U.S. patent application number 12/942679 was filed with the patent office on 2012-05-10 for combo wood and plastic modular storage shed.
Invention is credited to Wlliam J. Phillips, Michael R. Vogler.
Application Number | 20120110926 12/942679 |
Document ID | / |
Family ID | 46018312 |
Filed Date | 2012-05-10 |
United States Patent
Application |
20120110926 |
Kind Code |
A1 |
Phillips; Wlliam J. ; et
al. |
May 10, 2012 |
Combo Wood And Plastic Modular Storage Shed
Abstract
The present invention provides a system or kit which includes
wood and plastic components or plastic components only. These
components can be readily assembled to form a structure with the
use of a minimal number of tools. The components are precut so that
measurements and cutting of the component materials is eliminated.
This leads to a savings in wasted materials. The components are
readily assembled using conventional fasteners and simple hand
tools. The components have preformed notches and tabs in order to
facilitate assembly of the components without the requirement for
measurements. This assures that the components will be assembled
correctly and eliminates the opportunity for inaccurate
measurements and incorrect assembly. The roof and floor structures
are formed from plastic panels which interlock together.
Inventors: |
Phillips; Wlliam J.;
(Batavia, IL) ; Vogler; Michael R.; (Oswego,
IL) |
Family ID: |
46018312 |
Appl. No.: |
12/942679 |
Filed: |
November 9, 2010 |
Current U.S.
Class: |
52/79.9 ;
52/588.1 |
Current CPC
Class: |
E04B 2001/6195 20130101;
E04B 1/34321 20130101; E04B 1/6137 20130101; E04H 1/1205
20130101 |
Class at
Publication: |
52/79.9 ;
52/588.1 |
International
Class: |
E04H 1/12 20060101
E04H001/12; E04B 1/38 20060101 E04B001/38 |
Claims
1. A modular utility shed construction system utilizing molded
plastic structural panels comprising: a floor assembly for
enclosing a bottom of said utility shed, said floor assembly
including a plurality of like-configured floor panel members, one
of said floor panel members including a groove extending along a
longitudinal edge of said floor panel, another of said floor panel
members including a lip extending along a longitudinal edge of said
another floor panel member, said lip of said another floor panel
member engaging said groove of said one floor panel member thereby
securing said one floor panel member to said another floor panel
member, a groove extending around a perimeter of said floor
assembly, a plurality of apertures located within said groove
extending around said perimeter of said floor assembly; a pair of
side wall assemblies for enclosing left and right side sides of
said utility shed, said side wall assembly enclosing said left side
of said utility shed including a front side panel and a back side
panel, said wall assembly enclosing said right side of said utility
shed including a front side panel and a back side panel; at least
two tabs along a lower edge of each of said front and back side
wall panels, said tabs being constructed and arranged to fit into
said plurality of apertures located on said floor assembly when
said front and back side wall panels are tilted away from a
vertical position, said tabs locking said front and back side wall
panels to said floor assembly and preventing removal of said front
and back side panels from said floor assembly when said front and
back side panels are moved to a substantially vertical position; a
back wall assembly for enclosing a back portion of said utility
shed, said back wall assembly including a left back wall panel and
a right back wall panel secured together to form said back wall
assembly, at least two tabs along a lower edge of each of said left
and right back wall panels, said tabs being constructed and
arranged to fit into said plurality of apertures located on said
floor assembly when said left and right back wall panels are tilted
away from a vertical position, said tabs locking said left and
right back wall panels to said floor assembly and preventing
removal of said left and right back wall panels from said floor
assembly when said left and right side panels are moved to a
substantially vertical position; a roof assembly for enclosing an
upper portion of said utility shed, said roof assembly including a
plurality of roof panels secured together to form said roof
assembly, a plurality of recesses located along a perimeter of each
said roof panel; a plurality of projections located along a top
edge of each of said front and back side wall panels, said
plurality of projections on said front and back side wall panels
engaging said recesses on said roof panels thereby locking said
roof assembly onto said front and back side wall panels; and a door
assembly enclosing a front of said utility shed and permitting
access to said utility shed, said door assembly including at least
two door panels.
2. The modular utility shed construction system of claim 1 wherein
each said left and said right side wall assembly include an upper
edge which is higher at its midpoint than at its ends.
3. The modular utility shed construction system of claim 2 wherein
said roof assembly is curved along a traverse cross section, the
midpoint of the traverse cross section is higher than the ends of
the cross section.
4. The modular utility shed construction system of claim 3 wherein
the upper edge of said left and said right wall assemblies are the
same shape as the transverse cross section of the roof assembly,
whereby said roof assembly completely engages said left and said
right side wall assemblies.
5. The modular utility shed construction system of claim 1 wherein
each of said roof panels includes a channel along a longitudinal
edge, each of said channels being a complementary shape for the
other said channel whereby, when said channels of said roof panels
are placed together, they form a seal which prevents the intrusion
of water and other elements through the roof assembly and into the
utility shed.
6. The modular utility shed construction system of claim 1 wherein
said door assembly includes a plurality of door panels, each said
door panel is secured to a side wall assembly, one of said door
panels includes a latching device, said latching device is operable
from an interior of said door panel.
