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.

Description

FIELD OF THE INVENTION

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

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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

FIG. 1 is a front perspective view of a first embodiment of the present invention;

FIGS. 2A-F are views of side and back panels of a first embodiment of the present invention;

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;

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;

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;

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;

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;

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;

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;

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;

FIGS. 11A-D are details of the left side panels of a first embodiment of the present invention;

FIGS. 12A and B are details of the connection between the side panels and rear panels of a first embodiment of the present invention;

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;

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;

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;

FIGS. 16A and B are details of the connection of a handle to the left door of a first embodiment of the present invention;

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;

FIGS. 18A and B are details of a roof support of a first embodiment of the present invention;

FIGS. 19A and B are details of a roof support of a first embodiment of the present invention;

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;

FIG. 21 is a front perspective view of a second embodiment of the present invention;

FIGS. 22A and B are perspective views of a corner panel secured to a side panel;

FIGS. 23A and B are perspective views of a corner panel secured to a side panel;

FIG. 24 is a view of an inside of a side panel with additional braces;

FIG. 25 is a perspective view of one of the braces in FIG. 24;

FIGS. 26A and B are perspective views of a side panel and a face frame;

FIGS. 27A and B are detailed views of the attachment of the face frame to a corner panel;

FIG. 28 is a perspective view of a top connector and a side panel;

FIGS. 29A and B are views of a top connector secured to a side panel;

FIG. 30 is a perspective view of a bottom connector and a side panel;

FIG. 31 is a perspective view of a bottom panel secured to a side panel;

FIG. 32 is a perspective view of a filler board between two back panels;

FIGS. 33A and B are perspective views of the filler board of FIG. 32 secured to the two back panels;

FIG. 34 is a perspective view of support braces secured to the back panels;

FIG. 35 is a perspective view of a support brace;

FIG. 36 is a perspective view of a bottom connector being secured to one of the back panels;

FIG. 37 is a perspective view of the bottom connectors secured to the back panels;

FIGS. 38A and B are views of the back panel being secured to a floor panel;

FIG. 39 is a perspective view of the back panel secured to a floor panel;

FIG. 40 is a perspective view of a side and corner panels being secured to a floor panel;

FIG. 41 is a perspective view of a side and corner panels being secured to a floor panel;

FIG. 42 is a perspective view of a side, corner, and back panels secured to a floor panel;

FIG. 43 is a top perspective view of the side, corner and back panels secured to the floor panel;

FIGS. 44A and B are top perspective views of the top connectors of the back and side panels;

FIGS. 45A and B are top perspective views of the header being installed between the side panels;

FIG. 46 is a perspective view of the roof panel;

FIG. 47 is a cross sectional view of the roof securement taken along lines A-A in FIG. 21;

FIG. 48 is a cross sectional view of the roof securement taken along lines B-B in FIG. 21;

FIGS. 49A and B are views of hinges on the left door;

FIGS. 50A and B are views of hinges on the left door;

FIG. 51 is a view of a handle being installed on the left door;

FIGS. 52A and B are views, with the back panels removed, of the slide bolt being installed on the left door;

FIG. 53 is a view of a hasp to be installed on the doors;

FIG. 54 is a view of the hasp and handles on the doors; and

FIG. 55 is an exploded view of the second embodiment of the enclosure of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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).

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.

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.

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).

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.

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.

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.

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.

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.

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.

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. 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.