cupola assembly of claim 4 wherein said first
means for connecting includes at least one integrally formed
locking post extending outwardly from each of said first and said
second edges of said front side panel and said rear side panel,
wherein said first and said second edges of said front side panel
and said rear side panel each include at least one inwardly
extending socket, wherein said side panels are positioned
substantially perpendicular with respect to each other and wherein
said at least one locking post of said front and said rear side
panel are constructed and arranged to enter a corresponding socket
of an adjacently positioned left or right side panel resulting in a
mechanically secure connection therebetween.
7. The kit for a cupola assembly of claim 6 wherein said first and
said second edges of said front and said rear side panels include
at least two of said locking posts arranged in a linear fashion
along said first and said second edges, wherein said right side
panel and said left side panel include at least two said sockets
arranged in a linear fashion along said first and said second edges
thereof.
8. The kit for a cupola assembly of claim 6 wherein each of said at
least one locking post includes at least one spring lock integrally
formed thereto, wherein said at least one spring lock is
constructed and arranged to interlock with an adjacently positioned
front side panel or rear side panel to provide a secure connection
therebetween.
9. The kit for a cupola assembly of claim 8 wherein said front and
said rear side panels include at least one aperture positioned to
cooperate with said at least one spring lock, wherein said at least
one spring lock enters and engages said at least one aperture for
interlocking engagement between two substantially perpendicular
side panels.
10. The kit for a cupola assembly of claim 1 wherein left side
panel and said right side panel are substantially similar in
construction.
11. The kit for a cupola assembly of claim 1 wherein left side
panel and said right side panel are identical in construction.
12. The kit for a cupola assembly of claim 1 wherein front side
panel and said rear side panel are substantially similar in
construction.
13. The kit for a cupola assembly of claim 1 wherein left side
panel and said right side panel are identical in construction.
14. The kit for a cupola assembly of claim 1 wherein at least one
of said left side panel, said right side panel, said front side
panel and said rear side panel include a means for ventilating a
structure to which said cupola is attached.
15. The kit for a cupola assembly of claim 14 wherein said means
for ventilating includes a plurality of apertures extending through
said at least one panel, whereby air is free to flow into and out
of said cupola.
16. A kit for assembling a cupola comprising: a left side panel, a
right side panel, a front side panel, a rear side panel and a cover
panel, wherein each said panel includes connectors integrally
formed thereto for assembling said cupola without additional
fasteners, wherein said cupola may be shipped in a disassembled
compact state and wherein said cupola may be snapped together at a
desired site.
17. A cupola assembly comprising: a left side panel having
monolithic construction including; a first end having a first means
of connecting for interlocking cooperation with a second end of a
front side panel in a substantially perpendicular relationship; a
second end having said first means of connecting for interlocking
cooperation with a first end of a rear side panel in a
substantially perpendicular relationship; a top edge having a
second means of connecting for interlocking cooperation with a
cover panel; a bottom edge having a depending lip constructed and
arranged to accept fasteners for attaching said cupola to a
building structure; an inner surface; an outer surface; a right
side panel having monolithic construction including; a first end
having said first means of connecting for interlocking cooperation
with a second end of said rear side panel in a substantially
perpendicular relationship; a second end having said first means of
connecting for interlocking cooperation with a first end of said
front side panel in a substantially perpendicular relationship; a
bottom edge having a depending lip constructed and arranged to
accept fasteners for attaching said cupola to a building structure;
an inner surface; an outer surface; a front side panel having
monolithic construction including; a first end having said first
means of connecting for interlocking cooperation with said second
end of said right side panel in a substantially perpendicular
relationship; a second end having said first means of connecting
for interlocking cooperation with said first end of said right side
panel in a substantially perpendicular relationship; a bottom edge
having a depending lip constructed and arranged to accept fasteners
for attaching said cupola to a building structure; an inner
surface; an outer surface; a rear side panel having monolithic
construction including; a first end having said first means of
connecting for interlocking cooperation with said second end of
said right side panel in a substantially perpendicular
relationship; a second end having said first means of connecting
for interlocking cooperation with said first end of said right side
panel in a substantially perpendicular relationship; a bottom edge
having a depending lip constructed and arranged to accept fasteners
for attaching said cupola to a building structure; an inner
surface; an outer surface; wherein said cupola may be shipped in a
disassembled compact state and wherein said cupola may be snapped
together at a desired site.