7. The modular utility shed construction system of claim 1 wherein
said door assembly includes a plurality of door panels, each said
door panel is secured to a side wall assembly, each of said door
panels includes a handle for operatively opening and closing said
door panels.
8. The modular utility shed construction system of claim 1
including a roof brace, said roof brace extending between said side
wall assemblies and contacting an interior surface of said roof
assembly.
9. The modular utility shed construction system of claim 1 wherein
each said side wall back panel includes a flap which is hingedly
secured to longitudinal edge of said side wall back panel, each of
said left and said right back wall panels include a groove
extending along a longitudinal edge which is adjacent to said side
wall assemblies, said flap is constructed and arranged to fit into
groove to provide a means to secure said side wall back panels to
said back wall panels, said flap and said groove are constructed
and arranged to not extend outwardly of a plane of the outer
surfaces of said side wall back panels and said back wall
panels.
10. A utility shed construction kit comprising: a floor assembly
for enclosing a bottom of said utility shed, a plurality of
apertures located around a perimeter of said floor assembly; a pair
of side walls for enclosing left and right sides of said utility
shed, said side walls formed of a plurality of vertical members
secured together in a common plane; a pair of corner panels secured
to each said left and said right wall assembly, each said corner
panel formed of a plurality of vertical members secured together; a
back wall assembly for enclosing a back portion of said utility
shed, said back wall assembly including a left wall panel and a
right wall panel, each said left and right back wall panel formed
of a plurality of vertical members secured together in a common
plane; a filler member secured to and connecting said left and
right back wall panels to each other, said filler member is similar
to said vertical members in said back wall assembly; and a door
assembly enclosing a front of said utility shed and permitting
access to said utility shed, said door assembly including at least
two door panels.
11. The utility shed construction kit of claim 10 wherein each said
vertical member includes a groove extending along a longitudinal
edge and a tongue extending along an opposite vertical edge, said
tongue is constructed and arranged to fit into said groove to
provide a structural and weather tight seal between adjacent
vertical members.
12. The utility shed construction kit of claim 10 including a
plurality of substantially horizontal support braces extending
across each said side panel, each said back panel, and each said
corner panel.
13. The utility shed construction kit of claim 10 including
additional cross braces extending across both said back wall panels
and joining said back wall panels together to form said back wall
assembly.
14. The utility shed construction kit of claim 10 including a top
connector extending along a top edge of each said side wall
assemblies and said corner panels.
15. The utility shed construction kit of claim 14 including a top
connector extending along a top edge of each said back wall
panels.
16. The utility shed construction kit of claim 10 including a
bottom connector extending along a bottom edge of each said side
wall assemblies and said corner panels.
17. The utility shed construction kit of claim 17 including a
bottom connector extending along a bottom edge of each said back
wall panels.
18. The utility shed construction kit of claim 17 wherein each said
bottom connector includes a plurality of tabs, said tabs being
constructed and arranged to fit into said plurality of apertures in
said floor assembly when said side wall assemblies and said back
wall assembly are tilted away from a vertical position, said tabs
locking said side wall assemblies and said back wall assembly to
said floor assembly and preventing removal of said side wall
assemblies and said back wall assembly when said side wall
assemblies and said back wall assembly are moved to a substantially
vertical position.
19. The utility shed construction kit of claim 15 wherein each said
top connector includes a plurality of tabs, said tabs engaging a
plurality of apertures in said roof assembly when said roof
assembly is slid onto said utility shed whereby said roof assembly
is securely held onto said utility shed.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to enclosures, such as
utility or garden sheds, constructed of wood and plastic materials.
More specifically, the present invention relates to an enclosure
including walls having wood framing and wood siding, a plastic
panel roofing, and a floor made from plastic panels.
BACKGROUND OF THE INVENTION
[0002] Utility sheds are a necessity for lawn and garden
maintenance, as well as general all-around home storage space.
Typically, items such as lawn mowers, garden tillers, snow blowers,
wheel barrows, shovels, rakes, brooms and the like consume a great
deal of floor space in a garage. This results in the homeowner
parking his/her vehicles outside of the garage.
[0003] The prior art has proposed a number of different storage
buildings or utility sheds assembled from a kit which includes a
plurality of blow molded or extruded plastic panels and connectors.
These kits are readily assembled by a homeowner to form storage
structures or utility sheds of various sizes. These structures are
generally suitable for the storage of hand tools and smaller lawn
equipment. Typically, these kits require extruded metal or plastic
connector members having a specific cross-sectional geometry which
facilitates an engagement between the connector members and one or
more of the blow molded plastic panels having a complimentary edge
configuration. Due to the nature of the manufacturing process, blow
molded plastic components cannot be formed with the intricate
shapes and/or sharp corners required for integrated connectors. In
addition, blow molded plastic components are hollow and cannot be
formed with the integral strengthening ribs and gussets that
injection molded panels can be formed with.
[0004] A particularly common structure for the connector members is
the I-beam cross section. The I-beam defines free edge portions of
the connector member which fit within approximately dimensioned and
located slots in the panel members. U.S. Pat. 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 wall 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.
