Abstract:
The present invention provides a system or kit which includes plastic components which 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 enclosure is provided with a sliding roof panel and pivoting doors which permit easy access to the interior of the enclosure.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to U.S. Pat. No. 7,543,411, issued Jun. 9, 2009, entitled “LOW PROFILE PLASTIC PANEL ENCLOSURE” and to U.S. patent application Ser. No. 12/942,679, filed Nov. 9, 2010, entitled “COMBO WOOD AND PLASTIC MODULAR STORAGE SHED”, the entireties of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to enclosures, such as utility or garden sheds, constructed of plastic materials. More specifically, the present invention relates to an enclosure having walls, a roof, doors and a floor made from blow molded plastic materials. 
       BACKGROUND OF THE INVENTION 
       [0003]    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. 
         [0004]    The prior art has proposed a number of different storage buildings or utility sheds assembled from a kit which include 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. 
         [0005]    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. 
         [0006]    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. 
         [0007]    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 and 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 side walls 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. 
         [0008]    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. 
         [0009]    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 negatively affect the utility of the structure. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention provides a system or kit which includes plastic components which 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 are 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 enclosure is provided with a sliding roof panel and pivoting doors which permit easy access to the interior of the enclosure. 
         [0011]    Accordingly, it is an objective of the present invention to provide a system or kit for assembly of a utility enclosure which utilizes preformed plastic panels that permit ease of assembly of the utility enclosure. 
         [0012]    It is a further objective of the present invention to provide a utility enclosure system or kit which includes a sliding roof panel and pivoting doors that permit easy access to the interior of the enclosure. 
         [0013]    It is yet another objective of the present invention to provide a utility enclosure system or kit wherein the panel members include integrated connectors which accommodate plastic formation of the panel components for increased structural integrity. 
         [0014]    It is a still further objective of the present invention to provide a utility enclosure system or kit which utilizes structural corner assemblies for increased enclosure rigidity. 
         [0015]    It is still another objective of the instant invention to provide a utility enclosure system or kit which utilizes interlocking bosses and pockets to secure wall panels to a floor. 
         [0016]    It is still another objective of the instant invention to provide a utility enclosure system or kit which utilizes floor components which interlock together for structural stability and the prevention of incursion of water into the enclosure. 
         [0017]    Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0018]      FIG. 1  is a front perspective view of the present invention; 
           [0019]      FIG. 2  is one of the floor panels; 
           [0020]      FIG. 3  is a right wall side front panel; 
           [0021]      FIG. 4  is a right wall side rear panel; 
           [0022]      FIG. 5  is a rear panel; 
           [0023]      FIG. 6  is a left side wall rear panel; 
           [0024]      FIG. 7  is a left side wall front panel; 
           [0025]      FIG. 8  is a left door; 
           [0026]      FIG. 9  is a right door; 
           [0027]      FIG. 10  is a perspective of the floor panels prior to assembly; 
           [0028]      FIG. 11A  is a perspective view of the assembled floor panels; 
           [0029]      FIG. 11B  is a view of the fasteners used to assemble the floor panels; 
           [0030]      FIG. 12A  is a perspective view of a right side wall panel and the floor panels; 
           [0031]      FIG. 12B  is a detail of the right side wall panel and floor panel connection; 
           [0032]      FIG. 13A  is a perspective view of a right side wall panel and the floor panels; 
           [0033]      FIG. 13B  is a detail of the right side wall panel and floor panel connection; 
           [0034]      FIG. 14A  is a perspective view of the right side wall panels secured together and secured to the floor panels; 
           [0035]      FIG. 14B  is a view of the fasteners used to secure the right side wall panels together; 
           [0036]      FIG. 15  is a perspective view of the rear panel being secured to the floor panels; 
           [0037]      FIG. 16  is a perspective view of the right side panels and rear panel assembled; 
