Patent Publication Number: US-6701678-B1

Title: Modular storage enclosure

Description:
FIELD OF THE INVENTION 
     The present invention relates to a storage enclosure, and more particularly to a modular storage enclosure. 
     BACKGROUND OF THE INVENTION 
     Storage enclosures such as sheds typically include a set of walls, a door, a floor, and a roof. The walls, roof, or floor may be formed by assembly and attachment of a plurality of separate panels using fasteners such as screws, bolts, nails, and pins. Additionally, such storage enclosures are generally used for storing items such as lawn care tools and equipment, recreational equipment, athletic equipment, and the like. Storage of such items within known storage enclosures may include installation of organizational devices (e.g., shelves, boxes, bins, and the like) that are free-standing or fastened to a wall. Hooks, tool hangers and other accessories that assist in storing of items may be fastened to the walls using fasteners such as screws, bolts, nails, staples, or the like. 
     Known storage enclosures have several disadvantages. For example, many known storage enclosures require a substantial amount of time, labor, planning, and skill to install, configure and reconfigure (if reconfigurable at all). Assembly or installation of organizational devices is inefficient due to a large number of necessary structural components and fasteners and incompatibility of different products from different manufacturers. Also, fasteners used to attach organizational devices to the walls of the storage enclosure may be invasive or destructive to the walls. Additionally, known methods of coupling adjacent panels to form walls or the roof are also destructive or invasive to the components themselves, making the sheds difficult to modify or rearrange. Such problems may discourage use, reconfiguration, and reorganization of the sheds and associated organizational devices. 
     To provide an inexpensive, reliable, and widely adaptable technique of securing organizational devices or other accessories to a wall of a storage shed, or to couple adjacent wall panels, that avoids the above-referenced and other problems, would represent a significant advance in the art. 
     SUMMARY OF THE INVENTION 
     A primary feature of the present invention is to provide an inexpensive, easy-to-manufacture, and aesthetically pleasing storage enclosure that overcomes the above-noted disadvantages. 
     Another feature of the present invention is to provide attachment interfaces for a wide variety of modular organizational devices or other accessories that reduce manufacturing assembly costs in many applications, and that are quickly and easily reconfigurable. 
     Another feature of the present invention is to provide structural components for a storage enclosure (such as walls, roof, etc.) that are relatively quickly and easily assembled and disassembled, configured or reconfigured, and the like. 
     Another feature of the present invention is to provide a storage enclosure that is lightweight and yet provides suitable strength and rigidity as a storage enclosure or as a display panel. 
     How these and other advantages and features of the present invention is accomplished, individually, collectively, or in various subcombinations, will be described in the following detailed description of the preferred and other exemplary embodiments, taken in conjunction with the FIGURES. Generally, however, they may be accomplished in a storage enclosure including a plurality of panels defining an interior space. At least one of the plurality of panels includes a mounting interface configured to couple an accessory to one of the plurality of panels, and a panel interface configured to couple adjacent panels. 
     These and other advantages and features of the present invention may also be accomplished in a storage enclosure including a plurality of panels defining an interior space. At least one of the plurality of panels includes a mounting interface configured to couple an accessory to one of the plurality of panels. The mounting interface includes a flange that defines a receptacle. 
     These and other advantages and features of the present invention may further be accomplished in a panel including a mounting interface configured to couple an accessory to the panel. The mounting interface includes a flange which defines a retaining profile. 
     The disclosed embodiments further relate to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the present invention is accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the claims which follow. 
    
    
     DESCRIPTION OF THE FIGURES 
     FIG. 1 is an exploded perspective view of a modular storage enclosure according to an exemplary embodiment. 
     FIG. 2 is perspective view of an exterior surface of a panel for the modular storage enclosure of FIG.  1 . 
     FIG. 3 is a perspective view of an interior surface of the panel of FIG.  2 . 
     FIG. 4 is a sectional view of the panel of FIG. 2 taken along line  4 — 4 . 
     FIG. 5 is a sectional view of the panel of FIG. 3 taken along line  5 — 5 . 