[0005] Extruded components 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, the panels require connectors to achieve
adequate height 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. However, wall panels
utilizing connectors are vulnerable to buckling under loads and may
have an aesthetically unpleasing appearance. Moreover, roof loads
from snow and the like may cause such walls to bow outwardly due to
the clearances required between the connectors and the internal
bores of the conduits. 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 are situated to slidably engage
the conduits located in the side panel sections to create the
height required for utility shed walls.
[0006] The aforementioned systems can also incorporate roof and
floor panels to form a freestanding enclosed structure such as a
utility shed. U.S. Pat. Nos. 3,866,381; 5,036,634; and 4,557,091
disclose various systems having inter-fitting panel and connector
components. Such prior art systems, while working well, have not
met all of the needs of consumers to provide the structural
integrity required to construct larger sized structures. Larger
structures must perform differently than smaller structures. Larger
structures require constant ventilation in order to control
moisture within the structure. Large structures must also withstand
larger wind and snow loads 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, racking, and a roof
system which allows ventilation while preventing weather
infiltration. A further problem is that the walls formed by the
panels must tie into the roof and floor in such a way as to unify
the entire structure. Also, from a structural standpoint, the
structure should include components capable of withstanding the
increased wind, snow and storage loads required by larger
structures. From a convenience standpoint, a door must be present
which can be readily installed after assembly of the wall and roof
components. The door must also be comparable with the sidewalls and
provide ready access to the interior of the structure. Also, from a
convenience standpoint, the structure should permit natural as well
as artificial lighting. The structure should be aesthetically
pleasing in appearance to blend in with the surrounding
structures.
[0007] There are also commercial considerations that must be
satisfied by any viable structure assembly system or kit;
considerations which are not entirely satisfied by the state of the
art products. The structure must be formed from relatively few
components which are inexpensive to manufacture by conventional
techniques. The enclosure must also be capable of being packaged
and shipped in a knock-down state. In addition, the system or kit
must be modular and facilitate the creation of a family of
enclosures that vary in size but which share common,
interchangeable components.
[0008] Finally, there are ergonomic needs that an enclosure system
must satisfy in order to achieve acceptance by the end user. The
system must be easily and quickly assembled using integrally formed
connectors requiring minimal hardware and tools. Further, the
system must not require excessive strength to assemble or include
heavy component parts. Moreover, the system must assemble together
in such a way so as not to detract from the internal storage volume
of the resulting enclosure, or otherwise detract from the internal
storage volume of the resulting enclosure, or otherwise negatively
affect the utility of the structure.
SUMMARY OF THE INVENTION
[0009] The present invention provides a system or kit which
includes wood and plastic components or plastic components only.
These components can be readily assembled to form a structure with
the use of a minimal number of tools. The components are precut so
that measurements and cutting of the component materials is
eliminated. This leads to a savings in wasted materials. The
components are readily assembled using conventional fasteners and
simple hand tools. The components have preformed notches and tabs
in order to facilitate assembly of the components without the
requirement for measurements. This assures that the components will
be assembled correctly and eliminates the opportunity for
inaccurate measurements and incorrect assembly. The roof and floor
structures are formed from plastic panels which interlock
together.
[0010] Accordingly, it is an objective of the instant invention to
provide a system or kit for assembly of a utility enclosure which
utilizes precut wood and plastic components to create structures of
varying dimensions by using common components.
[0011] It is a further objective of the instant invention to
provide a utility enclosure system or kit which utilizes plastic
components to secure and connect wood components together.
[0012] It is yet another objective of the instant invention to
provide a utility enclosure system or kit which utilizes plastic
structural frame and panel members having integrated connectors for
creating enclosures of varying sizes.
[0013] It is a still further objective of the instant invention to
provide a utility enclosure system or kit wherein the panel members
include integrated connectors which accommodate plastic formation
of the panel components for increased structural integrity.
[0014] It is still another objective of the instant invention to
provide a utility enclosure system or kit which utilizes structural
corner assemblies for increased enclosure rigidity.
[0015] It is still another objective of the instant invention to
provide a utility enclosure system or kit which utilizes
interlocking bosses and pockets to secure wall panels to a floor
and/or roof.
[0016] It is still another objective of the instant invention to
provide a utility enclosure system or kit which utilizes roof and
floor components which interlock together for structural stability
and the prevention of incursion of water into the enclosure.