18. The cupola assembly of claim 17 wherein said inner surface of
said left side panel, said right side panel, said front side panel
and said rear side panel each include at least one rib extending at
least partially across said inner surface, wherein said at least
one rib increases the structural integrity of said cupola by
inhibiting said panels from bowing or bending inwardly or
outwardly.
19. The cupola assembly of claim 17 wherein said inner surface of
said left side panel, said right side panel, said front side panel
and said rear side panel each include at least one gusset extending
between said inner surface and said at least one rib, wherein said
at least one gusset increases the structural integrity of said
cupola by inhibiting said panels from bowing or bending inwardly or
outwardly.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to a cupola device
constructed of plastic structural panels. More specifically, the
present invention relates to a cupola kit utilizing modular
injection molded plastic panels. The cupola kit is capable of being
packaged and shipped in a knocked-down state and constructed into a
secure cupola assembly upon a desired site.
BACKGROUND INFORMATION
[0002] Permanent structures such as utility sheds or garages are
often utilized for storage of household items such as gardening
tools, children's toys, barbeque accessories and the like. A common
addition to the roof of such structures is the cupola. Cupolas have
been part of architectural design for many years. Most cupolas are
constructed of wood, with metal or shingle roofs, and may include
windows to admit light or louvers to vent hot air out of the
structure to which they are attached.
[0003] Wooden cupolas are generally custom made for a particular
roof and thus assembly and installation require a great deal of
time and expertise. Because these structures are made of wood they
also require a great deal of maintenance to prevent degradation
during the life of the structure to which they are attached.
[0004] Metal cupolas are also known in the art. Metal cupolas
generally include a plurality of metal panels having turned up
edges that are assembled by aligning the turned up edges and
thereafter sliding a U-shaped retainer over the joint to hold the
panels in position. For example, Nystrom U.S. Pat. No. D413,170
discloses an ornamental design for a metal cupola. Post Jr.
Discloses a pre-fabricated cupola and mounting bracket. Forsman et
al. Discloses a cupola having and adjustable mount.
[0005] Also known in the art of metal cupolas are panels with
snap-fit edges. For example, Coolman U.S. Pat. No. 6,170,206
discloses a cupola roof having panels with snap-fit edges. Each
combination cupola roof panel has a female snap-fit edge on one
side and a female snap-fit edge on the other side.
[0006] It is also known to combine metal panels and plastic panels
into a cupola structure. For example, Wilhelmson discloses a
satellite dish housing and roof ventilation device. The device
includes panels constructed of radio-frequency transparent material
so that television reception is not impaired.
[0007] Another cupola construction known in the art utilizes a
roto-molded construction wherein all four sides of the cupola are
formed as a single piece. See Van Gilst et al. U.S. Pat. No.
6,422,936.
[0008] Such prior art systems, while working well, have not met all
of the needs of manufacturers to provide a product that can be
easily manufactured, packaged and shipped or the needs of consumers
requiring structural integrity combined with modularity and
aesthetic appearance.
[0009] For example, the metal structures of the prior art include
numerous sharp edges and are difficult to assemble. In addition,
the thin sheet metal panels are easily bend during shipping and
assembly. The combination plastic and metal structures do not
include any integrated fasteners and thus require substantial skill
as well as numerous tools to assemble. The roto-molded structures
do not break down into small components and thus are expensive and
difficult to ship.
[0010] In addition, due to the nature of the manufacturing
processes utilized for constructing the prior art cupolas, the
panel components cannot be formed with the intricate shapes and/or
cross sections required for integrated connectors. Therefore, these
systems require a substantial number of fasteners in combination
with connector members having a specific cross-sectional geometry
that facilitate an engagement between the panels to complete the
structure.
[0011] Therefore, what is needed in the art is an injection molded
modular cupola assembly. The modular cupola assembly should achieve
objectives such as lightweight single walled panel construction.
