Plastic expandable utility shed

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 bosses 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.

FIELD OF THE INVENTION

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.

BACKGROUND INFORMATION

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.

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 appropriately 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, they 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 being situated to slidably engage the conduits located in the side panel sections to create the height needed for utility shed walls.

The aforementioned systems can also incorporate roof and floor panels to form a freestanding enclosed structure such as a small 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 small structures. Larger structures require constant ventilation in order to control moisture within the building. Large structures must also withstand increased wind and snow loads when compared to smaller structures. Paramount to achieving these needs is a panel system which eliminates the need for extruded connectors to create enclosure walls which resist panel separation, buckling, racking; and a roof system which allows ventilation while preventing weather infiltration. A further problem is that the wall formed by the panels must tie into the roof and floor in such a way as to unify the entire enclosure. Also, from a structural standpoint, the enclosure should include components capable of withstanding the increased wind, snow, and storage loads required by larger structures. From a convenience standpoint, a door must be present which can be easily installed after assembly of the wall and roof components, is compatible with the sidewalls, and which provides dependable pivoting door access to the enclosure. Also from a convenience standpoint, the structure should allow natural as well as artificial lighting. The structure should be aesthetically pleasing in appearance to blend in with surrounding structures.

The assignee of the instant invention is also the assignee of various other plastic enclosure systems, U.S. Pat. No. 6,892,497 entitled Plastic Panel Enclosure System, U.S. patent application Ser. No. 10/674,103 Plastic Expandable Utility Shed, the contents of which are incorporated herein in their entirety.

There are also commercial considerations that must be satisfied by any viable enclosure system or kit; considerations which are not entirely satisfied by state of the art products. The enclosure must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The enclosure must also be capable of being packaged and shipped in a knocked-down state. In addition, the system 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 minimal hardware and requiring a minimal number of 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.

BRIEF DESCRIPTION OF THE INVENTION

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 large utility shed. The corner sections, roof, wall and floor 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 receptacles to accept both roof and floor bosses for interlocking cooperative engagement to rigidly connect the components together.

The system incorporates a minimum number of components to construct a large heavy duty enclosure by integrally forming connectors into injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the enclosure. The symmetry of the corner sections, wall, roof, floor and door components also minimizes component shapes and simplifies enclosure construction. The heavy duty interlocking construction of the corner sections and the roof headers create a structural frame that allows construction of larger enclosures. Injection molding the wall panels allow them to be formed with adequate height for a large walk-in enclosure, eliminating the need for stacking panels to achieve such adequate height. Injection molding also allows the panels to be formed with integral cross-bracing, ribs, and gussets for increased rigidity when compared to blow molded or extruded panels.

In one embodiment, the enclosure system utilizes interlocking corner sections, roof headers, and floor panels to create a structural frame. Three types of panel constructions are integrated into the structural frame: the first being utilized for the side walls, the second being used for the door assembly, and the third being used for the roof. The wall panels are constructed to cooperate, via integrally formed connectors, with various members which allow the wall panels to be utilized for door frames as well as corner sections. The wall panels are also constructed to accept windows for natural lighting, and may include provisions for standard electrical current hookup. The internal surfaces of the wall panels include integrally formed connectors for easy assembly of added components such as shelving, baskets, slat wall storage and the like. The embodiment also incorporates a vented gabled roof assembly with anti-lift wind strapping and steel reinforcement. The system further includes a door assembly which may be locked in an open or closed position. The floor of the system is primarily constructed of a single type of floor panel in combination with front and rear edge assemblies to permit construction of sheds having various predetermined lengths and widths. The same wall, floor and roof components are used to create an entire family of utility enclosures of varying size, and the assembly of the system requires minimal hardware and a minimum number of hand tools.

Accordingly, it is an objective of the present invention to provide a utility enclosure system which utilizes plastic structural frame and panel members having integrated connectors for creating larger enclosures of varying dimension using common components.

A further objective is to provide a utility enclosure system wherein the structural panel members include integrated connectors which accommodate injection molding plastic formation of the panel components for increased structural integrity.

