Plastic utility shed wall system
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.
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 INVENTIONThis 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 INVENTIONUtility 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.
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.
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.
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.
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.
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.
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.
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.
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.
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 INVENTIONThe 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.
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.
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.
It is a still further objective of the invention to provide a plastic wall assembly which utilizes structural corner assemblies for increased enclosure rigidity.
Still another objective of the instant invention is to provide a wall system in which the wall panel members include integrally formed connectors.
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.
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.
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.
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
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.
Referring to
Referring to
Referring to
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 (
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 (
Referring to
In an alternate embodiment, shown in
Referring to
Referring to
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.
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
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.
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.
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.
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.
Type: Application
Filed: Dec 29, 2005
Publication Date: Aug 2, 2007
Inventors: Robert Stein (Aurora, IL), Jed Richardson (Batavia, IL)
Application Number: 11/323,554
International Classification: E04H 6/00 (20060101);