Abstract:
The present invention provides a system which includes injection molded floor panels having integrated connectors which combine to form a family of variously sized floor assemblies for utility enclosures. The floor panels are formed of injection molded plastic to create light-weight panels having integrally formed ribs and gussets for strength and integrity. The injection molding also facilitates integrally formed connectors so that the panels interlock with one another without the need for separate connectors. The outer ends of the floor panels have integrally formed apertures constructed for interlocking cooperative engagement with a plurality of wall bosses to rigidly connect the wall panels together with the floor assembly in a perpendicular relationship.

Description:
RELATED APPLICATIONS  
       [0001]     This application is a continuation of utility patent application entitled Plastic Expandable Utility Shed filed Aug. xx, 2005, the contents of which are herein incorporated in their entirety. This application is also related to Ser. No. 29/230,885 filed May 27, 2005, the contents of which are herein incorporated by reference in their entirety. This application is also related to Ser. No. 29/230,978 filed May 27, 2005, the contents of which are herein incorporated by reference in their entirety.  
       FIELD OF THE INVENTION  
       [0002]     This invention relates generally to expandable plastic utility sheds, and more specifically to a modular flooring system constructed of injection molded plastic panels for creating utility shed floors of various sizes from standardized components.  
       BACKGROUND OF THE INVENTION  
       [0003]     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, lawn tools and the like are stored within utility sheds for the convenience of the homeowner.  
         [0004]     The prior art has proposed a number of different panel systems, or kits, comprising blow molded and/or extruded panels which are combined with connector members for forming storage structures, e.g. utility sheds. Unfortunately, blow molding and/or extrusion of panels for utility sheds has resulted in shortcomings within the state of the art products. For example, due to the nature of the manufacturing process, blow molded and/or extruded plastic components cannot be formed with the intricate shapes and/or sharp corners required for integrated connectors. Therefore, these systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitate an engagement between the blow molded or extruded panels to complete the structure.  
         [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 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.  
         [0006]     Another drawback associated with blow molded panels is the requirement of an inner and an outer wall. The inner and outer walls are a necessary product of the blow molding manufacturing process. While the inner wall may add some rigidity to the panels, it also adds a significant amount of weight and dramatically increases the volume of plastic necessary to form a panel of a given size when compared to other methods of manufacturing, such as injection molding.  
         [0007]     In addition, because the blow molding process does not generally allow for supports to extend between the inner and the outer walls for load distribution, blow molded panels make weak floor structures. The panels are generally only connected around the perimeter, leaving the center area free of support. Therefore, when a heavy object such as a garden tractor traverses a blow molded panel, the center portion of the panel flexes downwardly distorting the floor structure. If a heavy object is left in place for an extended period of time the floor structure may be permanently distorted.  
         [0008]     Still yet another drawback associated with blow molded panels relates to accurate control of wall thickness throughout the panels. The blow molding process does not allow the wall thickness of the panels to be accurately controlled; once the molten plastic is conveyed to the tooling, there is minimal control over where the plastic flows during formation of the panel. In addition, the blow molding process does not allow the intentional formation of thick and thin sections within a single panel for engineered rigidity at the points of high stress or high load concentration.  
         [0009]     Extruded panels 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 also require connectors to achieve adequate length for utility shed floors. A common structure for connecting extruded members has a center I-beam with upper and lower protrusions for engaging the conduits. Floor panels utilizing these connectors are vulnerable to buckling under loads and may have an aesthetically unpleasing appearance. Moreover, loads from lawn tractors and the like may cause such floors to flex downwardly 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.  
         [0010]     Therefore, what is needed in the art is an injection molded modular floor system for utility enclosures. The modular floor system should achieve objectives such as lightweight single wall construction. The construction of the panels should eliminate the need for extruded I-beam connectors to create a floor assembly which resists panel separation, buckling, and racking. The floor assembly should be capable of withstanding the loads typically associated with utility enclosures. Also, from a convenience standpoint, the floor assembly should include features constructed to cooperate with shelving and/or other storage enhancements. In addition, the floor assembly should include convenience features that allow the doors to be latched in open, as well as closed, positions for easy loading and/or unloading of the enclosure.  
         [0011]     There are also commercial considerations that must be satisfied by any viable utility shed floor assembly or kit; considerations which are not entirely satisfied by state of the art products. The floor assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques, such as injection molding. The floor assembly must also be capable of being packaged and shipped in a knocked-down state. In addition, the floor assembly must be modular and facilitate the creation of a family of floor assemblies for enclosures that vary in size but which share common, interchangeable components.  
         [0012]     Finally, there are ergonomic needs that a floor assembly must satisfy in order to achieve acceptance by the end user. The floor assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the floor assembly must not require excessive strength to assemble or include heavy component parts. Moreover, the floor assembly 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.  
         [0013]     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. 10/729,689 filed Dec. 5, 2003, entitled Low Profile Plastic Panel Enclosure, and U.S. patent application Ser. No. 10/674,103 filed Aug. 29, 2003, entitled Plastic Expandable Utility Shed, the contents of which are incorporated herein in their entirety.  
       SUMMARY OF THE INVENTION  
       [0014]     The present invention provides a system including injection molded floor panels having integrated connectors which combine to form a family of variously sized floor assemblies for utility enclosures. The floor panels are formed of injection molded plastic to create light-weight panels having integrally formed ribs and gussets for strength and integrity. The injection molding also facilitates integrally formed connectors so that the panels interlock with one another without the need for separate connectors. The outer ends of the floor panels have integrally formed apertures constructed for interlocking cooperative engagement with a plurality of wall bosses to rigidly connect the wall panels together with the floor assembly in a perpendicular relationship.  
         [0015]     The system incorporates a minimum number of components to construct a large heavy duty enclosure floor 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 floor panels also minimizes component shapes and simplifies enclosure construction by not requiring the floor panels to be assembled into sub-assemblies. The heavy duty interlocking construction of the floor panels and the locking bosses create a structural floor assembly that allows construction of larger enclosures. Injection molding the floor panels allow them to be formed with various consumer convenience features such as anti-skid surfaces, shelving and bench alignment pockets, anchoring apertures and the like. Injection molding also allows the panels to be formed with integral cross-bracing, ribs, and gussets beneath the top surface for increased rigidity when compared to blow molded or extruded panels.  
         [0016]     The floor assembly 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 floor components may be 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.  
         [0017]     Accordingly, it is a primary objective of the instant invention to provide a plastic utility enclosure flooring assembly.  
         [0018]     It is a further objective of the instant invention to provide a plastic flooring assembly which utilizes floor panels having single wall construction with integrally formed ribs and gussets for a lightweight yet robust floor assembly.  
         [0019]     It is yet another objective of the instant invention to provide a plastic flooring system which accommodates injection molding plastic formation of the panel components for increased structural integrity.  
         [0020]     It is a still further objective of the instant invention to provide a flooring system in which the floor panel members include integrally formed connectors.  
         [0021]     Still another objective of the instant invention is to provide a flooring assembly which includes floor panels having predetermined sizes for creating enclosures of varying dimensions using common components.  
         [0022]     Yet another objective of the instant invention is to provide a flooring assembly which reduces the number of components required to assemble an enclosure and simplifies construction.  
         [0023]     Still yet another objective of the instant invention is to provide a floor assembly that includes removable and replaceable locking bosses.  
         [0024]     Still yet another objective of the instant invention is to provide a floor assembly having removable and replaceable front and rear end members.  
         [0025]     Other objectives 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  
       [0026]      FIG. 1  is a perspective view illustrating a floor assembly constructed with the teachings of the present invention;  
         [0027]      FIG. 2  is a top view illustrating a floor assembly constructed with the teachings of the present invention;  
         [0028]      FIG. 3  is a bottom view illustrating a floor assembly constructed with the teachings of the present invention;  
         [0029]      FIG. 4  is a top view illustrating a floor panel constructed with the teachings of the present invention;  
         [0030]      FIG. 5  is a top view illustrating a floor panel constructed with the teachings of the present invention;  
         [0031]      FIG. 6  is a perspective view illustrating assembly of a pair of floor panels constructed with the teachings of the present invention for creating a floor assembly having a predetermined width;  
         [0032]      FIG. 7  is a perspective view illustrating assembly of a plurality of floor panels constructed with the teachings of the present invention for creating a floor assembly having a predetermined length;  
         [0033]      FIG. 8  is a perspective view illustrating assembly of front and rear end portions;  
         [0034]      FIG. 9  is a partial perspective view taken along line  1 - 1  of  FIG. 1  illustrating features of the front end portion;  
         [0035]      FIG. 10  is a partial end view taken along line  2 - 2  of  FIG. 6  illustrating insertion of a locking boss into a floor panel aperture;  
         [0036]      FIG. 11  is a partial section view taken along line  3 - 3  of  FIG. 2  illustrating an assembled locking boss and floor panel;  
         [0037]      FIG. 12  is a partial section view taken along line  4 - 4  of  FIG. 2  illustrating an assembled locking boss and floor panel;  
         [0038]      FIG. 13  is a partial section view taken along line  5 - 5  of  FIG. 2  illustrating an assembled locking boss and floor panel;  
         [0039]      FIG. 14  is a partial section view taken along line  6 - 6  of  FIG. 8  illustrating assembly of the front end members to the assembled floor panels.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0040]     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.  
         [0041]     Referring to  FIGS. 1-14 , the floor assembly  100  includes a plurality of like-constructed floor panels  102 . Each panel has a top surface  104 , a 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 . Also adjacent to the closed edge is an integrally formed sealing ridge  184 . The sealing ridge is constructed and arranged with tapered side walls  186  to cooperate with a bottom surface of wall panels (not shown) to provide a weather resistant seal therebetween. In addition to providing the weather resistant seal, the sealing ridge cooperates with connected wall panels to provide consistent wall panel location that prevents the wall panels from rattling or moving during high wind loads.  
         [0042]     Referring to  FIGS. 4, 5 ,  10 - 12 , the bosses  116  are constructed and arranged to cooperate with wall panels (not shown) for connecting and maintaining a substantially perpendicular relationship between the wall panel members and the top surface of the floor panel members  102 . The locking bosses may be integrally formed as illustrated on the front and rear end members ( FIGS. 8 and 9 ). 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  ( FIG. 10 ) 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 second upper end  132  of the locking boss is preferably rectangular in shape when viewed from the top, however, other shapes suitable for locating and securing walls may be utilized without departing from the scope of the invention. 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.  
         [0043]     Referring to  FIGS. 1-8 , along the edges  110 ,  112 , and  114  of each floor panel  102  is the first means of connection illustrated herein as a series of spaced apart fingers  122  and recesses  124  for attaching the panels together into a floor assembly  100 , a portion of the fingers being provided with at least one countersank aperture  123  for receiving a fastener  113 . The fingers  122  and recesses  124  are constructed and arranged so that the fingers  122  of one panel overlap and mateably engage the recesses  124  of an adjacently positioned panel. The fasteners secure the panels together in an interfitting engagement with their respective top surfaces  104  in a co-planar arrangement. In a most preferred embodiment, a portion of the fingers  122  include an alignment boss  115  ( FIG. 13 ) projecting outwardly from a lower surface thereof. The alignment boss  115  mateably engages an alignment socket  117  positioned within an upper surface of an aligned recess  124 . In one embodiment the alignment boss may include an integrally formed spring clip (not shown) for interlocking engagement with the alignment socket  117 .  
         [0044]     Still referring to  FIGS. 1-8 , the floor panels  102  are interconnected to each other to form a utility shed floor assembly  100  having a width determined by the width of the panels and length determined by the number of panels assembled. The panels  102  may be manufactured having any suitable width as illustrated in  FIGS. 4 and 5  without departing from the scope of the invention. Opposing 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 as illustrated in  FIG. 6 . Adjacently positioned panels are assembled by sliding the panel inwardly toward other assembled panels at about a forty-five degree angle as illustrated in  FIG. 7 . This construction eliminates the need to assemble heavy and hard-to-manipulate sub-assemblies as shown in the prior art. The fingers  122  and recesses  124  along the second, third, and fourth edges of the floor panels  102  correspond 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 assembly  100 . 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. In this manner the same floor panels can be utilized to build structures of varying size utilizing substantially the same components.  
         [0045]     Referring to  FIG. 3 , the bottom surface of the floor assembly  100  is illustrated. The bottom surface  106  illustrates the cross-bracing  128  facilitated by injection molding of panels. Injection molding offers significant strength and stability advantages over blow-molding, extrusion or vacuum molding as utilized in the prior art. Injection molding also facilitates forming thicker and/or thinner portions within the floor panel members for areas of high or low stress concentrations. It should also be appreciated that the panels of the instant invention only require a single wall construction. In this manner, the enclosure of the instant invention is capable of handling a significant amount of weight while utilizing less plastic as compared to blow molded, vacuum formed or extruded enclosures.  
         [0046]     Referring to  FIGS. 1, 2 ,  8 ,  9 ,  13 - 14 , in addition to the floor panels, the floor assembly includes a front end assembly  142 . The front end assembly may include one or preferably two front end members  144 . Each front end member includes a top surface  146 , a bottom surface  156  ( FIG. 3 ), a first ramp edge  148 , a second edge  150  opposite the first edge, an outer edge  152 , and an inner edge  154 . The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members  102  to finish the front portion of the floor assembly  100 . The inner edges  154  include 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 edges  148  is a pair of integrally formed generally cylindrical hinge pins  176  extending upwardly. The hinge pins  176  cooperate with door panels (not shown) to allow pivotal movement. Adjacent to each of the hinge pins is a cylindrical boss  178  constructed and arranged to cooperate with a roof support pillar (not shown). The roof support is generally tubular and sized to encircle the cylindrical boss  178  as well as a like constructed cylindrical boss positioned on the bottom surface of a header assembly (not shown) to provide increased wind and snow load capacity to an enclosure. Also adjacent to the ramp edge is an integrally formed door stop  180 . The door stop is constructed and arranged to cooperate with the bottom surface of a door member to releasably secure the door member in an open position. The top surface of the front end member includes an integrally formed door bolster  182 . The door bolster provides support for the door members during high wind loads to prevent the door members from being forced inward. In addition, the door bolster prevents weather infiltration under the door member(s). The front end member also includes at least one door lifter  184 . The door lifter is constructed and arranged to cooperate with a lower surface of a door member to provide lift in the event that the door hinges become worn. In this manner the door will remain centered while in a closed position for improved aesthetic appearance.  
         [0047]     Referring to  FIGS. 1-3  and  8 , in addition to the floor panels, the floor assembly includes a rear end assembly  160 . The rear end assembly preferably includes two rear end members  162 . Each rear end member includes a top surface  164 , a bottom surface  166 , a rear closed edge  168 , a second edge  170  opposite the first edge, an outer edge  172 , and an inner edge  174 . The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members  102  to finish the rear portion of the floor assembly  100 . The inner edges  174  include 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  113  ( FIG. 13 ) 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.  
         [0048]     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.  
         [0049]     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.  
         [0050]     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.