Yet a further objective is to provide a utility enclosure system which utilizes structural corner assemblies for increased enclosure rigidity.

Another objective is to provide a utility enclosure system constructed with panels having interlocking bosses and pockets as well as ridge and groove edges to increase rigidity and prevent panel bowing or separation.

Yet another objective is to provide a utility enclosure system which reduces the number of components required to assemble an enclosure and simplifies construction.

Still yet another objective is to provide a utility enclosure system constructed and arranged with panels that allow wood and/or steel supports to be easily incorporated therein for increased snow and/or wind load resistance.

An even further objective is to provide a utility enclosure system constructed and arranged to allow airflow through the enclosure while preventing weather related moisture from entering the enclosure.

Yet a further objective is to provide a utility enclosure system which may be optionally configured with clear windows thereby allowing natural light to enter the enclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-3which are now referenced show isometric and exploded views of a heavy duty utility enclosure, generally referenced as10, constructed according to a preferred embodiment of the present invention. The enclosure is made up of a floor assembly100, left and right side wall assemblies200, corner post assemblies300, roof assembly400, rear wall assembly500, front wall assembly600and door assemblies700. 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 assembly100, post assemblies300, side wall assemblies200, roof assembly400, rear wall assembly500and front wall assembly600of the enclosure10are formed as unitary panels with integral connectors and cross bracing. Strengthening ribs and gussets206are 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 inFIG. 1. The injection molded construction is utilized for the floor assembly100, left and right wall assemblies200, the corner posts300, roof assembly400, rear wall assembly500, and front wall assembly600using a minimal number of components.

Referring toFIGS. 1-10, the enclosure includes a plurality of like-constructed floor panels102. Each panel has a top surface104, bottom surface106, a closed first edge108, a second edge110opposite said first edge, said second edge including a first means for connecting to juxtapositioned panel members, a third edge112substantially 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 edge114opposite 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 edge108is a second means of attaching the floor assembly to the wall assemblies illustrated herein as a plurality of bosses116extending upwardly from the top surface104. The bosses116are constructed and arranged to cooperate with pockets210located at each longitudinal end of the structural wall panels202and the structural L-shaped post assemblies300for 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 bosses116are removeable and replaceable, wherein each locking boss includes a first lower end130and a second upper end132. The first end includes a flange134constructed 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 aperture136integrally formed within the floor panels until the integrally formed spring clips138engage surface140for a secure connection, wherein the locking boss extends upwardly above the top surface of the floor panel.

Along the edges110,112, and114of each floor panel102is the first means of connection illustrated herein as a series of spaced apart fingers122and recesses124for attaching the panels together into a floor assembly100, a portion of the fingers being provided with at least one countersank aperture123for receiving a fastener113. The fingers122and recesses124are constructed and arranged so that the fingers122of one panel overlap and mateably engage the recesses124of an adjacently positioned panel. The fasteners secure the panels together in an inter-fitting engagement with their respective top surfaces104in a co-planar arrangement. In a most preferred embodiment a portion of the fingers include an alignment boss115(FIG. 9) projecting outwardly from a lower surface thereof. The alignment boss115mateably engages an alignment socket117positioned within an upper surface of an aligned recess124. In one embodiment the alignment boss may include an integrally formed spring clip (not shown) for interlocking engagement with the alignment socket117.

The floor panels102are interconnected to each other to form a utility shed floor assembly100having a width determined by the width of the panels and length determined by the number of panels assembled. The panels are assembled by juxtapositioning the edges of respective floor panels and sliding the fingers of one panel into the respective recesses of the adjacent panel while simultaneously engaging the alignment bosses into their respective sockets. The fingers122and recesses124along the second, third, and fourth edges of the floor panels102correspond in shape and size to that of the fingers and recesses integrally formed into the adjacently positioned panels. The result is a positive mechanical connection between the floor panels to create the floor assembly100. In this manner the length of the shed may be increased or decreased to suit the users needs by adding or subtracting the number of panels assembled.

