Plastic expandable utility shed
AssigneeSuncast Corporation
InventorsTorrence Anderson, Brian Moon, Jed C. Richardson
Life of this patent
Estimating the term…
Abstract
The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form an enclosure, commonly in the form of a utility shed. The panels are formed of injection molded plastic to interlock with one another without the need for separate I-beam connectors. The ends of the wall panels have cavities to accept both roof and floor outwardly projecting locking posts for interlocking cooperative engagement which serve to rigidly connect the components together. The symmetry of the wall, roof, floor and door components also minimizes component shapes and simplifies enclosure construction.
Claims43
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said at least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into said first or said second horizontal edge and secured in place by rotation of said T-connector within said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with a corresponding key-hole slot in an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, said roof assembly including at least two headers, a ridge cap assembly, and two pair of like-constructed roof panels, said at least two headers including an outer surface, an inner surface, an upper surface, and a lower surface, wherein said upper surface includes a plurality of vents constructed and arranged to allow airflow through the enclosure while preventing weather related moisture from entering said enclosure, wherein said lower surface includes a plurality of outwardly extending bosses constructed and arranged to cooperate with sockets located in a second end of said corner pillars, wherein said bosses are slid into the respective corner pillar sockets until the integrally formed spring tabs engage corresponding apertures formed in the corner pillar sockets,
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a symmetrical floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and
- right side of said heavy duty enclosure;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, said roof assembly including at least two headers, a ridge cap assembly, and at least one pair of like-constructed roof panels, said like-constructed roof panels including an outer surface, an inner surface, a first locking edge, a second locking edge, a first closed edge opposite said first locking edge, and a second closed edge opposite said second locking edge wherein said first locking edge is constructed and arranged to cooperate with said first or said second edge of said ridge cap for weather resistant engagement, wherein said second locking edge is constructed and arranged to cooperate with a second locking edge of an adjacent roof panel for weather resistant engagement, wherein said inner surface is constructed and arranged with a means of attaching said roof panels to said wall panels, said means of attaching said roof panels to said wall panels including a plurality of sockets arranged in a linear fashion adjacent to said first closed edge, wherein each said socket is constructed and arranged to cooperate with a connector for attachment to a socket in at least one of said wall panel assemblies;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a symmetrical floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, said roof assembly including at least two headers, a ridge cap assembly, and at least one pair of like-constructed roof panels, each including an outer surface, an inner surface, a first locking edge, a second locking edge, a first closed edge opposite said first locking edge, and a second closed edge opposite said second locking edge, said roof panels including a plurality of spaced apart structural tubes extending through each roof panel between said outer surface and said inner surface extending between said first locking edge and said first closed edge, wherein at least one of said tubes is constructed and arranged as a socket within said first locking edge to for receiving at least one locking boss for attaching said like-configured roof panels to said ridge cap;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said ar least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into and secured in place by said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure, said rear wall assembly including a pair of like-constructed rear wall panel members, said rear wall panel members having a first longitudinal end with an integral attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with said roof or said floor assemblies, a first horizontal edge having an attachment means constructed and arranged to cooperate with a corner pillar member, a second horizontal edge constructed and arranged to cooperate with at least one panel member to provide a weather resistant seal, wherein said first horizontal edge attachment means includes a semi-circular conduit extending from about said first longitudinal end to about the middle portion of said edge, said conduit having a generally circular aperture for accepting a dowel centrally located within said middle portion end of said semi-circular conduit, wherein said semi-circular conduit is brought into an overlapping relationship with a corresponding semi-circular conduit and a dowel pin enters and extends between said circular apertures in each conduit resulting in a mechanically secure connection between the two said panels, said first horizontal edge attachment means including at least two C-shaped annular portions integrally formed at about said first and said second longitudinal ends of said first horizontal edge, a C-shaped annular portion formed in said semi-circular conduit at about said middle portion of said edge, each of said C-shaped annular portions adapted to cooperate in an interlocking manner with a hinge cap, each said hinge cap including an integrally formed C-shaped annular portion slidingly engagable into a corresponding annular portion, whereby said rear wall panels are attached to said interconnected floor panels, said corner pillars, and said roof panels by sliding each said rear wall panel horizontally into place over a plurality of hinge pins arranged to enter said annular portions and wherein said hinge