U.S. patent application number 11/323554 was filed with the patent office on 2007-08-02 for plastic utility shed wall system.
Invention is credited to Jed C. Richardson, Robert J. Stein.
Application Number | 20070175108 11/323554 |
Document ID | / |
Family ID | 38227661 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175108 |
Kind Code |
A1 |
Stein; Robert J. ; et
al. |
August 2, 2007 |
Plastic utility shed wall system
Abstract
The present invention provides a system which includes injection
molded wall panels, corner posts, and doors having integrated
connectors which combine to form a family of variously sized wall
assemblies and door assemblies for utility enclosures. The
injection molding facilitates integrally formed connectors so that
the panels, posts and door frames interlock with one another
without the need for separate connectors. A window assembly is
provided which optionally can be installed in one of the wall
panels to provide light to the interior of the utility
enclosure.
Inventors: |
Stein; Robert J.; (Aurora,
IL) ; Richardson; Jed C.; (Batavia, IL) |
Correspondence
Address: |
MCHALE & SLAVIN, P.A.
2855 PGA BLVD
PALM BEACH GARDENS
FL
33410
US
|
Family ID: |
38227661 |
Appl. No.: |
11/323554 |
Filed: |
December 29, 2005 |
Current U.S.
Class: |
52/79.5 |
Current CPC
Class: |
E04B 1/6141 20130101;
E04B 2001/6195 20130101; E04B 1/6162 20130101; E04H 1/1205
20130101; E04B 1/34321 20130101 |
Class at
Publication: |
052/079.5 |
International
Class: |
E04H 6/00 20060101
E04H006/00 |
Claims
1. An injection molded plastic wall system for enclosing a utility
shed comprising: at least two like configured injection molded wall
panel members, wherein each of said wall panel members includes a
first edge, a second edge opposite said first edge, said second
edge including an integrally formed first means for connecting to
juxtapositioned wall panel members, a corner post or a door frame
member, said first means extends along and from said second edge,
said first edge including a plurality of integrally formed sockets
constructed and arranged to receive said first means extending
along and from said second edge, a first longitudinal end
substantially perpendicular to and extending between said first and
said second edges, a second longitudinal end opposed to and
substantially parallel to said first longitudinal end, a single
wall extending between said first and second edges and said first
and second longitudinal ends, said single wall being substantially
solid and having an inner surface and an outer surface, said at
least two like configured wall panel members may be assembled
together having a predetermined width; whereby said first means for
connecting to juxtaposed wall panels constitutes the sole means for
connecting said juxtaposed wall panels; wherein injection molding
of said wall panel members permits said wall panel members to be
molded with a single wall construction having integrally formed
connectors; wherein said wall system may be shipped in a
disassembled state and assembled on a desired site.
2. The plastic wall system of claim 1 wherein said first means for
connecting to juxtaposed wall panel members, a corner post or a
door frame includes a plurality of integrally formed bosses
arranged in linear fashion adjacent to said second edge, said
bosses are constructed and arranged to cooperate with said
juxtaposed wall panel member, corner post or door frame in an
interlocking coplanar relationship.
3. The plastic wall system of claim 2 wherein said first means for
connecting to juxtaposed wall panel members, a corner post or a
door frame includes a plurality of integrally formed elongated
inwardly extending arranged along said first edge, each of said
sockets includes two side surfaces, a top surface and a bottom
surface, said two side surfaces are constructed and arranged to
cooperate with said bosses arranged along said second edge to
secure said wall panel in a coplanar relationship with respect to
said juxtaposed wall member, corner post or door frame.
4. The plastic wall system of claim 3 wherein at least one of said
bosses includes a hook lock on a bottom surface thereof for
cooperative locking engagement with a hook lock aperture located in
said bottom surface of said socket positioned on an adjacently
positioned wall panel, corner post or door frame, wherein said
bosses are slid into said sockets and then downwardly to secure
said wall panel in a coplanar relationship with respect to said
juxtaposed wall member, corner post or door frame.
5. The plastic wall system of claim 4 wherein the hook lock of said
boss includes a ramp lock, said ramp lock is constructed and
arranged to cooperate with an aperture formed in said side surface
of said socket to oppose upward movement of said hook lock with
respect to said hook lock aperture.
6. The plastic wall system of claim 2 wherein said first means for
connecting wall panel members, a corner post or a door frame
further includes a metal strip extending along said bosses and
positioned between said bosses and said second edge, said metal
strip is positioned within an integrally formed groove, wherein
said groove is constructed and arranged to provide lateral support
of said metal strip.
7. The plastic wall system of claim 1 wherein said first edge
includes a groove extending from about said first longitudinal end
to about said second longitudinal end, wherein the groove is
brought into an interlocking relationship with a corresponding
ridge formed on said second edge of an adjacently positioned wall
panel, corner post or door frame resulting in a mechanically secure
connection.