Referring toFIG. 6, the bottom surface of the floor assembly100is illustrated. The bottom surface106illustrates the cross-bracing128facilitated by injection molding of panels. Injection molding offers significant strength and stability advantages over blow-molding as utilized in the prior art. In this manner, the enclosure of the instant invention is capable of handling a significant amount of weight as compared to blow molded or extruded enclosures.

Referring toFIGS. 1-10, in addition to the floor panels, the floor assembly includes a front end assembly142. The front end assembly preferably includes two front end members144. Each front end member includes a top surface146, a bottom surface156, a first ramp edge148, a second edge150opposite the first edge, an outer edge152, a an inner edge154. The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members102to finish the front portion of the floor assembly100. The inner edges154include a third means of connection for connecting to the inner edge of an adjacently positioned front end member, illustrated herein as an overlapping arrangement which includes fasteners to facilitate mechanical connection. It will be appreciated that the purpose of the overlapping arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The result is a mechanically secure connection between the two panels that resists separation when traversed with heavy loads. Adjacent to each of the ramp edges148is a pair of generally cylindrical hinge pins176extending upwardly. The hinge pins176cooperate with the door panels702to allow pivotal movement. Adjacent to each of the hinge pins is a cylindrical boss178constructed and arranged to cooperate with a roof support pillar602. The roof support is generally tubular and sized to encircle the cylindrical boss178as well as a like constructed cylindrical boss positioned on the bottom surface of the header assembly450(FIG. 28) to provide increased wind and snow load capacity to the enclosure.

Referring toFIGS. 1-10, in addition to the floor panels, the floor assembly includes a rear end assembly160. The rear end assembly preferably includes two rear end members162. Each rear end member includes a top surface164, a bottom surface166, a rear closed edge168, a second edge170opposite the first edge, an outer edge172, and an inner edge174. The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members102to finish the rear portion of the floor assembly100. The inner edges174include the third means of connection for connecting to the inner edge of an adjacently positioned rear end member, illustrated herein as an overlapping arrangement which includes fasteners to facilitate mechanical connection. It will be appreciated that the purpose of the overlapping arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The result is a mechanically secure connection between the two panels that resists separation.

Referring toFIG. 11, a structural corner post assembly300is shown. The corner post assembly300constitutes one of a plurality of like-configured structural corner post assemblies in the system used to add significant strength and rigidity to the enclosure10. The corner post assemblies300are generally L-shaped having a first member302extending at least partially along the front or rear wall of the enclosure and a second member304extending at least partially along a side wall of the enclosure. The first corner post members302are each configured having a first longitudinal end306and a second longitudinal end308each including an integrally formed fourth means of attachment illustrated herein as an inwardly extending socket210. The socket is generally constructed and arranged to cooperate with either a floor assembly100or a roof assembly400boss in a generally perpendicular relationship. To facilitate mechanical connection with other structural panel members202in a co-planar relationship the first post member is provided a first horizontal edge314including a fifth means of attachment illustrated herein as a plurality of inwardly extending sockets330. The sockets include an inner wall316, an outer wall318, and a bottom wall320. The bottom wall includes an aperture321or notch therethrough for cooperative engagement with a hook-lock322included on an adjacently positioned wall panel or second corner post member304. In the preferred embodiment the horizontal edge314also includes a groove324extending from about the first longitudinal end306to about the second longitudinal end308of the edge314. The groove324is arranged to cooperate with a wall panel member202having a complimentary ridge in an interlocking coplanar relationship. The second member304includes a first end330and a second end332. Extending outward along the length of the second member is a plurality of bosses constructed and arranged to cooperate with sockets330integrally formed into the side of the first member302. A portion of the bosses include integrally formed hook-locks322for cooperation with the apertures or notches321provided in the first member or wall panels. The first and second members are attached together by sliding the bosses of the second member into the sockets of the first member and thereafter sliding the second member downward to engage the hook-locks (FIG. 13). The result is a positive mechanical connection between the first member of the post302and the second member of the post304. The outer surface326of the corner post assemblies300are constructed generally smooth for aesthetic appearance, while the internal portion of the assembly includes a plurality of box structures328for added strength, rigidity and weight carrying capacity. The construction of the corner post assemblies increase the structural integrity of the enclosure10by preventing the corner posts300from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure10.