     FIG. 6 is a fragmentary perspective view of the panel of FIG.  3 . 
     FIG. 7 is an exploded schematic perspective view of an accessory and mounting brackets according to an exemplary embodiment. 
     FIG. 8 is a perspective view of an accessory with mounting brackets according to an exemplary embodiment. 
     FIG. 9 is an exploded perspective view of a mounting bracket of FIG.  8 . 
     FIG. 10 is an exploded perspective view of an accessory according to an exemplary embodiment. 
     FIG. 11 is a fragmentary side elevation view of the panel of FIG.  3 . 
     FIG. 12 is a fragmentary perspective view of the panel of FIG.  2 . 
     FIG. 13 is a fragmentary perspective of the panel of FIG.  3 . 
     FIG. 14 is a fragmentary sectional view of the modular storage enclosure. 
     FIG. 15 is a fragmentary sectional view of the modular storage enclosure. 
     FIG. 16 is a fragmentary side elevational view of the panel of FIG.  2 . 
     FIG. 17 is a fragmentary perspective view of the panel of FIG.  3 . 
     FIG. 18 is a fragmentary perspective view of the panel of FIG.  2 . 
     FIG. 19 is a fragmentary sectional view of the modular storage enclosure. 
     FIG. 20 is a fragmentary sectional view of the modular storage enclosure. 
     FIG. 21 is a perspective view of a connector according to a preferred embodiment. 
     FIG. 22 is a perspective view of the connector of FIG.  21 . 
     FIG. 23 is a fragmentary sectional view of the connector and panels. 
    
    
     DETAILED DESCRIPTION OF PREFERRED AND OTHER EXEMPLARY EMBODIMENTS 
     Before proceeding to the detailed description of the preferred and exemplary embodiments, several comments can be made about the general applicability and the scope thereof. 
     First, the exemplary embodiments described herein are configured to provide an inexpensive and efficient enclosure for manufacturing, shipping, storing, displaying, assembling, reconfiguring and modifying a modular storage enclosure. The modular storage enclosure may be sold as a kit or the individual structural components may be sold separately (i.e., “a la carte”) so that the consumer may purchase the appropriate components according to his or her desired dimensional and accessory configuration, for repair or replacement, or for reconfiguration of an existing storage enclosure. 
     Second, while the components of the disclosed embodiments will be illustrated as a shed, the features of the disclosed embodiments have a much wider applicability. For example, the accessory mounting interface design can be used for other storage devices, units, enclosures, boxes, bins, storage containers, display panels or boards, vehicle storage containers, totes for storing camping or other outdoor recreation gear, and other office or home organization and storage products. Also, the connectors can be used for any of a variety of containers that are made from a variety of materials such as plastics, wood, metal, or metal alloys. Further, the size of the various components and the size of the enclosures can be widely varied. 
     Third, the particular materials used to construct the exemplary embodiments are also illustrative. For example, blow molded high density polyethylene is the preferred material and method for making the panels, roof, and doors, but other materials can be used, including other thermoplastic resins such as structural foam polypropylene, polypropylene, acrylonitrile butadiene styrene (“ABS”), polyurethane nylon, any of a variety of homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form these components, such as injection molding, rotational molding, etc. Also, injection molded high density polyethylene is the preferred material and method for making the connectors, but other materials can be used, including other thermoplastic resins such as polypropylene, polyethylene, acrylonitrile butadiene styrene (“ABS”), polyurethane nylon, any of a variety of homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form these components. Alternatively, the panels and/or connectors may be made from other materials including metal, wood, and the like. Also, the panels and/or connectors may be from a variety of manufacturing techniques such as stamping of sheets, casting, machining, and the like. 
     Proceeding now to descriptions of the preferred and exemplary embodiments, FIG. 1 is an exploded perspective view of a storage enclosure  10  according to an exemplary embodiment. Storage enclosure  10  is shown as a modular structure that includes a floor assembly  12 , a wall assembly  14 , a door assembly  16 , and a roof assembly  18 . Floor assembly  12  forms a perimeter or a footprint for storage enclosure  10 , and includes a plurality of floor panels  20 . According to a preferred embodiment, floor panels  20  are coupled by interlocking teeth which provide a snap-fit engagement when assembled. According to an alternative embodiment, floor panels  20  include interfaces that are coupled together using any of a variety of fasteners. 