8. The plastic wall system of claim 7 wherein said ridge includes a
taper.
9. The plastic wall system of claim 1 further including a door
assembly, said door assembly including at least one door panel
member, said door panel member including a first longitudinal end,
a second longitudinal end, a first edge being constructed and
arranged to cooperate with an adjacently positioned door panel
member in a coplanar relationship, a second edge being constructed
and arranged to cooperate with a door frame in a pivotal
relationship, wherein said door assembly is allowed to open and
close in a pivotal fashion.
10. The plastic wall system of claim 9 wherein said door assembly
includes hinge conduits integrally formed on said door frame, hinge
pins integrally formed on said door panel members are constructed
and arranged to cooperate with said hinge conduits to allow said
door assembly to pivot.
11. The plastic wall system of claim 9 wherein said door assembly
includes at least on latch, said latch is located in an upper
portion, a lower portion or both areas of said door panel members
and is constructed and arranged to cooperate with a floor member or
a roof member to secure said door assembly in a closed
position.
12. The plastic wall system of claim 9 wherein said door assembly
includes door handles on said door panel members, said door handles
are provided with means to lock said door panel members in a closed
position.
13. The plastic wall system of claim 1 including a corner post,
said corner post including at least two members, said first corner
post member comprises a first group of sockets extending along the
length of said first member and a second group of sockets extending
along the length of said first member and substantially
perpendicular to said first group of sockets, said second corner
post member comprises a first group of bosses extending along the
length of said second member and a second group of bosses extending
along the length of said second member and substantially parallel
to said first group of bosses, said second member is constructed
and arranged to cooperate with said second group of sockets to form
said corner post.
14. The plastic wall system of claim 1 further including a window
assembly, said window assembly including at least two window frames
and a window panel, said window frames are constructed and arranged
to cooperate with a hole formed in a wall panel to form a window, a
perimeter portion of said window frames cooperates with said inner
and outer surfaces of said wall panel to form a weather resistant
seal there between, said window panel is positioned between said
window frames and in the hole formed in the wall panel.
15. The plastic wall system of claim 14 wherein said window frames
and window panel are connected together with friction type
fasteners integrally formed on said window frames.
16. The plastic wall system of claim 14 further including shutters
attached to said outer surface of said wall panel on both sides of
said window assembly.
17. The plastic wall system of claim 14 further including a flower
box assembly, said flower box assembly including a flower box, a
plurality of side brackets, and a support brace, said side brackets
include a hook at one end thereof, said hooks are constructed and
arranged to pass through a hole in said wall panel member and
cooperate with said support brace positioned on said inner surface
of said wall panel member, said side brackets are constructed and
arranged to engage the end portions of said flower box for support
thereof.
18. The plastic wall system of claim 2 including a shelf assembly,
said shelf assembly including a shelf and shelf brackets, said
shelf brackets are constructed and arranged to cooperate with
apertures in said second edge of said wall panel members and said
bosses to provide means to attach said shelf brackets to said wall
panel members, said shelf being supported by said shelf brackets.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of utility patent
application entitled Plastic Expandable Utility Shed filed Aug. 30,
2005, the contents of which are herein incorporated in their
entirety. This application is also related to Ser. No. 29/230,885
filed May 27, 2005; and Ser. No. 29/230,978 filed May 27, 2005, the
contents of which are herein incorporated by reference in their
entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to utility sheds, and more
specifically to a modular wall system constructed of injection
molded plastic panels for creating utility shed walls and doors of
various sizes from standardized components.
BACKGROUND OF THE INVENTION
[0003] Utility sheds are a necessity for lawn and garden care, as
well as general all-around home storage space. Typically, items
such as garden tractors, snow blowers, tillers, ATVs, motorcycles,
lawn tools and the like are stored within utility sheds for the
convenience of the homeowner.
[0004] The prior art has proposed a number of different panel
systems, or kits, comprising blow molded and/or extruded panels
which are combined with connector members for forming storage
structures, e.g. utility sheds. Unfortunately, blow molding and/or
extrusion of panels for utility sheds has resulted in shortcomings
within the state of the art products. For example, due to the
nature of the manufacturing process, blow molded and/or extruded
plastic components cannot be formed with the intricate shapes
and/or sharp corners required for integrated connectors. Therefore,
these systems require various metal or plastic connector members
having a specific cross-sectional geometry that facilitates an
engagement between the blow molded or extruded panels to complete
the structure.
[0005] A particularly common structure for the connector members
includes a member having cross section in the form of an I-beam.