The L-shaped corner post assemblies300are attached to the interconnected floor assembly100by sliding the first longitudinal end of the corner post assembly over a plurality of the bosses116extending outwardly from the floor assembly100. The pockets210in each end of the panels302correspond in shape and size to that of the bosses116and spring tabs126(FIG. 9) integrally formed into the bosses116align with apertures336in the pockets210to engage the corner post assembly300. The result is a positive mechanical connection between the corner post assemblies300and the floor assembly100.

Referring toFIGS. 3 and 14, a structural wall panel202is shown. The wall panel202constitutes one of a plurality of like-configured panels in the system used to construct the left, right, front and rear wall assemblies200,500,600. The structural wall panels202are each configured having a first longitudinal end208including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets210. A second longitudinal end212also including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets210. The sockets210are generally constructed and arranged to cooperate with either a floor assembly100or a roof assembly400to facilitate mechanical connection in a generally perpendicular relationship. The outer surface256and inner surface258of the panels202are constructed generally smooth having a plurality of ribs260, extending from the first edge214across the panel202to the second edge222, for added strength and aesthetic appearance. The ribs260increase the structural integrity of the enclosure10by preventing the panels202from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure10.

To facilitate mechanical connection with other structural wall panel members202in a co-planar relationship the panels are provided a first horizontal edge214constructed with a fifth means of attachment illustrated herein as a plurality of sockets330. The sockets include an inner wall316, an outer wall318, and a bottom wall320. The bottom wall includes an aperture321(FIG. 12) or notch therethrough for cooperative engagement with a hook-lock322included on an adjacently positioned wall panel or corner post. For additional structural rigidity between the side wall panels or between the side wall panels and the floor assembly, the wall panels may also include a groove216. The groove extends along first and second longitudinal ends as well as along the first horizontal edge of the panels. The groove216is arranged to cooperate with a corner post assembly300, wall panel member202, or floor assembly100having a complimentary ridge180in an interlocking coplanar relationship. The ridge180extends from about the first longitudinal end208of each panel to about the second longitudinal end212of each panel along the second edge222of the panels. An additional ridge180(FIGS. 4 and 5) extends around the perimeter of the floor assembly. The cooperation between the floor assembly ridge and wall panel groove provides a weather and insect resistant seal around the lower perimeter of the enclosure.

The second horizontal edge222of each wall panel is constructed generally flat having a plurality of outwardly extending bosses334. The bosses are constructed and arranged to cooperate with sockets330integrally formed into the second edge of the wall panel202. A portion of the bosses include integrally formed hook-locks322for cooperation with the apertures or notches321provided in the first member of the corner post assembly or first edge of the wall panels. In addition, the side surfaces of the bosses may include a ramp-lock250(FIG. 17) having a ramping surface254constructed to cooperate with apertures252positioned along the inner wall316.

Referring toFIGS. 14-17, engagement of the bosses334and sockets330is illustrated. The wall panels202are attached together by sliding the bosses of one panel into the sockets of an adjacently positioned wall panel (FIG. 15) and thereafter sliding the wall panel downward to engage the hook-locks (FIG. 16). In addition to engagement of the hook-locks, the downward motion preferably causes the ramping surface254to flex the inner wall316until the ramp-lock250slips through aperture252allowing the inner wall to return to its normal position, locking the wall panels in an engaged position. The result is a positive mechanical connection between the wall panels. The overlapping connection between the panels resists weather infiltration and prevents lifting of the panels under high wind loads.

Referring toFIGS. 15-17, and20, a door frame750member is attached to a wall panel202. The door frame member includes at least one hinge pin conduit718and a pair of hinge pin clearance pockets728integrally formed thereto. The door frame member also includes a door seal752integrally formed thereto to provide a weather resistant seal to the door assembly700. The wall panel202and the door frame member750are attached together by sliding the bosses of the panel into the sockets of the adjacently positioned door frame member, as shown inFIG. 15, and thereafter sliding the wall panel downward to engage the hook-locks, as shown inFIG. 16. In addition to engagement of the hook-locks, the downward motion preferably causes the ramping surface254to flex the inner wall316until the ramp-lock250slips through aperture252allowing the inner wall to return to its normal position locking the wall panels in an engaged position. The result is a positive mechanical connection between the wall panel and the door frame member750.