     Wall assembly  14  includes a plurality of panels (shown as side panels  22 , rear panels  24 , front panels  26 , and door panels  28 ) coupled to floor assembly  12  and roof assembly  18 . Each of the panels include an exterior face  30  and an interior face  32 . According to a preferred embodiment, exterior face  30  of the panels include channels  34  that are configured to provide an ornamental appearance, drainage properties, and additional rigidity. Alternatively, exterior face  30  of the panels may be generally flat or have any of a variety of cosmetic and/or functional textures or configurations. 
     Each of the panels also include a plurality of multi-functional mounting interfaces  36 , a plurality of panel or connector interfaces  38 , a plurality of roof interfaces  40 , and a plurality of floor interfaces  42 . According to a preferred embodiment, mounting interfaces  36 , connector interfaces  38 , roof interfaces  40 , and/or floor interfaces  42  are integrally formed with the panel (e.g., as a single, one piece molded article). 
     Referring to FIGS. 3 and 6, mounting interfaces  36  are disposed between a plurality of ribs  44 , and are configured to provide a retaining profile for coupling any of a variety of items (e.g., accessories such as tools), structural reinforcement, shelving, work surfaces, and the like. According to a preferred embodiment, mounting interface  36  is located on interior face  32  of the panel. Alternatively, mounting interface  36  may be located on exterior surface  30  of the panel (e.g., so that accessories may be attached to the exterior of enclosure  10 ). 
     According to an exemplary embodiment, mounting interface  36  includes a pair of opposing flanges  48  that define a slot  50  and a pocket or receptacle  52 . According to a preferred embodiment, flanges  48  are configured to provide a “dovetail” cross section so that an accessory may be inserted and slid into a secure engagement with the panel. Flanges  48  extend from sidewalls  54  of ribs  44  such that slot  50  has a varying width (e.g., slot  50  is tapered such that wider nearest its top portion than at its bottom portion). According to an alternative embodiment, multi-functional mounting interface  36  may be provided by any of a variety of shapes or configurations of retaining profiles configured to capture the accessory. 
     Referring to FIGS. 7-10, accessories are configured to be coupled to one or more of the panels to provide a variety of modular functionality, including support or organizational structures (such as shelving, hooks, etc.), work surfaces (such as desks, workbenches, countertops, etc.), containers, and the like. According to a preferred embodiment shown in FIG. 7, the accessory (shown as a rack  56 ) is mounted to the panel with a mounting bracket  58 . Mounting bracket  58  includes a base  60 , a projection  62  extending from base  60 , and an accessory interface  64 . Projection  62  is configured to engage mounting interface  36  and includes a head  66  connected to base  60  by a stem  68  which has a smaller cross-sectional dimension than head  66 . Preferably, slot  50  has a tapered width wherein the wider end is nearest recess  46 . Also preferably, head  66  and stem  68  are shaped to provide a snug fit with receptacle  52  and slot  50 , respectively. Mounting bracket  58  engages mounting interface  36  by positioning projection  62  between ribs  44  and sliding mounting bracket  58  downward so that head  66  is disposed in receptacle  52  and stem extends through slot  50 . 
     Accessory interface  64  is also configured to engage rack  56 . Accessory interface  64  includes a base  70  and a projection  72 . Base  70  is configured to provide a support surface for the accessory. Projection  72  is configured to engage the accessory by extending through an aperture  74  in rack  56 . Rack  56  includes a plurality of spaced apart support members  76  configured to support one or more items (e.g., stick goods such as a broom  78 , a work surface (not shown), tools, lawn care equipment, cleaning implements, etc.). Alternatively, accessory interface  64  may be used to couple any of a variety of storage devices or accessories to the panels. 