           [0038]      FIG. 17A  is a perspective view of a left side panel being secured to the rear panel and floor panels; 
           [0039]      FIG. 17B  is a detail of the left side wall panel and floor panel connection; 
           [0040]      FIG. 18A  is a perspective view of a left side wall panel being secured to the floor panels; 
           [0041]      FIG. 18B  is a detail of the left side wall panel and floor panel connection; 
           [0042]      FIG. 19  is a perspective view of the left side wall panels in their assembled positions; 
           [0043]      FIG. 20A  is a perspective view of a roof guide installed on the left side wall panels; 
           [0044]      FIG. 20B  is perspective view of an inner roof guide; 
           [0045]      FIG. 21A  is a perspective view of a roof support being installed; 
           [0046]      FIG. 21B  is a detail of the roof support and side wall panel connection; 
           [0047]      FIG. 22A  is a perspective view of a roof panel installed on the side wall panels; 
           [0048]      FIG. 22B  is a detailed view of the roof support, roof panel connection; 
           [0049]      FIG. 23A  is a view of the location of the rear panel to roof retainer clips; 
           [0050]      FIG. 23B  is a detail of the connection of the rear panel to roof retainer clips; 
           [0051]      FIG. 24  is a perspective view of the connection of the roof guide to roof panel connection; 
           [0052]      FIG. 25  is a perspective view of the sliding roof panel; 
           [0053]      FIG. 26A  is a perspective view of the sliding roof panel installed; 
           [0054]      FIG. 26B  is a perspective view of a roof guide installed on the sliding roof panel; 
           [0055]      FIG. 27A  is a perspective view of the location of the roof clips; 
           [0056]      FIG. 27B  is a view of a roof clip being installed; 
           [0057]      FIG. 27C  is a view of an installed roof clip; 
           [0058]      FIG. 27D  is a side view of a roof clip; 
           [0059]      FIG. 28  is a perspective view of the enclosure with a roof panel in the back or open position; 
           [0060]      FIG. 29  is a perspective view of a left door panel being installed; 
           [0061]      FIG. 30A  is a view of the left door panel installed; 
           [0062]      FIG. 30B  is a view of the left upper door retainer; 
           [0063]      FIG. 31A  is a view of a left lower door retainer installed; 
           [0064]      FIG. 31B  is a view of a left lower door retainer being installed; 
           [0065]      FIG. 31C  is a view of the location of the left lower door retainer; 
           [0066]      FIG. 32A  is a view of the location of the left upper door retainer; 
           [0067]      FIG. 32B  is a view of the fasteners used to install the left lower door retainer; 
           [0068]      FIG. 33  is a perspective view of the assembled enclosure with the roof panel in the back or open position; 
           [0069]      FIG. 34A  is a view of the handles installed on the doors of the enclosure; 
           [0070]      FIG. 34B  is a view of the handle to door connection; and 
           [0071]      FIG. 35  is a view of a lock used to secure the enclosure closed. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0072]    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. 
         [0073]      FIGS. 1-35 , which are now referenced, illustrate perspective and exploded views of a system or kit for the assembly of a preferred embodiment of the present invention. A utility enclosure or shed is generally illustrated at  10  in  FIG. 1 . The enclosure or shed  10  includes a right side wall  12 , a left side wall  14 , a rear wall  16 , doors  18 , a floor  20 , and a roof  22 . The right side wall includes a right side front wall  24  and a right side rear wall  26  ( FIGS. 3 and 4 ). The left side wall includes a left side front wall  28  and a left side rear wall  30  ( FIGS. 6 and 7 ). A rear wall is identified as  32  in  FIG. 5 . The doors include a left door  34  and a right door  36  ( FIGS. 8 and 9 ). The floor includes a front floor panel  38  and a rear floor panel  40  ( FIG. 10 ). The roof includes a front roof panel  42  and a rear roof panel  44  ( FIG. 25 ). These panels are preferably formed from molded plastic. 
         [0074]    The floor includes at least two floor panels  38  and  40  which are secured to each other to form the floor of the enclosure. The floor panels  38  and  40  are secured together in an overlapping connection as illustrated in  FIGS. 11A and 11B . Rear floor panel  40  includes a projection or lip  42  which extends along a width of the panel. This lip  42  overlaps a projection or lip  44 , which extends along a width of the panels, in an interlocking relation on the front floor panel ( FIG. 11B ). A plurality of fasteners  46  secure the front and rear floor panels together, as illustrated in  FIG. 11B . These fasteners are preferably machine screws. However, other screws and/or fasteners can be employed. 