Referring toFIGS. 21-23, the wall panels202are attached to the interconnected floor-panels102and corner post assemblies300by sliding the first longitudinal end of a wall panel208over a plurality of the bosses116. The pockets210in each end of the panels202correspond in shape and size to that of the bosses116and spring tabs126(FIG. 8) integrally formed into the bosses116align with apertures234in the pockets210to engage the wall panel202. The result is a positive mechanical connection between the wall-panels200and the floor assembly100. The first wall panel being attached to the floor assembly100and the corner post assembly300with the first longitudinal end208downward interlocking the two panels via the ridge, groove and boss arrangement extending along the sides of the wall panels. The second wall panel is thereafter attached in a coplanar relationship to the first panel interlocking the two panels via the ridge, groove, and boss arrangement extending along the sides of the wall panels. It will be appreciated that the purpose of the ridge180and the groove216arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The ridge180and the groove216are brought into an interlocking relationship wherein the ridge180enters the corresponding groove216(FIG. 17). The result is a mechanically secure connection between the two panels. The interlocking edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for I-beam connectors. Second, the design allows the panels to be formed at sufficient height for a walk-in enclosure by creating a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another. Fourth, the design provides a sealed connection between the panels preventing weather infiltration. The resultant wall created by the combination of the interlocking wall panels benefits from high structural integrity and reliable operation.

Referring toFIGS. 18-19, a wall panel reinforcement channel701is illustrated. The side wall reinforcement channel is generally C-shaped and includes a first end740, a second end742, an inner surface746, and an outer surface747. The inner surface includes a plurality of formed flexible hooks748. Each flexible hook includes a barb749. In operation the reinforcement channel is attached to the inner socket wall316of a pair of assembled wall panels202by inserting the flexible hooks through apertures254until the barbs710engage the inner surface of the socket330. The reinforcement channels are preferably constructed of steel or other suitable metal and provide significant rigidity and weight carrying capacity to the wall assemblies. In addition, the reinforcement channels prevent the panels202from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure10. Still yet, the reinforced ribs provide support for optional cantilever shelves800(FIG. 45-46) or stackable shelves900(FIGS. 47-50) by distributing any load applied to the shelves across the length of the wall panels.

Referring toFIGS. 3,24and25, the door assembly700is illustrated. The door assembly includes a pair of door panels702, a pair of door frame members750, a hinge means720, a door handle assembly726,728, and a latch assembly724. The door panel702constitutes one of a plurality of like-configured panels in the system used to construct the door assembly. The door panels702are configured each having a first longitudinal end708, a second longitudinal end712, an inner surface704, an outer surface706, a first edge714, and a second edge716. To facilitate mechanical connection with door frame members750in a pivoting, relationship the first edge of the panels are provided with a pair of circular hinge conduits718and a hinge pin720. The hinge conduits and hinge pin are constructed and arranged to cooperate with hinge pins and conduits integrally formed onto the door frame members750to allow pivoting movement of the door panel. The second horizontal edge716is constructed generally flat with the exception of an optional overlapping seal722(FIG. 3) extending the full length of the panel. The optional overlapping seal722may be attached by any suitable fastening means well known in the art or may be integrally formed with the panel. The door panels702are also provided with an upper and lower sliding latch mechanism724(FIGS. 24-25) as well as left and right door handles726,728(FIG. 3).

Continuing with regard toFIGS. 3,24and25, the outer surface706of the panels702are constructed generally smooth having a plurality of raised panels726for added strength and aesthetic appearance. The inside surface of the panel704is constructed with a plurality of raised panels726for added strength and aesthetic appearance. The raised panels726increase the structural integrity of the enclosure10by preventing the panels702from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure10.