The construction of the panels should eliminate the need for
additional connectors to create a cupola assembly which resists
panel separation, buckling, and racking. The cupola assembly should
be capable of withstanding the snow and wind loads typically
associated with enclosures. Also, from a convenience standpoint,
the cupola assembly should include features constructed to
cooperate with lighting and/or fans or other enhancements. In
addition, the cupola assembly should include convenience features
that allow the cupola to be easily attached to an enclosure.
[0012] There are also commercial considerations that must be
satisfied by any viable cupola assembly or kit; considerations
which are not entirely satisfied by state of the art products. The
cupola assembly must be formed of relatively few component parts
that are inexpensive to manufacture by conventional techniques,
such as injection molding. The cupola assembly must also be capable
of being packaged and shipped in a knocked-down state. In addition,
the cupola assembly must be modular and facilitate the creation of
a family of cupola assemblies for enclosures that vary in size but
which share common, interchangeable components.
[0013] Finally, there are ergonomic needs that a cupola assembly
must satisfy in order to achieve acceptance by the end user. The
cupola assembly must be easily and quickly assembled using minimal
hardware and requiring a minimal number of tools. Further, the
cupola assembly must not require excessive strength to assemble or
include heavy component parts. Moreover, the cupola assembly must
assemble together in such a way so as not to detract from the
appearance or function of the resulting enclosure, or otherwise
negatively affect the utility of the structure.
[0014] The assignee of the instant invention is also the assignee
of various other plastic enclosure systems, U.S. Pat. No. 6,892,497
entitled Plastic Panel Enclosure System, U.S. patent application
Ser. No. 10/729,689 filed Dec. 5, 2003, entitled Low Profile
Plastic Panel Enclosure, and U.S. patent application Ser. No.
10/674,103 filed Aug. 29, 2003, entitled Plastic Expandable Utility
Shed, the contents of which are incorporated herein in their
entirety.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The present invention provides a system, or kit, of
injection molded panels having integrated connectors which combine
to form a roof mountable cupola. The panels are formed of injection
molded plastic to interlock with one another without the need for
separate fasteners or connectors. The system incorporates a minimum
number of components to construct a cupola by integrally forming
the connectors into the injection molded panels. This minimizes the
need for separate extruded or molded connectors to assemble the
cupola. The integrated connection of the side walls and cover
components also simplifies cupola construction. Injection molding
allows the panels to be formed with integral cross-bracing, ribs
and gussets for increased rigidity when compared to blow molded or
extruded panels. The same side wall and cover panel components may
be used to create a variety of cupolas and the assembly thereof
requires minimal hardware and a minimum number of hand tools.
[0016] The front and rear wall panels have outwardly projecting
locking posts for interlocking cooperative engagement with sockets
in the left and right side wall panels. The engagement between the
locking posts and the sockets serve to rigidly connect the
components together. The system further includes a cover which
slides into place after the front, rear, left and right wall panels
have been fully assembled. The cover may include spring locks for
engagement with the side panels or alternatively may be held in
place with suitable fasteners. The system is constructed to allow
various cover panels to be utilized further increasing the utility
of the assembled cupola.
[0017] Accordingly, it is an objective of the present invention to
provide a modular cupola assembly having integrated connectors for
creating various cupolas using common components.
[0018] A further objective is to provide a modular cupola assembly
wherein the panels include integrated connectors accommodated by
injection molding plastic formation for increased structural
integrity.
[0019] Yet a further objective is to provide a modular cupola
assembly in which the side walls and cover panels are integrally
interlocked without separate connectors or fasteners.
[0020] Another objective is to provide an cupola assembly
constructed of modular panels having a cover panel which allows
interchangeability after all other parts are assembled.
[0021] Yet another objective is to provide a kit for a cupola that
is capable of being packaged and shipped in a knocked-down state
and constructed into a secure cupola upon a desired site.