The I-beam defines free edge portions of the connector member which
fit within appropriately dimensioned and located slots in the edges
of the panel members. U.S. Patent No. D-371,208 teaches a corner
extrusion for a building sidewall that is representative of the
state of the art I-beam connector members. The I-beam sides of the
connector engage with the peripheral edge channels of a respective
panel and thereby serve to join such panels together at right
angles. Straight or in-line versions of the connector members are
also included in the kits to join panels in a coplanar relationship
to create walls of varying length.
[0006] Another shortcoming associated with blow molded panels is
the requirement of an inner and an outer wall. The inner and outer
walls are a necessary product of the blow molding manufacturing
process. While the inner wall may add some rigidity to the panels,
it also adds a significant amount of weight and dramatically
increases the volume of plastic necessary to form a panel of a
given size when compared to other methods of manufacturing, such as
injection molding.
[0007] A further shortcoming associated with blow molded panels
relates to accurate control of wall thickness throughout the
panels. The blow molding process does not allow the wall thickness
of the panels to be accurately controlled. Once the molten plastic
is conveyed to the tooling, there is minimal control over where the
plastic flows during formation of the panel. Also, the blow molding
process does not allow the intentional formation of thick and thin
sections within a single panel for engineered rigidity at the
points of high stress or high load concentration.
[0008] Extruded panels generally require hollow longitudinal
conduits for strength. Due to the nature of the manufacturing
process, the conduits are difficult to extrude in long sections for
structural panels. Thus, they also require connectors to achieve
adequate length for utility shed walls. A common structure for
connecting extruded members has a center I-beam with upper and
lower protrusions for engaging the conduits. Wall panels utilizing
these connectors are vulnerable to buckling under loads, such as
those produced by snow and wind, and may have aesthetically
unappealing appearance. U.S. Pat. No. 6,250,022 discloses an
extendable shed utilizing side wall connector members representing
the state of the art. The connectors have a center strip with
hollow protrusions extending from its upper and lower surfaces
along its length; the protrusions being situated to slidably engage
the conduits located in the panel sections to create the height
needed for utility shed walls.
[0009] Larger structures must perform differently than small
structures. Large structures must withstand increased wind and snow
loads when compared to smaller structures. Paramount to achieving
these needs is a panel system which eliminates the need for
extruded connectors to create enclosure walls which resist panel
separation, buckling, and racking. A further problem is that the
wall formed by the panels must tie into the roof and floor in such
a way as to unify the entire enclosure. Also, from a structural
standpoint, the enclosure should include components capable of
withstanding the increased wind, snow, and storage loads required
by large structures. From a convenience standpoint, a door must be
present which is compatible with the sidewalls, and which provides
dependable pivoting access to the enclosure.
[0010] Therefore, what is needed in the art is an injection molded
modular wall system for utility enclosures. The modular wall system
should achieve objectives such as lightweight single wall
construction. The construction of the panels should eliminate the
need for I-beam type connectors to create a wall assembly which
resists panel separation, buckling, and racking. The wall assembly
should be capable of withstanding the loads typically associated
with utility enclosures. Also, from a convenience standpoint, the
wall assembly should include various design features to enable
cooperation with shelving and/or other storage enhancements.
[0011] There are also commercial considerations that must be
satisfied by any viable utility shed enclosure system or kit;
considerations which are not entirely satisfied by state of the art
products. The wall assembly must be formed of relatively few
component parts that are inexpensive to manufacture by conventional
techniques. The wall assembly must also be capable of being
packaged and shipped in a knocked-down state. In addition, the wall
assembly must be modular and facilitate the creation of a family of
wall assemblies that vary in size but which share common,
interchangeable components.
[0012] Finally, there are ergonomic needs that a wall assembly must
satisfy in order to achieve acceptance by the end user. The wall
assembly must be easily and quickly assembled using minimal
hardware and requiring a minimal number of tools. Further, the wall
components must not require excessive strength to assemble or
include heavy component parts. Moreover, the wall components must
assemble together in such a way so as to not detract from the
internal storage volume of the resulting enclosure, or otherwise
negatively affect the utility of the structure.
SUMMARY OF THE INVENTION
[0013] The present invention provides a system including injection
molded wall panels having integrated connectors which combine to
form a family of variously sized wall assemblies for utility
enclosures. The wall panels are formed of injection molded plastic
to create light-weight panels having integrally formed ribs and
gussets for strength and integrity. The injection molding also
facilitates integrally formed connectors so that the panels
interlock with one another without the need for separate connectors
or fasteners. These integrally formed connectors also allow the
wall panels to be utilized for door frames as well as corner
sections. The wall panels are also constructed to accept windows
for natural lighting, and may include provisions for standard
electrical current hookup. The internal surfaces of the wall panels
include integrally formed connectors for easy assembly of added
components such as shelving, baskets, slat wall storage and the
like. The wall assembly further includes a door assembly which may
be locked in an open or closed position. The wall assembly
eliminates the need for extruded connectors to create enclosure
walls which resist panel separation, buckling, racking; and a roof
system which allows ventilation while preventing weather
infiltration. The walls formed by the panels must tie into the roof
and floor in such a way as to unify the entire enclosure.
