Plastic expandable utility shed

#This invention relates generally to a large enclosure constructed of plastic structural panels. More specifically, the present invention relates to a modular construction system utilizing injection molded plastic structural panels having integrated connectors to construct various sized enclosures using the same components.

#Utility sheds are a necessity for lawn and garden care, as well as general all-around home storage space. Typically, items such as garden tractors, snow blowers, tillers, ATVs, motorcycles and the like consume a great deal of the garage floor space available, forcing the homeowner to park his automobile outside.

#The prior art has proposed a number of different panel systems, or kits, comprising blow molded or extruded panels and connector members for forming a wide variety of smaller sized storage structures. These structures are generally suitable to store hand tools and smaller lawn equipment. Typically, such systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitate an engagement between such members and one or more 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 possible with injection molding.

#FIG. 1 is a front perspective view of an enclosure constructed using the instant utility enclosure system;

#FIG. 2 is a rear perspective view of an enclosure constructed using the instant utility enclosure system;

#FIG. 3 is an exploded view of the enclosure shown in FIG. 1;

#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.

#FIGS. 1-3 which are now referenced show isometric and exploded views of a heavy duty utility enclosure, generally referenced as 10, constructed according to a preferred embodiment of the present invention. The enclosure is made up of a floor assembly 100, left and right side wall assemblies 200, corner post assemblies 300, roof assembly 400, rear wall assembly 500, front wall assembly 600 and door assemblies 700. In the preferred embodiment, the panels comprising the assemblies are formed of but not limited to a suitable plastic such as polystyrene, polypropylene or polyethylene, through the process of injection molding. The result is that the panels comprising the floor assembly 100, post assemblies 300, side wall assemblies 200, roof assembly 400, rear wall assembly 500 and front wall assembly 600 of the enclosure 10 are formed as unitary panels with integral connectors and cross bracing. Strengthening ribs and gussets 206 are formed within the inner surfaces of the various panels and components in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in FIG. 1. The injection molded construction is utilized for the floor assembly 100, left and right wall assemblies 200, the corner posts 300, roof assembly 400, rear wall assembly 500, and front wall assembly 600 using a minimal number of components.

#Referring to FIGS. 1-10, the enclosure includes a plurality of like-constructed floor panels 102. Each panel has a top surface 104, bottom surface 106, a closed first edge 108, a second edge 110 opposite said first edge, said second edge including a first means for connecting to juxtapositioned panel members, a third edge 112 substantially perpendicular to and extending between said first and said second edges, the third edge including the first means for connecting to juxtapositioned panel members, and a fourth edge 114 opposite to and substantially parallel to said third edge, the fourth edge including the first means for connecting to juxtapositioned panel members. Adjacent to the closed edge 108 is a second means of attaching the floor assembly to the wall assemblies illustrated herein as a plurality of bosses 116 extending upwardly from the top surface 104. The bosses 116 are constructed and arranged to cooperate with pockets 210 located at each longitudinal end of the structural wall panels 202 and the structural L-shaped post assemblies 300 for connecting and maintaining a substantially perpendicular relationship between the wall panel members and the top surface of the floor panel members. Within the preferred embodiment, the locking bosses 116 are removeable and replaceable, wherein each locking boss includes a first lower end 130 and a second upper end 132. The first end includes a flange 134 constructed and arranged to cooperate with a floor panel to provide a secure connection between the panels and to prevent lifting or tipping of wall panels secured thereto. The locking boss is inserted through a conjugately shaped aperture 136 integrally formed within the floor panels until the integrally formed spring clips 138 engage surface 140 for a secure connection, wherein the locking boss extends upwardly above the top surface of the floor panel.