[0017] 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
[0018] FIG. 1 is a front perspective view of a first embodiment of
the present invention;
[0019] FIGS. 2A-F are views of side and back panels of a first
embodiment of the present invention;
[0020] FIGS. 3A-C are perspective views of the floor assembly and
the interlocking connection of the floor components of a first
embodiment of the present invention;
[0021] FIGS. 4A and B are views of the assembly and connection of
the rear panel to the floor assembly of a first embodiment of the
present invention;
[0022] FIGS. 5A-D are views of the assembly and connection of the
right side panels to the floor assembly of a first embodiment of
the present invention;
[0023] FIGS. 6A and B are views of the assembly and connection of
the left side panels to the floor assembly and rear panel of a
first embodiment of the present invention;
[0024] FIGS. 7A-C are views of the assembly and connection of the
right side panels to the floor assembly and another side panel of a
first embodiment of the present invention;
[0025] FIGS. 8A and B are views of the assembly and connection of
the right side panels to each other of a first embodiment of the
present invention;
[0026] FIGS. 9A and B are views of the assembly and connection of
the left side panels to each other of a first embodiment of the
present invention;
[0027] FIGS. 10A-C are views of the assembly and connection of the
left side panels to each other of a first embodiment of the present
invention;
[0028] FIGS. 11A-D are details of the left side panels of a first
embodiment of the present invention;
[0029] FIGS. 12A and B are details of the connection between the
side panels and rear panels of a first embodiment of the present
invention;
[0030] FIGS. 13A-C are views of the assembly and connections of the
roof assembly to the side panels of a first embodiment of the
present invention;
[0031] FIGS. 14A and B are views of the assembly and connection of
the components of the roof assembly to each other of a first
embodiment of the present invention;
[0032] FIGS. 15A-D are views of the assembly and connections of the
left door panel to the side panels of a first embodiment of the
present invention;
[0033] FIGS. 16A and B are details of the connection of a handle to
the left door of a first embodiment of the present invention;
[0034] FIGS. 17A-D are views of the assembly and connections of the
right door panel to the side panels of a first embodiment of the
present invention;
[0035] FIGS. 18A and B are details of a roof support of a first
embodiment of the present invention;
[0036] FIGS. 19A and B are details of a roof support of a first
embodiment of the present invention;
[0037] FIGS. 20A and B are details of a roof support and the
fasteners employed to secure it to the utility enclosure of a first
embodiment of the present invention;
[0038] FIG. 21 is a front perspective view of a second embodiment
of the present invention;
[0039] FIGS. 22A and B are perspective views of a corner panel
secured to a side panel;
[0040] FIGS. 23A and B are perspective views of a corner panel
secured to a side panel;
[0041] FIG. 24 is a view of an inside of a side panel with
additional braces;
[0042] FIG. 25 is a perspective view of one of the braces in FIG.
24;
[0043] FIGS. 26A and B are perspective views of a side panel and a
face frame;
[0044] FIGS. 27A and B are detailed views of the attachment of the
face frame to a corner panel;
[0045] FIG. 28 is a perspective view of a top connector and a side
panel;
[0046] FIGS. 29A and B are views of a top connector secured to a
side panel;
[0047] FIG. 30 is a perspective view of a bottom connector and a
side panel;
[0048] FIG. 31 is a perspective view of a bottom panel secured to a
side panel;
[0049] FIG. 32 is a perspective view of a filler board between two
back panels;
[0050] FIGS. 33A and B are perspective views of the filler board of
FIG. 32 secured to the two back panels;
[0051] FIG. 34 is a perspective view of support braces secured to
the back panels;
[0052] FIG. 35 is a perspective view of a support brace;
[0053] FIG. 36 is a perspective view of a bottom connector being
secured to one of the back panels;
[0054] FIG. 37 is a perspective view of the bottom connectors
secured to the back panels;
[0055] FIGS. 38A and B are views of the back panel being secured to
a floor panel;
[0056] FIG. 39 is a perspective view of the back panel secured to a
floor panel;
[0057] FIG. 40 is a perspective view of a side and corner panels
being secured to a floor panel;
[0058] FIG. 41 is a perspective view of a side and corner panels
being secured to a floor panel;
[0059] FIG. 42 is a perspective view of a side, corner, and back
panels secured to a floor panel;
[0060] FIG. 43 is a top perspective view of the side, corner and
back panels secured to the floor panel;
[0061] FIGS. 44A and B are top perspective views of the top
connectors of the back and side panels;
[0062] FIGS. 45A and B are top perspective views of the header
being installed between the side panels;
[0063] FIG. 46 is a perspective view of the roof panel;
[0064] FIG. 47 is a cross sectional view of the roof securement
taken along lines A-A in FIG. 21;
[0065] FIG. 48 is a cross sectional view of the roof securement
taken along lines B-B in FIG. 21;
[0066] FIGS. 49A and B are views of hinges on the left door;
[0067] FIGS. 50A and B are views of hinges on the left door;
[0068] FIG. 51 is a view of a handle being installed on the left
door;
[0069] FIGS. 52A and B are views, with the back panels removed, of
the slide bolt being installed on the left door;
[0070] FIG. 53 is a view of a hasp to be installed on the
doors;
[0071] FIG. 54 is a view of the hasp and handles on the doors;
and
[0072] FIG. 55 is an exploded view of the second embodiment of the
enclosure of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0073] 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, albeit not limiting, embodiment
with the understanding that the present disclosure is to be
considered an exemplification of the present invention and is not
intended to limit the invention to the specific embodiments
illustrated.