[0014] Accordingly, it is an objective of the instant invention to
provide a plastic wall assembly which utilizes wall panels having
single wall construction with integrally formed ribs and gussets
for a lightweight yet robust wall assembly.
[0015] It is yet another objective of the instant invention to
provide a plastic wall assembly which accommodates injection
molding plastic formation of the panel components for increased
structural integrity.
[0016] It is a still further objective of the invention to provide
a plastic wall assembly which utilizes structural corner assemblies
for increased enclosure rigidity.
[0017] Still another objective of the instant invention is to
provide a wall system in which the wall panel members include
integrally formed connectors.
[0018] Yet another objective of the instant invention is to provide
a wall assembly which includes wall panels having predetermined
sizes for creating enclosures of varying dimensions using common
components.
[0019] Still yet another objective of the instant invention is to
provide a wall assembly which may be optionally configured with
clear windows thereby allowing natural light to enter the
enclosure.
[0020] Still yet another further objective of the instant invention
is to provide a wall assembly which reduces the number of
components required to assemble an enclosure and simplifies
construction.
[0021] Other objects and advantages of this invention will become
apparent from the following description taken in conjunction with
any accompanying drawings wherein are set forth, by way-of
illustration and example, certain embodiments of this invention.
Any drawings contained herein 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
[0022] FIG. 1 is a front perspective view of an enclosure
constructed using the instant utility wall system;
[0023] FIG. 2 is an exploded view of the walls and doors of the
enclosure shown in FIG. 1;
[0024] FIG. 3 is a rear perspective view illustrating a wall panel
as utilized in the instant invention;
[0025] FIG. 4 is a partial section view illustrating assembly of
adjacently positioned wall panels;
[0026] FIG. 5 is a partial section view illustrating assembly of
adjacently positioned wall panels;
[0027] FIG. 6 is a partial view illustrating the assembled wall
panels;
[0028] FIG. 7 is a partial sectional view illustrating assembly of
the top portion of the wall panels;
[0029] FIG. 8 is a partial sectional view illustrating the
assembled top portion of the wall panels;
[0030] FIG. 9A is a rear perspective of a wall panel;
[0031] FIG. 9B is a partial sectional view illustrating a metal
reinforcing strip in the panel connectors;
[0032] FIG. 10 is a perspective view illustrating one of the corner
posts utilized in the instant invention;
[0033] FIG. 11 is a perspective view illustrating one of the corner
posts utilized in the instant invention;
[0034] FIG. 12 is a perspective view illustrating assembly of first
and second corner post members;
[0035] FIG. 13 is a perspective view illustrating assembly of the
door frame member to a wall panel;
[0036] FIG. 14 is a perspective view illustrating assembly of a
wall panel to the floor assembly;
[0037] FIG. 15 is a perspective view illustrating assembly of the
corner post assembly to the wall panel and floor assembly;
[0038] FIG. 16 is a perspective view illustrating the assembled
wall and floor panels;
[0039] FIG. 17 is a perspective view illustrating one of the door
panels utilized in the instant invention as well as assembly of a
sliding door latch;
[0040] FIG. 18 is a perspective view illustrating one of the door
panels utilized in the instant invention as well as assembly of a
sliding door latch;
[0041] FIG. 19 is a perspective view illustrating assembly of a
door panel to the assembled wall panels;
[0042] FIG. 20 is a partial perspective view taken along line 1-1
of FIG. 19, illustrating the lower hinge pin, door catch feature, a
portion of the roof support structure, door gap seal, and wall key
as utilized in the instant invention;
[0043] FIG. 21A is a perspective view illustrating assembly of the
other door frame member to a wall panel and a roof support
member;
[0044] FIG. 21B is a partial view illustrating assembly of the
other door frame member to a wall panel and a roof support
member;
[0045] FIG. 21C is an enlarged view of FIG. 21B;
[0046] FIG. 22A is a perspective view illustrating the assembly of
a reinforcement channel and wall panels;
[0047] FIG. 22B is a partial view illustrating the assembly of a
reinforcement channel and wall panels;
[0048] FIG. 23 is a perspective view illustrating the assembly of
shelf support brackets onto the wall panels;
[0049] FIG. 24 is a partial perspective view taken along line 2-2
of FIG. 23, illustrating wall panel engagement feature of the shelf
support;
[0050] FIG. 25 is a perspective view illustrating a corner shelf
mounted on the wall panels;
[0051] FIG. 26 is a perspective view illustrating a wall panel with
a portion cut out for a window;
[0052] FIG. 27 is a perspective view illustrating a wall panel and
the assembly of a window;
[0053] FIG. 28 is a perspective view illustrating a wall panel and
the assembly of a window frame;
[0054] FIG. 29 is a perspective view illustrating a wall panel and
the assembly of window shutters;
[0055] FIG. 30 is a perspective view illustrating a wall panel and
the assembly of flower box supports; and
[0056] FIG. 31 is a perspective view illustrating a wall panel and
the assembled window, shutters, and flower box.