[0022] Other objectives and advantages of this invention will
become apparent from the following description taken in conjunction
with the accompanying drawings wherein are set forth, by way of
illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include
exemplary embodiments of the present invention and illustrate
various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0023] FIG. 1 is a perspective view of one embodiment of the cupola
assembly;
[0024] FIG. 2 is a perspective view of the inner surface of a wall
panel utilized in the instant invention;
[0025] FIG. 3 is a perspective view of the front and rear panels of
embodiment shown in FIG. 1;
[0026] FIG. 4 is a perspective exploded view of the wall panels
utilized in the instant invention;
[0027] FIG. 5 is a bottom view of one embodiment of the top panel
utilized in the instant invention;
[0028] FIG. 6 is a perspective view illustrating assembly of the
top panel;
[0029] FIG. 7 is front plan view of the instant invention;
[0030] FIG. 8 is a section view taken along line 1-1 of the cupola
embodiment shown in FIG. 7 illustrating the cooperative engagement
between the side panels and cover panel;
[0031] FIG. 9 is a side plan view of the instant invention;
[0032] FIG. 10 is a section view taken along line 2-2 of the cupola
embodiment shown in FIG. 9 illustrating the cooperative engagement
between the side panels and cover panel;
[0033] FIG. 11 is a perspective view illustrating the instant
invention in a shipping configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] While the present invention is susceptible of embodiment in
various forms, there is shown in the drawings and will hereinafter
be described a presently preferred embodiment with the
understanding that the present disclosure is to be considered an
exemplification of the invention and is not intended to limit the
invention to the specific embodiments illustrated.
[0035] FIGS. 1-10 which are now referenced illustrate perspective,
exploded and sectioned views of the cupola assembly and kit
therefor, generally referenced as 100, according to a preferred
embodiment of the present invention. The cupola assembly is made up
of substantially like-constructed left wall panel and right side
panel 200, substantially like constructed rear side panel and front
side panel 300 and cover panel 400. In the preferred embodiment,
the panels comprising the assembly are formed of but not limited to
a suitable plastic such as polystyrene, polypropylene, polyvinyl
chloride, polyethylene or the like, through the process of
injection molding. The result is that the side and cover panels
comprising the cupola assembly 100 are formed as unitary panels
with integral connectors, and cross bracing. Strengthening ribs 202
and gussets 204 are formed within the inner surfaces of the side
panels 200, 300 and cover panel 400 in order to enhance rigidity of
the panels while leaving the external surface in a generally smooth
condition for aesthetic purposes, as shown in FIG. 1.
[0036] Referring to FIG. 2, the inner surface 302 of the front and
rear side panels 300 is shown. The front and rear side panels 300
are each configured having a first end 308 and a second end 312.
Both ends 308, 312 include an integrally formed first attachment
means illustrated as at least one outwardly extending attachment
post 310. The attachment posts 310 are generally constructed and
arranged to cooperate with inwardly extending sockets 208 provided
in either end of the left and right panels 200. The top surface 314
includes a second attachment means illustrated herein as one side
of an upwardly extending boss 316. When all four side panels are
assembled the boss 316 is constructed and arranged to cooperate
with a socket 408 (FIG. 5) that extends around the perimeter of the
lower surface of the cover panel 400.
[0037] Referring to FIG. 4, the left and right side panels 200 are
shown. The left and right side panels include a top surface 205,
bottom surface 206, first end 210 and second end 212. Adjacent to
each of the first and second edges 210, 212 is a means of attaching
the left and right side panels 200 to the front and rear side
panels 300 illustrated herein as a plurality of integrally formed
sockets 216 extending downwardly from about the top surface 205 to
about the bottom surface 206. The formed sockets 216 are
constructed and arranged to cooperate with locking posts 310
extending outwardly along the first and second edges 308, 312 of
the front and rear side panels 300. The locking posts 310 and
sockets 216 are constructed and arranged so that the locking posts
310 enter and mateably engage the sockets 216 securing the panels
together in an inter-fitting engagement with their respective outer
surfaces in a perpendicular arrangement.
[0038] Referring to FIG. 5, the bottom surface of the cover panel
400 is illustrated. The bottom surface of the cover panel 400 is
constructed with a socket 408 extending around the perimeter of the
bottom surface 402. The socket 408 is constructed and arranged to
cooperate with the boss 316 (FIG. 4) extending upwardly from the
top surfaces of the front, back, and side panels. The boss 316 and
socket 408 arrangement increases the structural integrity of the
cupola assembly 100 by preventing the panels 200, 300 from bowing
or bending inwardly or outwardly, and thus, adversely affecting the
appearance or operation of the cupola 100.