Referring toFIGS. 26-27, the door panels702are attached to the interconnected floor panels100, left and right corner post assemblies300, and front wall assembly600by sliding the respective hinge pin720into the corresponding hinge conduits718located along the edge of the door frame750and the front end member of the floor assembly. Either door panel702is aligned with the hinge pins by sliding it vertically into place over the respective pins. It should be appreciated that this construction provides economic advantage allowing hinge components to be integrally formed onto the door panels. The door panels are also provided with removable and replaceable door latching mechanisms including slide latches724, left door handle726and right door handle728(FIG. 3).

Referring toFIGS. 24-25, installation of the upper and lower slide latches724is illustrated. The slide latches are constructed and arranged to allow simple push-in installation. The latch housings730are merely pushed into apertures732located adjacent to edge716in the door panels702until the spring clips (not shown) engage an inner surface of the panel. Thereafter the one end of the door latch pin734is inserted through the housing730and downwardly until spring clip736is snapped into place. In this manner the door latches can be installed and removed as needed without the need for tools or screw type fasteners. By sliding the latch pin734to extend it outwardly to engage the roof assembly400or the floor assembly100, the contents contained within the enclosure10are secured. The door handles726,728are constructed and arranged to allow simple push-in installation. The handles are merely pushed into apertures738contained in door panels702until the spring clips (not shown) engage an inner surface of the panel702. In this manner the door handles can be installed and removed as need without the need for tools or screw type fasteners. The handles are also provided with lock apertures allowing the contents contained within the enclosure to be secured with a padlock or the like.

Referring toFIGS. 28-32the roof assembly400includes a pair of like constructed header assemblies450. The header assembly is a truss like structure molded with an aesthetically pleasing generally smooth wall on its outer surface452and integrally formed box bracing454and a plurality of pockets456constructed and arranged to accept roof support beams on its inner surface454. In the preferred embodiment the header is constructed of a center member472and a pair of outer members474. This construction permits the center member to be exchanged for narrower or wider members to construct different sized enclosures while the outer members may remain the same. Each member of the header assembly includes an upper surface458and a lower surface460. The lower surface460includes a third means of connection illustrated herein as a plurality of inwardly extending engagement sockets462constructed and arranged to cooperate with removable and replaceable bosses464and/or door hinge pins466. The bosses464or hinge pins466are slid into their respective engagement sockets462until the integrally formed spring tabs468engage corresponding apertures470formed in the engagement sockets. The end surfaces476,478of the members include a ninth means of connection illustrated herein as a plurality of outwardly extending inter-fitting tubes480. The tubes are constructed and arranged to extend into an adjacently positioned header member until integrally formed spring locks engage. This construction provides a load distributing connection between the members that prevent separation and bowing of the assembly under load. In addition, the design provides a sealed connection between the panels preventing weather infiltration. The resultant header created by the combination of the interlocking members benefits from high structural integrity and reliable operation.

The front header is assembled to the floor and wall assemblies by sliding the hinge pins466into their respective hinge conduits718while simultaneously sliding the locking bosses464into the wall sockets210until the integrally formed spring clips engage the apertures234formed into the wall panels. The result is a positive lock that maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another.

Referring toFIGS. 28,33, at least three and up to five roof supports482are inserted into their respective pockets456in each of the headers and secured in place with suitable fasteners. The support beams482are preferably constructed of steel, but may be constructed of other materials well known in the art capable of providing structural support to the roof assembly; such materials may include but should not be limited to plastic and/or wood as well as suitable combinations thereof.FIG. 33is shown with a portion of the enclosure omitted for clarity, illustrating the placement of the support beams482in the preferred embodiment. The roof assembly400also includes a plurality of like constructed ridge cap members484and a plurality of like-constructed roof panels402. Each ridge cap member484includes a tenth means of connection illustrated herein as at least one outwardly extending boss486and at least one socket488for securing the ridge cap members together. The ridge cap members484are slid together until the ramp-locks490integrally formed into the bosses486engage corresponding apertures (not shown) formed in the sockets488. The assembled ridge cap is slid into place over the headers and fastened in cooperative engagement with the support beams482and the headers450. Ramp-locks490(FIG. 38B) integrally formed into the front surface452of the headers450cooperates with apertures492formed into a front depending wall494(FIG. 38A) to secure the ridge cap assembly in place. As the ridge caps are pushed into place over the header the depending wall is deflected by the ramp-lock until the aperture492snaps over the ramp-lock to secure the ridge cap assembly in place.