DETAILED DESCRIPTION OF THE INVENTION
[0057] 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.
[0058] Referring to FIGS. 1-31 the walls of the enclosure are
formed of left and right side wall assemblies 200, corner post
assemblies 300, rear wall assembly 500, front wall assembly 600 and
door assembly 700. In various illustrative, albeit non-limiting
embodiments, the panels comprising the assemblies may be formed of
a suitable plastic such as polystyrene, polypropylene or
polyethylene, through the process of injection molding. The result
is that the panels comprising the side wall assemblies 200, corner
post assemblies 300, rear wall assembly 500 and front wall assembly
600 of the enclosure 10 are formed as unitary panels with integral
connectors and cross bracing. Strengthening ribs and gussets are
formed within the inner surfaces of the various panels and
components 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.
[0059] Referring to FIGS. 10-12, a structural corner post assembly
300 is shown. The corner post assembly 300 constitutes one of a
plurality of like-configured structural corner post assemblies in
the system used to add significant strength and rigidity to the
enclosure 10. The corner post assemblies 300 are generally L-shaped
having a first member 302 extending at least partially along the
front or rear wall of the enclosure and a second member 304
extending at least partially along a side wall of the enclosure.
The first corner post members 302 are each configured having a
first longitudinal end 306 and a second longitudinal end 308 each
including an integrally formed means of attachment illustrated
herein as at least one inwardly extending socket 210. The socket is
generally constructed and arranged to cooperate with either a floor
assembly boss 180 or a roof assembly boss 418 in a generally
perpendicular relationship, as shown in FIGS. 2 and 20. To
facilitate the perpendicular connection the roof and/or floor
assemblies are provided with outwardly extending bosses which
preferably have a generally conjugate shape with respect to the
sockets. To facilitate the mechanical connection with other
structural panel members 202, in a coplanar relationship, the first
corner post member is provided a first edge 314 including a means
of attachment illustrated herein as a plurality of inwardly
extending sockets 330 (FIGS. 10 and 11). The sockets include an
inner wall 316, an outer wall 318, and a bottom wall 320. The
bottom wall includes at least one and more preferably includes a
plurality of apertures or notches 321 there through for cooperative
engagement with at least one or a plurality of hook-locks 322
included on an adjacently positioned wall panel or second corner
post member 304 (FIGS. 7 and 8). In the preferred embodiment the
first edge 314 also includes a groove 324 extending from about the
first longitudinal end 306 to about the second longitudinal 308 of
the first edge 314. The groove 324 is arranged to cooperate with a
wall panel member 202 having a complimentary ridge which includes
tapered side walls for compressive engagement with the groove in an
interlocking coplanar relationship, as shown in FIG. 13. This
interlocking coplanar relationship prevents panel separation,
weather and insect intrusion. The second member 304 includes a
first end 330 and a second end 332. Extending outwardly along the
edge of the second member is a plurality of bosses constructed and
arranged to cooperate with sockets 330 integrally formed into the
edge of the first member 302. A portion of the bosses include
integrally formed hook-locks 322 for cooperation with the apertures
or notches 321 provided in the first member or wall panels. The
first and second members are attached together by sliding the
bosses of the second member into the sockets of the first member
and thereafter sliding the second member downward to engage the
hook-locks (FIG. 12). The result is a positive mechanical
connection between the first member of the post 302 and the second
member of the post 304. The outer surface 326 of the corner post
assemblies 300 are constructed generally smooth for aesthetic
appearance, while the internal portion of the assembly includes a
plurality of box structures 328 for added strength, rigidity, and
weight carrying capacity. The construction of the corner posts 300
assemblies increase the structural integrity of the enclosure 10 by
preventing the corner posts 300 from bowing or bending inwardly or
outwardly, and thus, adversely affecting the appearance or
operation of the enclosure 10. The L-shaped corner post assemblies
300 are attached to the floor assembly by sliding the first
longitudinal end of the corner post assembly over a plurality of
bosses, not shown, which extend upwardly from the floor
assembly.