[0039] Referring to FIGS. 1-10, the outer surface of the side
panels 200, 300 are constructed generally smooth having a plurality
of inwardly bowed grooves 218 for added strength and aesthetic
appearance. In an alternative embodiment, a portion of each groove
includes an elongated aperture (not shown). In this embodiment, the
apertures are constructed and arranged to allow air to flow through
the cupola for ventilation of the structure to which it is attached
as is well known in the art. The inside surface of the side panels
200, 300 are constructed with a plurality of integrally formed
strengthening ribs 202 extending across the panels with a portion
of the ribs 202 being provided with a plurality of gussets 204 to
further strengthen the panels. The ribs 202 and gussets 204
increase the structural integrity of the cupola 100 by preventing
the side panels 200, 300 from bowing or bending inwardly or
outwardly, and thus, adversely affecting the appearance or
operation of the cupola 100. The integrally formed ribs 202 and
gussets 204 are facilitated by injection molding. Injection molding
offers significant strength and stability advantages over cupola
constructions utilized in the prior art. In this manner the cupola
assembly of the instant invention is capable of handling a
significant amount of snow and wind loads.
[0040] Referring to FIG. 4, the left and right side panels 200 are
attached to the front and rear panels 300 by inserting the locking
posts 310 into sockets 216 until the spring tabs 318 integrally
formed onto the locking posts 310 engage the apertures 220
integrally formed into the sockets 216 of the left and right side
panels 200. It will be appreciated that the purpose of the locking
posts 310 are to align two panels in a perpendicular relationship
and to facilitate their mechanical connection. The perpendicular
panels are brought into an overlapping relationship wherein the
contoured locking posts 310 enter the corresponding socket 216 in
the left and right panels 200. The result is a mechanically secure
connection between the two panels. The overlapping edges between
the panels as described above provides a secure connection and
offers several advantages. First, the design allows the panels to
be connected without the need for separate connectors. Second, the
design creates a positive lock that prevents separation of the
panels. Third, the design maintains alignment of the panels and
prevents bowing or bending of either panel relative to one another.
The resultant cupola assembly created by the combination of the
interlocking panels benefits from high structural integrity and
reliable operation.
[0041] Referring to FIG. 6, the side panels 200, 300 are attached
to the cover panel 400 by sliding the boss 316 formed along the top
edges 205, 314 of the assembled side panels into the corresponding
socket 408 integrally formed into the bottom surface of the cover
panel. The socket 408 in the cover panel 400 corresponds in shape
and size to that of the boss 316. In one embodiment spring tabs 318
integrally formed onto the boss 316 align with apertures 220 in the
socket 408 to engage the cover panel to the side panels 200 and
300. In an alternative embodiment self threading fasteners (not
shown) are inserted through apertures 220 for engagement a side
surface 410 of the cover socket. The result of either embodiment is
a positive mechanical connection between the side panels 200, 300,
and the cover panel 400.
[0042] Referring to FIG. 11, the kit for assembling a cupola is
illustrated in a knocked-down configuration. Within this compact
configuration the cupola may be packaged, shipped and stored more
economically than prior art cupolas.
[0043] All patents and publications mentioned in this specification
are indicative of the levels of those skilled in the art to which
the invention pertains. All patents and publications are herein
incorporated by reference to the same extent as if each individual
publication was specifically and individually indicated to be
incorporated by reference.
[0044] It is to be understood that while a certain form of the
invention is illustrated, it is not to be limited to the specific
form or arrangement herein described and shown. It will be apparent
to those skilled in the art that various changes may be made
without departing from the scope of the invention and the invention
is not to be considered limited to what is shown and described in
the specification.
[0045] One skilled in the art will readily appreciate that the
present invention is well adapted to carry out the objectives and
obtain the ends and advantages mentioned, as well as those inherent
therein. The embodiments, methods, procedures and techniques
described herein are presently representative of the preferred
embodiments, are intended to be exemplary and are not intended as
limitations on the scope. Changes therein and other uses will occur
to those skilled in the art which are encompassed within the spirit
of the invention and are defined by the scope of the appended
claims. Although the invention has been described in connection
with specific preferred embodiments, it should be understood that
the invention as claimed should not be unduly limited to such
specific embodiments. Indeed, various modifications of the
described modes for carrying out the invention which are obvious to
those skilled in the art are intended to be within the scope of the
following claims.
* * * * *