         [0075]    The right side wall  12  includes a right side wall front panel  24  secured to a right side wall rear panel  26 . First, the right side wall front wall panel  24  is secured to the front floor panel  38  in the manner illustrated in  FIG. 12A . The right side wall front panel includes at least three bosses  48  located at a lower portion of the panel. These bosses  48  engage corresponding sockets (not shown) in the floor panel. The right side wall front panel  24  is placed on an edge of the floor panel  38 . The bosses  48  then engage corresponding sockets and the panel  24  is slid rearward. This motion interlocks the bosses into the corresponding sockets. The right side wall rear panel  26  is installed on the rear floor panel  40  in a manner similar to the installation of the right side wall front panel  24 . The panel  26  includes at least three bosses  50  located on a lower portion of the panel. These bosses  50  engage corresponding sockets (not shown) on the floor panel  40 . The right side wall rear panel  26  is placed on an edge of the floor panel  40 . The bosses  50  then engage corresponding sockets and the panel  26  is slid forward. This motion interlocks the bosses into the corresponding sockets. The right side wall front and rear panels are secured to each other with fasteners  52  at the locations indicated illustrated in  FIG. 14A . As can be seen in  FIG. 14A , the rear portion of right side wall rear panel includes a curved wall portion  54 . This curved wall portion  54  forms a curved transition between the right side wall and the rear wall  32 . 
         [0076]    The rear wall panel  32  includes at least two bosses  56  ( FIG. 15 ). These bosses are located on a lower portion of the rear wall panel. These bosses  56  engage corresponding sockets (not shown) on the floor panel  40 . The rear wall rear panel  32  is placed on an edge of the floor panel  40 . The bosses  56  then engage corresponding sockets in the floor panel  40  and the rear wall panel  32  is slid either to the left or to the right. This motion interlocks the bosses into the corresponding sockets. Fasteners, similar to fasteners  52 , are used to secure the rear wall panel  32  to the right side wall rear panel  26 , as illustrated at  58  in  FIG. 16 . 
         [0077]    The left side wall  14  includes a left side wall front panel  30  secured to a left side wall rear panel  28 . First, the left side wall rear wall panel  28  is secured to the rear floor panel  40  in the manner illustrated in  FIG. 17A . The left side wall rear panel includes at least three bosses  60  located at a lower portion of the panel ( FIGS. 17A  and B). These bosses  60  engage corresponding sockets (not shown) in the floor panel. The left side wall rear panel  28  is placed on an edge of the floor panel  40 . The bosses  60  then engage corresponding sockets and the panel  28  is slid forward. This motion interlocks the bosses into the corresponding sockets. The left side wall front panel  30  is installed on the front floor panel  38  in a manner similar to the installation of the left side wall rear panel  28 . The panel  30  includes at least three bosses  62  located on a lower portion of the panel. These bosses  62  engage corresponding sockets (not shown) on the floor panel  38 . The left side wall front panel  30  is placed on an edge of the floor panel  30 . The bosses  62  then engage corresponding sockets and the panel  30  is slid forward. This motion interlocks the bosses into the corresponding sockets. The left side wall front and rear panels are secured to each other with fasteners, similar to fasteners  52 , at the locations  64  indicated in  FIG. 19 . As can be seen in  FIG. 19 , the rear portion of left side wall rear panel includes a curved wall portion  66 . This curved wall portion  66  forms a curved transition between the right side wall and the rear wall  32 . Fasteners, similar to fasteners  52 , are used to secure the rear wall panel  32  to the left side wall rear panel  28 , as illustrated at  68  in  FIG. 19 . 