[0060] Referring to FIGS. 2 and 3, a structural wall panel 202 is
shown. The wall panel 202 constitutes one of a plurality of
like-configured panels in the system used to construct the left,
right, front and rear wall assemblies 200, 600, and 500. The
structural wall panels 202 are each configured having a first
longitudinal end 208 including an integrally formed means of
attachment illustrated herein as a plurality of sockets 210. A
second longitudinal end 212 also including an integrally formed
means of attachment illustrated herein as a plurality of sockets
210. The sockets are generally constructed and arranged to
cooperate with either a floor assembly or a roof assembly to
facilitate mechanical connection in a generally perpendicular
relationship. The outer surface 256 and inner surface 258 of the
panels 202 are constructed generally smooth having a plurality of
ribs 260, extending from the first edge 214 across the panel 202 to
the second edge 222, for added strength and aesthetic appearance.
The ribs 260 increase the structural integrity of the enclosure 10
by preventing the panels 202 from bowing or bending, inwardly or
outwardly and thus adversely affecting the appearance or operation
of an assembled enclosure 10.
[0061] To facilitate mechanical connection with other structural
wall panel members 202 in a co-planar relationship the panels are
provided with a first edge 214 constructed with a means of
attachment illustrated herein as a plurality of sockets 330. The
sockets include an inner wall 316, an outer wall 318, and a bottom
wall 320. The bottom wall includes an aperture 321 (FIG. 4) or
notch there through for cooperative engagement with a hook-lock 322
included on an adjacently positioned wall panel or corner post. For
additional structural rigidity between the side wall panels or
between the side wall panels and the floor assembly, the wall
panels may also include a groove 216. The groove extends along
first and second longitudinal ends as well as along the first edge
of the panels. The groove 216 is arranged to cooperate with a
corner post assembly 300, wall panel member 202, or floor assembly
having a complimentary ridge 180 in an interlocking coplanar
relationship. The ridge 180 extends from about the first
longitudinal end 208 of each panel to about the second longitudinal
end 212 of each panel along the second edge 222 of the panels (FIG.
13). An additional ridge 180 (FIGS. 14 and 20) extends around the
perimeter of the floor assembly. In a most preferred embodiment the
ridge includes a taper constructed and arranged to cooperate with
the wall panel groove to provide a weather and insect resistant
seal around the lower perimeter of the enclosure.
[0062] The second edge 222 of each wall panel is constructed
generally flat having a plurality of outwardly extending bosses
334. The bosses are constructed and arranged to cooperate with
sockets 330 integrally formed into the second edge of the wall
panel 202. A portion of the bosses include integrally formed
hook-locks 322 for cooperation with the apertures or notches 321
provided in the first member of the corner post assembly or first
edge of the wall panels. In addition, the side surfaces of the
bosses may include a ramp-lock 250 (FIG. 6) having a ramping
surface 254 constructed to cooperate with apertures 252 positioned
along the inner wall 316. Bosses 334 are also provided with
apertures 340 and function as a means to connect accessories such
as shelving, benches and the like to the inner surface of a wall
assembly. An additional means is provided to facilitate the
mechanical connection with the wall panels and the corner post
assemblies. At the junction of the second edge and the second
longitudinal end 212 of a wall panel a hook shaped boss 322 is
formed. This boss cooperates with a socket 321 formed at the
junction of the second longitudinal end and first edge 214 (FIGS. 7
and 8).
[0063] Referring to FIGS. 4-6, engagement of the bosses 334 and
sockets 330 is illustrated. The wall panels 202 are attached
together by sliding the bosses of one panel into the sockets of an
adjacently positioned wall panel (FIG. 4) and thereafter sliding
the wall panel downward to engage the hook-locks (FIG. 5). In
addition to engagement of the hook-locks, the downward motion
preferably causes the ramping surface 254 to flex the inner wall
316 until the ramp-lock 250 slips through aperture 252 allowing the
inner wall to return to its normal position, locking the wall
panels in an engaged position. Also, aperture 340 of boss 334 comes
into alignment with aperture 256 of wall panel 202. The result is a
positive mechanical connection between the panels. The overlapping
connection between the panels resists weather infiltration and
prevents lifting and/or separation of the panels under high wind
loads.
[0064] In an alternate embodiment, shown in FIGS. 9A and 9B, a
metal strip 350 is provided for additional reinforcement. The metal
strip is positioned between bosses 334 and the second edge 222 of a
wall panel. This strip enhances the strength of the mechanical
connection between the panels to further prevent the panels from
bowing or bending inwardly or outwardly. It should be appreciated
that the groove is constructed and arranged to provide support to
the sides of the metal strip 350 to add further rigidity to the
assembly.