[0074] FIGS. 1-20B, which are now referenced, show isometric and
exploded views of a system or kit for the assembly of a first
embodiment of the present invention. A utility enclosure or shed is
generally illustrated at 10. The enclosure or shed 10 includes a
right side wall assembly including right side front panel 12 and a
right side rear panel 14, a back wall assembly including a back
right panel 16 and a back left panel 18, and a left said wall
assembly including a left side front panel 20 and a left side rear
panel 22 (FIGS. 2A-F). These panels are secured to one another in a
manner which will be described hereinafter. Panels 12-22 are
secured to a floor assembly 24, FIG. 3A.
[0075] The floor assembly includes at least two floor panels 26 and
28 which are secured to each other to form the floor of the
enclosure. As can be seen in FIGS. 3A-C, the floor panels 26 and 28
are secured to each other along a longitudinal edge of each panel.
The panel 26 includes an upwardly facing groove 29, FIG. 3B, which
extends along a longitudinal edge thereof. Adjacent the groove 29
is a lip or upturned ridge 30. The lip or ridge 30 extends along
the length of groove 29 and is adjacent thereto. Floor panel 28
includes a downwardly facing groove 32, FIG. 3B, which extends
along a longitudinal edge thereof. Adjacent groove 32 is a lip or
ridge 34 which extends along the length of the groove 32. Lip 34 is
constructed sized to mate with groove 29. Lip 30 is constructed and
sized to mate with groove 32. The structural inter-fitting of the
lips into the grooves provides structural integrity and support for
the connection of the floor panels 26 and 28 to each other. This
structural relationship also provides a seal or boundary which
prevents the intrusion of water or other fluids from passing from
the bottom of the panels to the top of the panels. This structure
therefore prevents water or other fluids from entering into the
enclosure or shed from below. In addition, fasteners, such as
screws, are utilized to connect the floor panels 26 and 28
together.
[0076] FIGS. 4A and B illustrate the manner in which a rear panel
16 is secured to a floor panel 26. The rear panel 16 includes a
plurality of tabs 36 formed to or secured along a bottom portion or
edge. The tabs 36 are formed as a curved member which includes a
bend of substantially 90 degrees, as seen in FIG. 4B. A peripheral
portion of both floor panels 26 and 28, include apertures or slots
38, FIGS. 4A and B. The tabs 36 fit into the apertures and engage
the peripheral portion of the floor panel 26 to secure the rear
panel 16 onto the floor panel 26. This engagement is accomplished
by tilting the top of the rear panel 16 downwardly prior to
inserting the tabs 36 into the slots 38. Next, panel 16 is returned
to its upright, vertical position. This moves the outer edge 37 of
tabs 36 below the peripheral portion of the floor panel and
prevents the rear panel 16 from moving upwardly and thus becoming
detached from the floor panel. Rear panel 16 also includes
apertures 40 and 42 which will be described hereinafter.
[0077] A right side rear panel 14 is illustrated in FIGS. 5A-D. It
is secured to the floor assembly 24 utilizing the same construction
and elements that rear panel 16 utilizes to be secured to the floor
assembly 24. Tabs 44 on the bottom portion or lower edge of right
side rear panel 14 fit into apertures or slots 46 on the peripheral
portion of the floor panel 26 to secure the right side rear panel
14 onto the floor panel 26. This engagement is accomplished by
tilting the top of the right side rear panel 14 downwardly prior to
inserting the tabs 44 into the slots 46. Next, panel 16 is returned
to its upright, vertical position. This moves the outer edge of
tabs 44 below the peripheral portion of the floor panel and
prevents the right side rear panel 14 from moving upwardly and thus
becoming detached from the floor panel. Right side rear panel 14
also includes a corner member or flap 48 (FIG. 5B) which is
hingedly secured to panel 14 along an edge portion. Corner member
48 engages and is secured along an edge 50 of rear panel 16 (FIG.
5C). Corner member 48 fits into a groove 52 which extends along the
edge 50. This enables the outer surface of the corner member 48 to
be flush with the outer surface of rear panel 16. This presents an
aesthetically pleasing appearance to the outer portion of the
enclosure 10. Fastening elements 54, such as screws, are employed
to secure corner member 48 to rear panel 16. The fastening elements
54 pass through the apertures 40 in panel 16 and engage corner
member 48, thus securing panels 16 and 14 to each other, as
illustrated in FIG. 6A. A tool 56, such as a screwdriver, is
employed to connect fastening elements 54 to panel 14.
[0078] A right side front panel 12 and right side rear panel 14 are
illustrated in FIGS. 7A and 8A. The right side front panel 12
includes a plurality of tabs 58 on the bottom portion or lower edge
of right side front panel 12 which fit into apertures or slots 60
on the peripheral portion of the floor panel 28 to secure the right
side front panel 12 onto the floor panel 28. This engagement is
accomplished in a manner similar to the securing of panel 14 to
floor panel 26. The right side front panel 12 includes a groove 62
which extends along the length of the panel. The right side rear
panel 14 includes a groove 64 which extends along the length of the
panel. Grooves 62 and 64 are constructed and arranged to mate with
each other so as to enable panels 12 and 14 to be joined together.
The grooves 62 and 64 further provide a connection between panels
12 and 14 which does not distract from the inner or outer surfaces
of the panels. The grooves also present an aesthetically pleasing
appearance of a single said wall of the utility enclosure.