         [0078]    The roof includes a front roof panel  42  and a rear roof panel  44  ( FIG. 25 ). The rear roof panel  44  is secured to the right, left and rear wall panels in a fixed position. The front roof panel  42  is movable between an open position ( FIG. 22A ) and a closed position ( FIG. 1 ). The roof panels  42  and  44  are convexly curved along a traverse cross section, thereby permitting rain and other weather elements to shed off of the roof A roof guide  68  is secured to an upper portion of both the front and rear left side wall panels  30  and  28  ( FIG. 20A ). Fasteners  70  are used to secure roof guide  68  to the side wall panels. Fasteners  70  are similar to fasteners  52 . Roof guide  68  also provides an additional device or means to secure the front and rear left side wall panels to each other. A similar roof guide (not shown) is secured to the upper portions of the front and rear right side wall panels in the same manner as roof guide  68 . An inner roof guide  72  is slidably secured between the roof guide  68  and the left side wall front panel  30  ( FIG. 20B ). Another inner roof guide (not shown) is secured between the other roof guide and the right side wall front panel. Both inner roof guides are secured to the front roof panel  42 . The inner roof guides and roof guides allow the front roof panel to slidably move between an open and a closed position. 
         [0079]    A roof support  74  is secured between the roof guides ( FIGS. 21A and 22A ). A slot  76  is formed on both the roof supports into which respective ends of the roof support  74  is inserted. The front of the rear roof panel  44  is placed onto the roof support  74  ( FIGS. 22A  and B). The sides of the rear roof panel  44  are secured to the roof guides  68  with fasteners  76 , as illustrated in  FIG. 24 . The other side of the rear roof panel  44  is also secured to a roof guide (not shown) with fasteners  76  in a similar manner. The rear end portion of the rear roof panel  44  is secured to the rear wall panel with retainers  78  and fasteners  80  ( FIG. 23B ). All of these connections secure the rear roof panels  44  to the right, left and back wall panels in a fixed position. 
         [0080]    The front roof panel  42  is secured to the inner roof guides  72  using fasteners  82  ( FIG. 26B ). The inner roof guides are preferably secured to a forward portion of the front roof panel  42  as indicated at  84  in  FIG. 26A . When the front roof panel  42  is in the closed position ( FIG. 1 ) the rear portion of the panel  42  is secured to the front portion of rear roof panel  44  by at least two clips  84  ( FIGS. 27A-D ). As illustrated in  FIGS. 27A-C  there is a groove or slot  86  on both sides of a rear portion of the front roof panel  42  and a groove or slot  88  on both sides of a front portion of the rear roof panel  44 . When the roof panels are in the closed position, the lower portion of clip  84  is first placed into groove or slot  88  and then pivoted upward to be placed into groove or slot  86 . This connection securely locks the front roof panel  42  to the rear roof panel, thereby preventing the roof panels from separating and preventing access to the interior of the enclosure. When it is desired to open the roof, the clips  84  are removed and the front roof panel  42  is slid rearwardly, as illustrated in  FIG. 28 . 
         [0081]      FIGS. 29-32  illustrated the manner in which the left door panel  34  is installed on the enclosure. The left side wall front panel  30  includes at least three connectors  90 ,  92  and  94  which function as hinges. These connectors,  90 - 94 , operatively cooperate with pins  96 ,  98 , and  100  on the left door panel  34  to allow the left door panel to be moved from a closed position to an open position and back again. Pin  96  is secured in connector  90  using a securing member  102  ( FIG. 30  A). A fastener  104  secures the securing member  102  to the left side wall front panel  30 . Pins  98  are slid into connector  92  and frictionally held therein. Pin  100  is secured in connector  94  using a securing member  106  ( FIGS. 31A-C  and  32 A). Fasteners  108  secure the securing member  106  to the left side wall front panel  30  and the floor  38  ( FIG. 32  B). The right door panel  36  is secured to the right side wall front panel  26  and the floor panel  38  in the same manner as of the left door panel  34 . A plurality of handles  110  are secured to the upper portions of door panels  34  and  36  using fasteners  112 , as illustrated in  FIGS. 34A  and B. A securing or locking element  114  is provided on the front roof panel  42  ( FIG. 35 ). A securing or locking element  116  is provided on the right door panel  36  ( FIG. 35 ). A lock  118  can securely connect elements  114  and  116  together, thus preventing unauthorized entry into the enclosure  10 . 
         [0082]    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. 
         [0083]    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. 
         [0084]    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.