[0065] Referring to FIGS. 4-6, 13, 21A, 21B and 21C, a door frame
member 750 is attached to a wall panel 202. The door frame member
includes at least one hinge pin conduit 718 and a pair of hinge pin
clearance sockets 728 integrally formed thereto. The door frame
member also includes a door seal 752 integrally formed thereto to
provide a weather resistant seal to the door assembly 700. The wall
panel 202 and the door frame member 750 are attached together by
sliding the bosses of the panel into the sockets of the adjacently
positioned door frame member, as shown in FIG. 4, and thereafter
sliding the wall panel downwardly to engage the hook-locks, as
shown in FIG. 5. In addition to engagement of the hook-locks, the
downward motion preferably causes the ramping surface 254 to flex
the inner wall 316 until the ramp-lock 250 slips through aperture
252 allowing the inner wall to return to its normal position
locking the wall panels in an engaged position. The result is a
positive mechanical connection between the wall panel and the door
frame member 750. Another door frame member 760, as shown in FIGS.
21A, 21B and 21C, is attached to a wall panel 202. The door frame
member is provided with a hinge conduit 718 which cooperates with a
hinge pin 720 formed on a door panel 702 to allow pivoting movement
of the door panel. Additional support for door frame member 760 is
provided by hook 764 positioned on roof support pillar 602. Hook
764 passes through aperture 256 of wall panel 202 and aperture 340
of door frame member 760 to provide a strong mechanical connection
to roof support pillar 602.
[0066] Referring to FIGS. 2, 17 and 18 the door assembly 700 is
illustrated. The door assembly includes a pair of door panels 702,
a pair of door frame members 750, 760, a hinge means 720, a door
handle assembly 728, 729, and a latch assembly 724. The door panel
702 constitutes one of a plurality of like-configured panels in the
system used to construct the door assembly. The door panels are
configured each having a first longitudinal end 708, a second
longitudinal end 712, an inner surface 704, and outer surface 706,
a first edge 714, and a second edge 716. To facilitate mechanical
connection with door frame members 750, in a pivoting relationship,
the first edge of the panels are provided with a pair of circular
hinge conduits 718 and a hinge pin 720. The hinge conduits and
hinge pin are constructed and arranged to cooperate with hinge pins
and conduits integrally formed onto the door frame members 750, 760
to allow pivoting movement of the door panel. The second edge 716
is constructed generally flat with the exception of an optional
overlapping seal 722 (FIG. 2) extending the full length of the
panel. The optional overlapping seal 722 may be attached by any
suitable fastening means well known in the art or may be integrally
formed with the panel. The door panels 702 are also provided with
an upper and lower sliding latch mechanism 724 (FIGS. 17 and 18),
as well as left and right door handles 728, 729 (FIG. 2).
[0067] The outer surface 706 of the panels 702 are constructed
generally smooth having a plurality of raised panels 726 for added
strength and aesthetic appearance. The inside surface of the panel
704 is constructed with a plurality of raised panels 726 for added
strength and aesthetic appearance. The raised panels 726 increase
the structural integrity of the enclosure 10 by preventing the
panels 702 from bowing or bending, inwardly or outwardly and thus,
adversely affecting the appearance or operation of the enclosure
10.
[0068] Referring to FIGS. 17 and 18, the door panels 702 are
attached to the floor panels, and front wall assembly 600 by
sliding the respective hinge pin 720, located on door panel 702,
hinge pin 176, located on the floor panel (FIG. 20) and a hinge pin
located in a header portion of the roof, not shown, into the
corresponding hinge conduits 718 located along the edge of the door
panels 702. Either door panel is aligned with the hinge pins by
sliding it vertically into place over the respective pins. It
should be appreciated that this construction provides an economic
advantage by allowing hinge components to be integrally formed onto
the door panels. The door panels are also provided with removable
and replaceable door latching mechanisms including slide latches
724, left door handle 729 and right door handle 728 (FIG. 2).
[0069] Referring to FIGS. 17 and 18, installation of the upper and
lower slide latches 724 is illustrated. The slide latches are
constructed and arranged to allow simple push-in installation. The
latch housings 730 are merely pushed into apertures 732 located
adjacent the edge 716 in the door panels 702 until the spring clips
(not shown) engage an inner surface of the panel. Thereafter one
end of the door latch pin 734 is inserted through the housing 730
and pushed downward until spring clip 736 is snapped into place. In
this manner the door latches can be installed and removed as needed
with out the need for tools or screw type fasteners. By sliding the
latch pin 734 to extend it outwardly to engage the roof assembly or
the floor assembly the contents within the enclosure 10 are
secured. The door handles 728, 729 are constructed and arranged to
allow simple push-in installation. The handles are merely pushed
into apertures 738 contained in door panels 702 until the spring
clips (not shown) engage an inner surface of the panel 702. In this
manner the door handles can be installed and removed as needed
without the need for tools or screw type fasteners. The handles are
also provided with lock apertures allowing the contents within the
enclosure to be secured with a padlock or the like.