Fasteners 54 are utilized to secure panels 12 and 14 together, as
illustrated in FIGS. 8A and B. Fasteners 54 pass through apertures
40 in panel 12 and are screwed in panel 14, thus securing panels 12
and 14 together.
[0079] FIGS. 9A and B illustrate the right and left back panels 16
and 18 secured to floor panel 26. The back panel 18 is secured to
the floor panel utilizing tabs 36 on the back panel and apertures
38 on the floor panel 26; similar to the manner in which back panel
16 is secured to floor panel 26. Back panels 16 and 18 also include
grooves 66 and 68 respectively along their length. Grooves 66 and
68 are constructed and arranged to mate with each other in a manner
similar to grooves 62 and 64. Fasteners 54 pass through apertures
40 in panel 16 and are screwed into panel 18 so as to secure panels
16 and 18 together. This connection is similar to the connection
which joins panels 12 and 14 together.
[0080] FIGS. 10A-C describe the connection of left side panels 20
and 22 to each other, and their installation onto floor panels 26
and 28. Left side front panel 20 includes a plurality of tabs 70
formed to or secured along a bottom portion or edge. The tabs 70
are similar to tabs 36 on panel 16. Tabs 70 fit into apertures 72
on floor panel 28. Panel 20 is secured to floor panel 26 in a
manner similar to that of panel 16 being secured to floor panel 26.
Left side rear panel 22 also includes tabs (not shown) along a
bottom portion thereof. These tabs fit into apertures in floor
panel 28 and thus secure panel 22 to floor panel 28 in a manner
similar to that employed to secure panel 20 to floor panel 26. Left
side panels 20 and 22 include channels 74 and 76, respectively,
which extend along their length. Channels 74 and 76 are constructed
and arranged to mate with each other so as to enable panels 20 and
22 to be joined together. The grooves 74 and 76 further provide a
connection between panels 20 and 22 which does not distract from
the inner or outer surfaces of the panels. The grooves also present
an aesthetically pleasing appearance of a single said wall of the
utility enclosure. Fasteners 54 are utilized to secure panels 20
and 22 together. Fasteners 54 pass through apertures 40 in panel 22
and are screwed in panel 20, thus securing panels 20 and 22
together.
[0081] FIGS. 11B-C illustrate the connection between left side rear
panel 22 and left back panel 18. Left side rear panel 22 includes a
corner member or flap 78 (FIG. 11B) which is hingedly secured along
an edge portion. Corner member 78 fits into a groove 80 which
extends along an edge of panel 18. This enables the outer surface
of the corner member 78 to be flush with the outer surface of panel
18. This presents an aesthetically pleasing appearance to the outer
portion of enclosure 10. Fastening elements 54, such as screws, are
employed to secure panels 22 and 18 together, similar to the manner
in which the other panels are secured to each other. FIGS. 12A and
B illustrate the manner in which fastening elements 54 secure
panels 22 and 18 together.
[0082] FIGS. 13A-C illustrate a roof assembly for the utility
enclosure 10. The roof assembly includes a front roof panel 82 and
a rear roof panel 84. The roof panels 82 and 84 are curved along
their lateral dimension. This construction provides a curved
surface on top of enclosure 10 which enables rain, snow and other
elements of the weather to readily roll off the roof. This prevents
accumulation of water, etc. on the roof which can lead to water
leaking into the enclosure 10. Each of the side panels 12, 14, 20
and 22 have at least one projection 86 positioned along an upper
edge of the panel. In a preferred embodiment, there are two
projections 86 on each panel. Each of the roof panels 82 and 84
have at least one and preferably two recesses or channels 88
positioned on an inside edge at each end of the panels, as
illustrated in FIGS. 13A and B. Each of the roof panels is
separately placed on the enclosure 10. The roof panels are placed
atop the side panels, offset to the front or rear of the enclosure.
The panels are then slid or moved toward the center of the
enclosure 10. The projections 86 on the side panels are then slid
in and engage the recesses 88. This then locks the roof panels in
place on the enclosure without the use of separate fasteners. Each
of the roof panels 82 and 84 are provided with a channel 90 and 92,
respectively, along a longitudinal edge thereof. The channels 90
and 92 are formed as compliments to each other so that when the
channels 90 and 92 are engaged they form an interlocking seal
between roof panels 82 and 84 (FIG. 14B). This interlocking seal
holds the panels together and prevents the intrusion of water or
other fluids into the enclosure.
[0083] The front of the enclosure 10 includes a door assembly which
comprises two door panels. A left door panel 94 (FIG. 15A) and a
right door panel 96 (FIG. 17A). The door panels are hingedly secure
to the side panels, as illustrated in FIGS. 15-17. Left door panel
94 is hingedly secured to left front panel 20 with three hinges 98,
100, and 102, as illustrated in FIGS. 15B, 15C and 15D
respectively. Hinges 98, 100, and 102 are slid into apertures on
panel 20. These apertures retain the hinge members and prevent
their disengagement from the side panel. The apertures also permit
the hinge members to pivot which permits the doors to open and
close. Door panel 94 is also provided with a handle 104 the assist
the opening and closing of the door panel. Handle 104 is secured to
the door panel with fasteners 106.