caps are slidingly engaged to said C-shaped annular portions to close said each respective C-shaped annular portions to secure said panels to said hinge pins;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said at least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into and secured in place by said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, wherein said roof assembly includes at least two headers, a ridge cap assembly, and two pair of like-constructed roof panels, said at least two headers include an outer surface, an inner surface, an upper vented surface, and a lower surface, wherein said lower surface includes a plurality of outwardly extending bosses constructed and arranged to cooperate with sockets located in a second end of said corner pillars, wherein said bosses are slid into the respective corner pillar sockets until the integrally formed spring tabs engage corresponding apertures formed in the corner pillar sockets;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said at least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into and secured in place by said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, said roof assembly including at least two headers, a ridge cap assembly, and two pair of like-constructed roof panels, said like-constructed roof panels including an outer surface, an inner surface, a first locking edge, a second locking edge, a first closed edge opposite said first locking edge, and a second closed edge opposite said second locking edge wherein said first locking edge is constructed and arranged to cooperate with said first or said second edge of said ridge cap for weather resistant engagement, wherein said second locking edge is constructed and arranged to cooperate with a second locking edge of an adjacent roof panel for weather resistant engagement, wherein said inner surface is constructed and arranged with a means of attaching said roof panels to said wall panels, said means of attaching said roof panels to said wall panels including a plurality of sockets arranged in a linear fashion adjacent to said first closed edge, wherein each said socket is constructed and arranged to cooperate with a connector for attachment to a corresponding socket in an upper edge of said wall panel assemblies;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said at least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into and secured in place by said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure;
- a roof assembly for enclosing the top of said heavy duty enclosure system, said roof assembly including at least two headers, a ridge cap assembly, and two pair of like-constructed roof panels, said like-constructed roof panels including an outer surface, an inner surface, a first locking edge, a second locking edge, a first closed edge opposite said first locking edge, and a second closed edge opposite said second locking edge wherein said first locking edge is constructed and arranged to cooperate with said first or said second edge of said ridge cap for weather resistant engagement, wherein said second locking edge is constructed and arranged to cooperate with a second locking edge of an adjacent roof panel for weather resistant engagement, wherein said inner surface is constructed and arranged with a means of attaching said roof panels to said wall panels, said roof panels including a plurality of spaced apart structural tubes extending through each roof panel between said outer surface and said inner surface extending between said first locking edge and said first closed edge, wherein at least one of said tubes is constructed and arranged as a socket within said first locking edge to for receiving at least one locking boss for attaching said like-configured roof panels to said ridge cap;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
A heavy duty injection molded utility enclosure comprising:
- a floor assembly for enclosing the bottom of said heavy duty enclosure;
- four L-shaped corner pillars for providing strength and rigidity to said enclosure;
- a pair of side wall assemblies for enclosing the left side and right side of said heavy duty enclosure, each of said side wall assemblies including at least one side wall panel member, wherein said at least one wall panel member includes a first longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a second longitudinal end having an attachment means constructed and arranged to cooperate with a floor assembly or a roof assembly, a first horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking coplanar relationship and a second horizontal edge having an attachment means constructed and arranged to cooperate with a side wall panel member or a corner pillar member in an interlocking co-planar relationship, said first horizontal edge attachment means including at least one slot constructed and arranged for attachment of at least one T-connector, said at least one T-connector having a first end portion and a second end portion, wherein said first end portion of said at least one T-connector is inserted into and secured in place by said slot, wherein said second end portion of said at least one T-connector extends outwardly from said first horizontal edge for interlocking cooperation with an adjacent side wall panel or corner pillar resulting in a mechanically secure connection between said panels;
- a rear wall assembly for enclosing the back of said heavy duty enclosure;
- a door assembly for enclosing and providing ingress into and egress from said heavy duty enclosure, said door assembly including a pair of like-constructed door panels each having a first longitudinal end including at least one integrally formed socket, means, a second longitudinal end including an integrally formed hinge means, a first horizontal edge having a semi-circular conduit extending from about said first longitudinal end to about the middle portion of said edge said conduit having an integrally formed hinge means, a second horizontal edge being generally flat;
- a roof assembly for enclosing the top of said heavy duty enclosure system;
- wherein a heavy duty enclosure can be shipped in a disassembled state and assembled on a desired site.
Dependencies are inferred from the claim text.