[0070] Referring to FIGS. 22A and 22B, a wall panel reinforcement
channel 701 is illustrated. The wall panel reinforcement channel is
generally C-shaped and includes a first end 740, a second end 742,
an outer surface 747, and side surfaces 744. A plurality of
flexible hooks 748 extend inwardly from aperture 750. In operation
the reinforcement channel is attached to the inner socket wall 316
of a pair of assembled wall panels 202 by inserting the flexible
hooks through apertures 256 until the side surfaces 744 engage the
wall panels 202. The reinforcement channels are preferably
constructed of steel or other suitable metal and provide
significant rigidity and weight carrying capacity to the wall
assemblies. In addition, the reinforcement channels prevent the
panels 202 form bowing or bending inwardly or outwardly, and thus,
adversely affecting the appearance or operation of the enclosure
10. In addition, the reinforced ribs provide support for optional
cantilever shelves or stackable shelves (not shown) by distributing
any load applied to the shelves across the length of the wall
panels.
[0071] Referring to FIGS. 23-25 a shelf system 760 is illustrated.
The shelf system includes a shelf 762 supported by shelf brackets
764. Although a corner shelf is illustrated, a straight shelf of
any length may also be employed. The shelf brackets 764 are
attached to wall panels 202 by means of hooks 766. Each bracket
normally has two hooks. The hooks 766 are constructed and arranged
to pass through apertures 256 of the wall panels 202 and engage
aperture 340 of boss 334. Additional support is provided by hooks
768 which engage the inner portions of inner wall 316 of socket
330. Working in cooperation with hook 768, base plate 770 engages
the outer portions of inner wall 316. This provides a tight
frictional fit between the wall panels and the brackets while also
distributing the load along the wall panel. The shelf is attached
to the bracket 764 by engagement of both the base plate and front
lip 772 (FIG. 25). In this manner the shelves and shelf brackets
can be installed and removed as needed without the need for tools
or screw type fasteners.
[0072] Referring to FIGS. 26-31 installation of a window system 800
is illustrated. The window assembly includes an interior window
frame 804, a window panel 806, an exterior window frame 808,
shutters 810, 812, and a flower box 814. A wall panel 202 is
provided with an area 802 (FIG. 26) to be removed for the
installation of the window if desired. The area 802 is provided
with means to indicate which portion of the wall panel is to be
removed prior to installation of the window. Once this portion of
the wall panel is removed, the interior window frame 804 is
inserted into the opening. The window frame 804 is provided with a
plurality of projections 816 (FIG. 27). A window panel 806 is
placed over the interior window frame. The window panel is made of
a transparent material and provided with apertures 818 and notches
820 which cooperate with projections 816 to align the window panel
with the frame. The exterior window frame 808 is placed over the
window panel. The exterior window frame is provided with
projections (not shown) which cooperate with 816 to hold the window
assembly together. Both the interior and exterior window frames are
provided with notches 822 and edge portions 824 that form an
interlocking coplanar relationship with the inner surface 258, the
outer surface 256, and the ribs 260 of wall panel 202. The result
is a positive mechanical connection between the components of the
window assembly which will resist weather infiltration.
[0073] Referring to FIGS. 29-31 window shutters 810 and 812 are
illustrated. The shutters are provided with notches 826 and edge
portions 828 that form an interlocking coplanar relationship with
the outer surface 256 and ribs 260 of the wall panel. In addition,
the shutters have notches 830 that cooperate with the first edge
214 of the wall panels. The shutters are attached to the wall
panels with fasteners.
[0074] Referring to FIGS. 30 and 31 a flower box assembly is
illustrated. The flower box assembly includes a flower box 814,
side brackets 830, and support brace 832. The support brace is
provided with an attachment bracket 834 at each end thereof (only
one is shown). The bracket is provided with hooks 836. These pass
through apertures 256 in the edge portions of the wall panels and
hook onto bosses 334 located in sockets 330 of the wall panel.
Plates 838 which are provided with an aperture 840 are securely
attached to support brace 832 (only one plate is shown). The side
brackets are provided with hooks 844, as shown in FIG. 30. The
hooks are inserted through apertures 844, formed in the wall panel,
and apertures 840 of plate 838 to securely attach the side brackets
to the wall panel. The side brackets extend outwardly from the wall
panel for cooperative engagement with the upper edge portions of
flower box 814 (FIG. 31).
[0075] 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.
[0076] 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 and any drawings/figures included herein.
[0077] 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.
* * * * *