[0084] Right door panel 96 is hingedly secured to left front panel
12 with three hinges 108, 110, and 112, as illustrated in FIGS.
17B, 17C and 17D respectively. Hinges 108, 110, and 112 are slid
into apertures on panel 12. These apertures retain the hinge
members and prevent their disengagement from the side panel. The
apertures also permit the hinge members to pivot which permits the
doors to open and close. Door panel 96 is also provided with a
handle (not shown) to assist the opening and closing of the door
panel. The handle is secured to the door panel with fasteners
similar to 106.
[0085] FIGS. 18A and 18B illustrate a roof brace 114 secured to
left side panel 20 with fasteners. The roof brace provides
additional support for the roof panels. This additional support is
useful to prevent collapse of the roof under heavy snow loads, etc.
FIGS. 19A and 19B illustrate the roof brace 114 secured to right
side panel 12 with fasteners. FIG. 20B illustrates the fasteners
116 used to secure the roof brace 114 to the side panels.
[0086] FIGS. 21-52, which are now referenced, show isometric and
exploded views of a system or kit for the assembly of a second
embodiment of the present invention. A utility enclosure or shed is
generally illustrated at 200. The enclosure or shed 200 includes a
right side panel 202, a left side panel 204, a back panel 206 (FIG.
22A), corner panels 208 (FIG. 22A), a roof panel 210, a floor panel
212 and front doors 214 and 216. The right side panel, left side
panel, corner panels, back panels and doors are formed mainly from
wood. These panels are secured to each other in a manner which will
be described hereinafter.
[0087] A corner panel 208 includes a plurality of wooden boards or
siding 218 (FIG. 22B). Each board or siding 218 is provided with a
"tongue side" 220 along one longitudinal edge and a "groove side"
222 along an opposite longitudinal edge (FIG. 22B). The tongue side
of each board fits into the groove side of an adjacent board, as
illustrated in FIG. 22B, to provide a water tight joint between the
boards. This type of connection also provides a secure, structural
connection between adjacent boards. A plurality of braces 224, are
secured to an inner side of the corner panels. These braces 224
hold the boards or siding 218 together and provide structural
support for the boards 218. While three braces 224 are illustrated,
any number can be employed on each of the corner panels.
[0088] Support braces 226 are illustrated in FIGS. 22A and B, the
support braces 226 are secured to the top and bottom portions of
the side panel 204. Each of the boards or siding 218 on the side
panel 204 are secured to the support braces. The ends of the
support braces 226 are provided with apertures 228 (FIG. 22B).
Fastening devices, such as screws, are set in to these apertures to
secure the braces 226 of the side panel to the boards 218 of the
corner panel (FIGS. 22B, 23A and B).
[0089] Additional support braces 227 are provided on the side panel
between the top and bottom support braces (FIG. 24). These
additional support braces provide structural strength and rigidity
to the side panel. The additional support braces are secured to the
corner panel 208 in the same manner that the top and bottom support
braces were secured to the corner panel.
[0090] A face frame member 228 is secured to a corner panel (FIGS.
26A and B). A longitudinal edge of the face frame 228 is provided
with a "groove" 230 along the length thereof. The groove 230 is
constructed and arranged to mate with the "tongue" 220 along the
edge of a board 218 of the corner panel 208. Fasteners, such as
screws, pass through apertures 232 on the face frame. These
fasteners are used to secure the face frame 228 to the corner panel
208 (FIG. 27A and B). Portions of the face frame are cut away at
234 to allow the face frame to fit around the braces 224 on the
corner panel 208. A similar face frame member 229 (FIG. 45A) is
secured to an opposite corner panel on the other side of the
enclosure.
[0091] A top connector member 236 is secured along the top edge of
a side panel and corner panel, as illustrated in FIGS. 28, 29A and
29B. The top connector member 236 includes a plurality of apertures
238. Fasteners, such as screws, are passed through these apertures
and secure the top connector member 236 to the side and corner
panels (FIG. 29A). The top connector member 236 is made of a
plastic or resin material.
[0092] A bottom connector member 240 is secured along the bottom
edge of a side panel and corner panels, as illustrated in FIGS. 30
and 31. The bottom connector member 240 includes a plurality of
apertures 242. Fasteners, such as screws, are passed through these
apertures and secure the bottom connector member 240 to the side
and corner panels (FIG. 31). The bottom connector includes a
plurality of tabs 241. The bottom connector panel 240 is made of a
plastic or resin material.
[0093] The back panel 206 of the enclosure includes a left back
panel 244 and a right back panel 246 (FIG. 33A). This is mainly for
manufacturing and shipping purposes. A filler board 248 is designed
to be inserted between the left and right back panels, and provide
a support to secure the left and right back panels together. A
"groove" is provided along one longitudinal edge of filler board
248 and a "tongue" is provided along an opposite longitudinal edge
of the filler board. These tongue and groove connections mate with
comparable tongue and groove connections on boards 218 of the left
and right back panels (FIG. 33B).
[0094] FIGS. 34, the left and right back panels are provided with
support braces 226 along a top and bottom edge thereof. These
support braces hold the boards 218 together during shipping, prior
to assembly and afterwards. Additional support braces 250 extend
across the widths of the left and right back panels. These
additional braces 250, together with the filler board 248, securely
hold the left and right back panels to each other and thus form the
back panel 206. The support braces 250 are provided with apertures
252. Fasteners, such as screws, are passed through these apertures
and secure the support braces 250 to the back panels and the corner
panels.
[0095] Bottom connectors 254 are secured along the bottom edge of
the back panel 206. As illustrated in FIG. 36, there are two bottom
connectors secured to the bottom edge of panel 206. While two
bottom connectors are illustrated, any number of connectors can be
employed. The bottom connectors 254 are made of a plastic or resin
material. The bottom connectors 254 are provided with tabs 256
(FIG. 38B). These tabs are similar to tabs 36 on the back panels of
the first embodiment of the present invention. Tabs 256 fit into or
slots, not shown, on the floor panel 212 (FIG. 38A). The back panel
206 is tilted downwardly and the tabs 256 are inserted into the
slots on the floor panel. Next the back panel is tilted to its
upright position (FIG. 39). The back panel is then slid to the
right, as indicated by the arrow. This locks the tabs 256 into the
slots and prevents the back panel from separating from the floor
panel. The floor panel is made from a plastic or resin material.
This permits the enclosure to be set on the ground without the
danger of the wood boards rotting. Also, the floor panel prevents
the intrusion of water and other fluids into the enclosure.
[0096] FIGS. 40 and 41 illustrate the manner in which the left side
panel 204 and corner panels 208 are secured to the floor panel 212.
The side and corner panels are tilted downwardly. Next, tabs 241 on
the bottom connector of the side panels are inserted into slots,
not shown, on the floor panel 212. Finally, the side and corner
panel assembly is tilted upwardly into its final upright position
(FIG. 42).
[0097] Top connectors 258 are installed on the top edge of the back
panel 206. Top connectors 258 are secured to the support braces 226
with fasteners, such as screws. The top connectors 236 and 258
serve as means to attach and secure the roof to the enclosure, as
will be described hereinafter. The junction between top members 236
and 258 is illustrated in FIGS. 44A and B.
[0098] FIG. 45A and B, a header member 260 is secured to the left
and right face frame members 228 and 229. Apertures 262 are
provided on the header which permit fasteners, such as screws, to
secure the header to the face frame members. In a preferred
embodiment the header 260 is made from metal. Other materials can
also be used for the header.
[0099] FIG. 46-47, roof panel 210 is secured to the top connectors
236 and 258. The roof panel is placed on top of the connectors and
then slid toward the front of the enclosure. The left and right top
connectors 236 are provided with tabs 264. These tabs slide into
"L" shaped grooves 266 which are formed in the bottom edges of the
roof panel 210. This now locks the roof panel onto the enclosure.
Roof panel 210 also includes tabs 268 which engage the top
connectors 258 on the back panel. Tabs 268 help to lock the roof
panel in place and prevent it from sliding off once it has been
installed on the enclosure.
[0100] FIGS. 49A and B illustrate the left door 214 and hinges 270
which are employed to secure the door to the face frame 228.
Fasteners, such as screws, are used to secure the hinges 270 to the
door and the face frame. FIGS. 50A and B also illustrate the manner
in which the door 214 is secured to the face frame. In a preferred
embodiment, the edges of the door 214 and the face frame 228 are
mortised to permit the hinges to be mounted flush with the surfaces
of the door and face frame, as illustrated in FIGS. 50A and B.
[0101] FIG. 51 illustrates the manner in which a door handle 272
and face plate 274 are secured to door 214. A fastener 276 is
employed to secure the handle 272 and face plate 274 to the door. A
similar handle 278 and face plate 280 are secured to the right hand
door 216 in the same manner (FIG. 54). A slide bolt 282 is secured
to the top of the left door 214 (FIG. 52B). The slide bolt moves up
and down to engage and disengage an aperture in header 260. When
the slide bolt engages header 260 it locks the door 214 in a closed
position. To open the door, one simply lowers the slide bolt 282
until it disengages the header. The door 214 can now be opened.
[0102] FIG. 53 illustrates a hasp 284 which is installed on the
doors 214 and 216 to lock the door in a closed position. The hasp
includes a left portion 286 and a right portion 288. The right
portion 288 includes a pivotable locking member 290. The locking
member 290 fits through aperture 292 in the left portion 286. The
locking member can then be pivoted so that it cannot pass through
the aperture. This action interlocks the left and right portions of
the hasp together. Since the left and right portions are mounted on
the left and right doors respectively, this action also locks the
doors 214 and 216 of the enclosure in a closed position. A lock,
such as a padlock, can also be placed through the aperture 294 of
the locking member 290. This enables the enclosure to be securely
locked and prevents unauthorized intrusion.
[0103] 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.
[0104] 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.
[0105] 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.
* * * * *