     Referring to FIGS. 8 and 9, the accessory is shown as a shelf assembly  80 . Shelf assembly  80  includes a mounting bracket  82  and a panel  84  supported by mounting bracket  82 . Mounting bracket  82  includes a frame  86  and a projection (shown as a hook  88 ) extending from frame  86 . Hook  88  includes a downward portion  90  configured to engage mounting interface  36 . According to a preferred embodiment, hook  88  is a flat member that is inserted into recess  46  and lowered so that downward portion  90  is disposed in receptacle  52  and held in place by flanges  48 . Frame  86  includes a base member  92  and a shelf support member  94 . Base member  92  and/or shelf support member  94  may include a projection  96  for supporting or suspending one or more items. 
     Referring to FIG. 10, the accessory is shown as a shelf assembly  98  according to an alternative embodiment. Shelf assembly  98  includes a mounting bracket  100  and a panel  102  supported by mounting bracket  100 . Mounting bracket  100  includes a frame  104  and a projection  106  extending from frame  104 . Projection  106  is configured similarly to projection  96  shown in FIG. 7 or projections  108  shown in FIG.  21 . Projection  106  includes a head and stem configured to engage flanges  48  of mounting interface  36 . Frame  104  includes a base member  110 , a shelf support member, and a brace member  112 . According to a preferred embodiment, panel  102  includes a plurality of vertical grooves  114  along edges  116  that are configured to receive ends  118  of brace member  112 . As such, panel  102  may be supported by a selectable number of mounting brackets  100 , depending on expected load forces, desired strength, panel configuration (e.g., some panels may have more or fewer spaced apart mounting interfaces  36 ), and the like. Panel  102  and/or mounting bracket  100  may also include one or more hooks  120 . 
     Also disposed between ribs  44  are a plurality of recesses  122  (also known as “tack-offs”), which are compression points wherein an interior face  32  contacts or joins to an exterior face  30 . According to a preferred embodiment, interior face  32  and exterior face  30  contact during the blow molding operation and solidify together to provide rigidity and strength to the panel, and to prevent interior and exterior faces  32 ,  30  from sliding with respect to one another. 
     Referring to FIGS. 3,  6 , and  23 , connector interface  38  is configured to provide a retaining profile for receiving a connector  128  that couples adjacent panels (e.g., adjacent rear panels  24 , adjacent side panels  22 , etc.). According to a preferred embodiment, connector interface  38  is located on interior face  32  of the panel. Alternatively, connector interface  38  may be located on exterior face  30 . 
     Connector interface  38  includes a recess  130  and a pair of flanges  132  that define a slot  134  and a receptacle  136 . Recess  130  is disposed above opening of flanges  132  and is configured to provide an area to align and receive connector  128 . According to a preferred embodiment, connector interface  38  is a “dovetail” cavity. 
     Referring to FIGS. 1,  3 ,  6 , and  20 - 23 , connector  128  includes a base  138  and one or more projections  140  extending from base  138 . Base  138  may have any of a variety of shapes and configurations and may include one or more reinforcement ribs  142  configured to provide additional strength and rigidity to connector  128 . Projections  140  are configured to engage flanges  132  in connector interface  38  on the panels. According to a preferred embodiment, projections  140  include a head  144  and a stem  146  which has a smaller cross sectional dimension than head  144  (e.g., “T”-shaped, or the like). Connector  128  engages connector interfaces  38  by inserting projection  140  into recess  130  and sliding connector  128  downward so that head  144  is disposed in receptacle  136  and stem  146  extends through slot  134  when connector  128  is engaged with a panel. Alternatively, projections  140  provide any of a variety of peripheral cross-sectional shapes that coincides with the shape of receptacle  136  of the retaining profile to provide a snug or secure engagement between connector interface  38  and side panel  22 . 
     Referring to FIGS. 1-3,  5 ,  16 ,  19 , and  20 , side panels  22 , rear panels  24 , and front panels  26 , each include floor interface  42  configured to couple the panels to floor assembly  12 . Floor interface  42  includes a fin or flange  150  that extends below each of the panels and includes one or more detents  152 . Detents  152  include a catch surface  154  extending generally perpendicular to flange  150  and a ramped surface  156 . Ramped surface  156  of flange  150  is inserted into slots or apertures  158  in floor panels  20  so that catch surface  154  engages a bottom surface  160  (e.g., in a snap-fit arrangement). Preferably, detents  152  are configured to allow removal from apertures  158  in floor panels  20  (e.g., for disassemblying, reconfiguration, etc.) 