Referring toFIGS. 28-41, each roof panel has a top surface404, bottom surface406, a first locking edge408, a second locking edge410, a third locking edge412and a closed edge414. Along the bottom surface406adjacent to the closed edge412is a fifteenth means of connection illustrated herein as a plurality of sockets416constructed and arranged to receive roof connectors418. The roof connectors are constructed and arranged to cooperate with pockets210located at second longitudinal end212of the structural wall panels202as well as the sockets416located on the lower surface406of the roof panels402. A series of spaced apart structural ribs420extend across the lower surface of each roof panel402to provide increased weight carrying capacity to the roof assembly400. The first and second locking edges of the roof panel402include a thirteenth and fourteenth means of connection illustrated herein as a W-shaped overlapping connection416(FIG. 40). The distal portion418of the first edge overlapping connection including a plurality of ramp-locks490arranged to cooperate with apertures492formed into the second edge overlapping connection. The W-shaped overlapping connection provides a water resistant seal between the panels and prevents the panels from bowing or separating under wind or snow loads. The third locking edge408of each roof panel402includes a twelfth means of connection illustrated herein as an interlocking tube422constructed and arranged to cooperate with a ridge cap484having a conjugately shaped receiver424(FIG. 41) to create a weather resistant seal. The roof panels402are slid into the receiver424until the integrally formed ramp-locks490engage corresponding apertures formed in the ridge cap484. For interlocking cooperation between the roof panels402and the roof supports482a sixteenth means of connection is provided. The sixteenth means of connection is illustrated herein as a second roof connector420. The second roof connector includes a first boss end423constructed and arranged to cooperate with sockets416and a second end424constructed and arranged to cooperate with the roof supports482. For installation, the third edge of each roof panel is secured to the ridge cap and the closed edge is pivoted downward to engage the first and second roof connectors.

Referring toFIGS. 42-44a cupola800is illustrated. The cupola includes a pair of side walls802and a front and rear wall804. The cupola is generally constructed and arranged for shipment in a disassembled state and may thereafter be assembled at a desired site. The edges of the side panels are preferably constructed to receive the edges of the front and rear panels in an interlocking relationship. Thereafter the top panel may be assembled to the side walls to finish assembly of the cupola. In one embodiment the lower portion of the cupola side walls are contoured to fit over the ridge cap of the instant embodiment. The cupola may be secured to the enclosure by any suitable means which may include fasteners, spring locks, ramp-locks or suitable combinations thereof.

Referring toFIGS. 45-46installation and assembled views of cantilever type modular shelving800are illustrated. The cantilever shelving includes cantilever wall mounts802constructed and arranged to cooperate with wall panels202for snap-in engagement. The cantilever shelf804is constructed and arranged to snap into engagement with the wall mounts. This arrangement permits assembly without the need for fasteners. The plurality of apertures254formed into the inner surface of the wall panels permits the shelving to be mounted in various predetermined positions within the enclosure to suit a user's needs.

FIGS. 47-50illustrate assembly of stackable shelving850. The stackable shelving includes at least two horizontal members852, at least two vertical members854, and a shelf member856. The horizontal members are constructed and arranged to cooperate with aperture254formed into the inner surface of the wall panels at a first end and the vertical members854at a second end. The bottom portion of the vertical members include an integrally formed projection for interlocking cooperation with an indentation856(FIG. 47) formed into the upper surface of the floor panels102. Additional shelves may be added to the assembly in a vertical manner by engaging additional vertical members into sockets858formed into the upper surface of the horizontal member852and thereafter assembling additional horizontal members thereto.

Referring toFIGS. 51-53, alternative embodiments of the present invention are shown wherein the enclosures are made larger by adding floor panels, roof panels, and adding additional side wall panels. The enlarged enclosures may also include additional door panels to facilitate entering the shed at more than one position. In this manner the same construction can be utilized to build structures of varying size utilizing substantially the same components.