     Referring to FIGS. 1-3,  5 ,  11 ,  14 , and  15 , side panels  22  each include roof interface  40  configured to couple side panels  22  to roof assembly  18 . Roof interface  40  includes a fin or flange  162  that extends above each of side panels  22  and include one or more detents  164 . Detents  164  include a catch surface  166  extending generally perpendicular to flange  162 , and a ramped surface  168 . Ramped surface  168  of flange  162  is inserted into slots or apertures  170  in roof panels  172  so that catch surface  166  engages a bottom surface  174  (e.g., in a snap-fit arrangement). Preferably, detents  164  are configured to allow removal from apertures  170  in roof panels  172  (e.g., for disassemblying, reconfiguration, etc.) 
     Referring to FIGS. 1,  14 , and  15 , roof assembly  18  includes a plurality of roof panels  172  coupled to side panels  22  and a pair of gables  184 . Adjacent roof panels  172  are coupled by a plurality of roof connectors  186  which engage connector interfaces (not shown) on roof panels  172 . Roof panels  172  include one or more channels  188 , which are configured to provide drainage and additional rigidity. According to a preferred embodiment, roof assembly  18  is configured as a pitch or angled roof, and includes a ridge beam  190  that couples opposing roof panels  172 . According to alternative embodiments, roof assembly  18  may have any of a variety of shapes and configurations configured to provide a cover to enclosure  10 . 
     Referring to FIGS. 1,  6 , and  20 - 22 , roof assembly  18  includes plurality of roof panels  172  coupled to side panels  22  and a pair of gables  184 . Adjacent roof panels  172  are coupled by a plurality of roof connectors  186  which engage connector interfaces (not shown) on roof panels  172 . Roof panels  172  include one or more channels  188 , which are configured to provide drainage and additional rigidity. According to a preferred embodiment, roof assembly  18  is configured as a pitched or angled roof, and includes a ridge beam  190  that couples opposing roof panels  172 . According to alternative embodiments, roof assembly  18  may have any of a variety of shapes and configurations configured to provide a cover to enclosure  10 . 
     Gables  184  include a ridge beam interface  192  and panel interfaces  194 . Ridge beam interface  192  includes a plurality of ribs or flanges  196  configured to engage the profile of ridge beam  190 . Preferably, ridge beam interface  192  includes a surface  198  configured to support ridge beam  190  and thus a portion of the weight of roof assembly  18 . During assembly, roof panels  172  engage ridge beam  190  at an approximately horizontal orientation, and are then rotated approximately 25° to interlock protrusions on roof panels  172  to ridge beam  190  to capture ridge beam interface  192  on gables  184 . Panel interface  194  includes a member  200 . Member  200  extends downwardly from gable  184  and includes projections  204  (i.e., similar to the “T”-shaped projections shown on connector  128  in FIG. 20) configured to engage slots  202  on rear panel  24  or front panel  26 . During assembly, projections  204  engage slots  202  (e.g., dovetail cavities or the like). Gable  184  may also have a plurality of ribs or fins  206  configured to provide additional strength and rigidity. 
     It is also important to note that the construction and arrangement of the elements of the modular storage enclosure as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the mounting interfaces for accessories may be used in a panel that is mounted on a wall (e.g., near a workbench, in an office environment, at a work site, in other industrial or institutional environments). Also, a panel with the mounting interfaces may be used individually as a separate, stand alone structure. Further, it is important to note that the terms “storage enclosure,” “interface,” and “accessories,” are intended to be broad terms and not terms of limitation. The interfaces and connectors may be used with any of a variety of products or arrangements and are not intended to be limited to use with storage enclosures or sheds, but are intended to be used with any arrangement where modular, selective, or custom configuration or coupling is employed. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims.