Patent Abstract:
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.

Full Description:
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. 
   Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings 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 
       FIG. 1  is a front perspective view of an enclosure constructed using the instant utility enclosure system; 
       FIG. 2  is a rear perspective view of an enclosure constructed using the instant utility enclosure system; 
       FIG. 3  is an exploded view of the enclosure shown in  FIG. 1 ; 
       FIG. 4  is a perspective view of one embodiment of the floor assembly utilized in the instant invention; 
       FIG. 5  is an exploded perspective view of the floor assembly shown in  FIG. 4 ; 
       FIG. 6  is a bottom view of the floor assembly illustrating the integrally formed cross-bracing; 
       FIG. 7  is a partial section view taken along line  1 - 1  of  FIG. 4 , illustrating the connection between a floor panel and a locking boss; 
       FIG. 8  is a partial section view taken along line  2 - 2  of  FIG. 4 , illustrating the connection between a floor panel and a locking boss; 
       FIG. 9  is a partial section view taken along line  3 - 3  of  FIG. 4 , illustrating the connection between a floor panel and a front end assembly; 
       FIG. 10  is a partial perspective view taken along line  4 - 4  of  FIG. 4 , illustrating the lower hinge pin, door catch feature, a portion of the roof support structure, door gap seal, and wall key as utilized in the instant invention; 
       FIG. 11  is a perspective view illustrating one of the corner posts utilized in the instant invention; 
       FIG. 12  is a perspective view illustrating one of the corner posts utilized in the instant invention; 
       FIG. 13  is a perspective view illustrating assembly of first and second corner post members; 
       FIG. 14  is a rear perspective view illustrating a wall panel; 
       FIG. 15  is a partial section view illustrating assembly of adjacently positioned wall panels; 
       FIG. 16  is a partial section view illustrating the assembly of adjacently positioned wall panels; 
       FIG. 17  is a partial view illustrating the assembled wall panels; 
       FIG. 18A  is a perspective view illustrating the inner surface of a reinforcement channel as utilized in the instant invention; 
       FIG. 18B  is a partial perspective view illustrating the reinforcement channel in engagement with a wall assembly; 
       FIG. 19  is a perspective view illustrating the outer surface of a reinforcement channel as utilized in the instant invention; 
       FIG. 20  is a perspective view illustrating assembly of the door frame member to a wall panel; 
       FIG. 21  is a perspective view illustrating assembly of a wall panel to the floor assembly; 
       FIG. 22  is a perspective view illustrating assembly of the corner post assembly to the wall panels and floor assembly; 
       FIG. 23  is a perspective view illustrating the assembled wall and floor panels; 
       FIG. 24  is a perspective view illustrating one of the door panels utilized in the instant invention as well as assembly of a sliding door latch; 
       FIG. 25  is a perspective view illustrating one of the door panels utilized in the instant invention as well as assembly of a sliding door latch; 
       FIG. 26  is a perspective view illustrating assembly of a door panel to the assembled wall panels; 
       FIG. 27  is a perspective view illustrating assembly of a second door panel to the assembled wall panels; 
       FIG. 28  is an exploded view of the roof assembly as utilized in the instant invention; 
       FIG. 29  is a front perspective exploded view of a header assembly as utilized in the instant invention; 
       FIG. 30  is a rear perspective exploded view of a header assembly as utilized in the instant invention; 
       FIG. 31  is a rear perspective view of a header assembly as utilized in the instant invention; 
       FIG. 32  is a front perspective view of a header assembly secured to the front wall assembly and corner posts; 
       FIG. 33  is a perspective view illustrating the assembly of the roof header and roof support beams; 
       FIG. 34  is a perspective view illustrating a roof panel as utilized in the instant invention; 
       FIG. 35A  is a partial perspective view illustrating the connection between the roof and wall panels; 
       FIG. 35B  is a partial perspective view illustrating assembly of a connector boss to a roof panel; 
       FIG. 36A  is a partial perspective view illustrating the assembled connection of a wall panel and a pair of roof panels; 
       FIG. 36B  is a partial perspective view illustrating the assembled connection of a wall panel and a pair of roof panels; 
       FIG. 37A  is a partial perspective view illustrating assembly of a connector boss to a roof support; 
       FIG. 37B  is a partial perspective view illustrating a connected roof panel and roof support; 
       FIG. 38A  is a partial perspective view illustrating a roof panel connected to the front header assembly and the ridge cap; 
       FIG. 38B  is a partial perspective view illustrating a ramp-lock as utilized in the instant invention; 
       FIG. 39A  is a partial top view of roof panels assembled to a header member; 
       FIG. 39B  is a section view taken along line  5 - 5  of  FIG. 39A ; 
       FIG. 39C  is a rear view of the partial view shown in  FIG. 39A ; 
       FIG. 40  is a section view taken along line  6 - 6  of  FIG. 39A  illustrating the overlapping connection between the roof panels; 
       FIG. 41  is a partial perspective view illustrating assembly of roof panels to the assembled ridge cap, headers and roof supports; 
       FIG. 42  is a partial exploded view illustrating assembly of the cupola walls; 
       FIG. 43  is a partially exploded view illustrating assembly of the cupola top member; 
       FIG. 44  is an assembled view of the cupola as utilized in the instant invention; 
       FIG. 45  is a partial perspective illustrating installation of a cantilever shelf embodiment securable to the inner surface of the wall panels; 
       FIG. 46  is a partial perspective view illustrating an assembled cantilever shelf embodiment secured to the inner surface of the wall assemblies; 
       FIG. 47  is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly; 
       FIG. 48  is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly; 
       FIG. 49  is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly; 
       FIG. 50  is a partial perspective view illustrating an assembled stackable shelf arrangement secured to the inner surface of a wall assembly; 
       FIG. 51  is a front perspective view illustrating a larger utility enclosure constructed with the teachings of the instant invention; 
       FIG. 52  is a rear perspective view of the embodiment shown in  FIG. 51 ; 
       FIG. 53  is a front perspective view illustrating a larger utility enclosure constructed with the teachings of the instant invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
     FIGS. 1-3  which are now referenced show isometric and exploded views of a heavy duty utility enclosure, generally referenced as  10 , constructed according to a preferred embodiment of the present invention. The enclosure is made up of a floor assembly  100 , left and right side wall assemblies  200 , corner post assemblies  300 , roof assembly  400 , rear wall assembly  500 , front wall assembly  600  and door assemblies  700 . In the preferred embodiment, the panels comprising the assemblies are formed of but not limited to a suitable plastic such as polystyrene, polypropylene or polyethylene, through the process of injection molding. The result is that the panels comprising the floor assembly  100 , post assemblies  300 , side wall assemblies  200 , roof assembly  400 , rear wall assembly  500  and front wall assembly  600  of the enclosure  10  are formed as unitary panels with integral connectors and cross bracing. Strengthening ribs and gussets  206  are formed within the inner surfaces of the various panels and components in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in  FIG. 1 . The injection molded construction is utilized for the floor assembly  100 , left and right wall assemblies  200 , the corner posts  300 , roof assembly  400 , rear wall assembly  500 , and front wall assembly  600  using a minimal number of components. 
   Referring to  FIGS. 1-10 , the enclosure includes a plurality of like-constructed floor panels  102 . Each panel has a top surface  104 , bottom surface  106 , a closed first edge  108 , a second edge  110  opposite said first edge, said second edge including a first means for connecting to juxtapositioned panel members, a third edge  112  substantially perpendicular to and extending between said first and said second edges, the third edge including the first means for connecting to juxtapositioned panel members, and a fourth edge  114  opposite to and substantially parallel to said third edge, the fourth edge including the first means for connecting to juxtapositioned panel members. Adjacent to the closed edge  108  is a second means of attaching the floor assembly to the wall assemblies illustrated herein as a plurality of bosses  116  extending upwardly from the top surface  104 . The bosses  116  are constructed and arranged to cooperate with pockets  210  located at each longitudinal end of the structural wall panels  202  and the structural L-shaped post assemblies  300  for connecting and maintaining a substantially perpendicular relationship between the wall panel members and the top surface of the floor panel members. Within the preferred embodiment, the locking bosses  116  are removeable and replaceable, wherein each locking boss includes a first lower end  130  and a second upper end  132 . The first end includes a flange  134  constructed and arranged to cooperate with a floor panel to provide a secure connection between the panels and to prevent lifting or tipping of wall panels secured thereto. The locking boss is inserted through a conjugately shaped aperture  136  integrally formed within the floor panels until the integrally formed spring clips  138  engage surface  140  for a secure connection, wherein the locking boss extends upwardly above the top surface of the floor panel. 
   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 inter-fitting engagement with their respective top surfaces  104  in a co-planar arrangement. In a most preferred embodiment a portion of the fingers include an alignment boss  115  ( FIG. 9 ) 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 . 
   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 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 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. 
   Referring to  FIG. 6 , 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 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 to  FIGS. 1-10 , in addition to the floor panels, the floor assembly includes a front end assembly  142 . The front end assembly preferably includes two front end members  144 . Each front end member includes a top surface  146 , a bottom surface  156 , a first ramp edge  148 , a second edge  150  opposite the first edge, an outer edge  152 , a 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 generally cylindrical hinge pins  176  extending upwardly. The hinge pins  176  cooperate with the door panels  702  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  602 . 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 the header assembly  450  ( FIG. 28 ) to provide increased wind and snow load capacity to the enclosure. 
   Referring to  FIGS. 1-10 , 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 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 to  FIG. 11 , a structural corner post assembly  300  is shown. The corner post assembly  300  constitutes one of a plurality of like-configured structural corner post assemblies in the system used to add significant strength and rigidity to the enclosure  10 . The corner post assemblies  300  are generally L-shaped having a first member  302  extending at least partially along the front or rear wall of the enclosure and a second member  304  extending at least partially along a side wall of the enclosure. The first corner post members  302  are each configured having a first longitudinal end  306  and a second longitudinal end  308  each including an integrally formed fourth means of attachment illustrated herein as an inwardly extending socket  210 . The socket is generally constructed and arranged to cooperate with either a floor assembly  100  or a roof assembly  400  boss in a generally perpendicular relationship. To facilitate mechanical connection with other structural panel members  202  in a co-planar relationship the first post member is provided a first horizontal edge  314  including a fifth means of attachment illustrated herein as a plurality of inwardly extending sockets  330 . The sockets include an inner wall  316 , an outer wall  318 , and a bottom wall  320 . The bottom wall includes an aperture  321  or notch therethrough for cooperative engagement with a hook-lock  322  included on an adjacently positioned wall panel or second corner post member  304 . In the preferred embodiment the horizontal edge  314  also includes a groove  324  extending from about the first longitudinal end  306  to about the second longitudinal end  308  of the edge  314 . The groove  324  is arranged to cooperate with a wall panel member  202  having a complimentary ridge in an interlocking coplanar relationship. The second member  304  includes a first end  330  and a second end  332 . Extending outward along the length of the second member is a plurality of bosses constructed and arranged to cooperate with sockets  330  integrally formed into the side of the first member  302 . A portion of the bosses include integrally formed hook-locks  322  for cooperation with the apertures or notches  321  provided 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 post  302  and the second member of the post  304 . The outer surface  326  of the corner post assemblies  300  are constructed generally smooth for aesthetic appearance, while the internal portion of the assembly includes a plurality of box structures  328  for added strength, rigidity and weight carrying capacity. The construction of the corner post assemblies increase the structural integrity of the enclosure  10  by preventing the corner posts  300  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure  10 . 
   The L-shaped corner post assemblies  300  are attached to the interconnected floor assembly  100  by sliding the first longitudinal end of the corner post assembly over a plurality of the bosses  116  extending outwardly from the floor assembly  100 . The pockets  210  in each end of the panels  302  correspond in shape and size to that of the bosses  116  and spring tabs  126  ( FIG. 9 ) integrally formed into the bosses  116  align with apertures  336  in the pockets  210  to engage the corner post assembly  300 . The result is a positive mechanical connection between the corner post assemblies  300  and the floor assembly  100 . 
   Referring to  FIGS. 3 and 14 , a structural wall panel  202  is shown. The wall panel  202  constitutes one of a plurality of like-configured panels in the system used to construct the left, right, front and rear wall assemblies  200 ,  500 ,  600 . The structural wall panels  202  are each configured having a first longitudinal end  208  including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets  210 . A second longitudinal end  212  also including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets  210 . The sockets  210  are generally constructed and arranged to cooperate with either a floor assembly  100  or a roof assembly  400  to facilitate mechanical connection in a generally perpendicular relationship. The outer surface  256  and inner surface  258  of the panels  202  are constructed generally smooth having a plurality of ribs  260 , extending from the first edge  214  across the panel  202  to the second edge  222 , for added strength and aesthetic appearance. The ribs  260  increase the structural integrity of the enclosure  10  by preventing the panels  202  from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure  10 . 
   To facilitate mechanical connection with other structural wall panel members  202  in a co-planar relationship the panels are provided a first horizontal edge  214  constructed with a fifth means of attachment illustrated herein as a plurality of sockets  330 . The sockets include an inner wall  316 , an outer wall  318 , and a bottom wall  320 . The bottom wall includes an aperture  321  ( FIG. 12 ) or notch therethrough for cooperative engagement with a hook-lock  322  included 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 groove  216 . The groove extends along first and second longitudinal ends as well as along the first horizontal edge of the panels. The groove  216  is arranged to cooperate with a corner post assembly  300 , wall panel member  202 , or floor assembly  100  having a complimentary ridge  180  in an interlocking coplanar relationship. The ridge  180  extends from about the first longitudinal end  208  of each panel to about the second longitudinal end  212  of each panel along the second edge  222  of the panels. An additional ridge  180  ( 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 edge  222  of each wall panel is constructed generally flat having a plurality of outwardly extending bosses  334 . The bosses are constructed and arranged to cooperate with sockets  330  integrally formed into the second edge of the wall panel  202 . A portion of the bosses include integrally formed hook-locks  322  for cooperation with the apertures or notches  321  provided 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-lock  250  ( FIG. 17 ) having a ramping surface  254  constructed to cooperate with apertures  252  positioned along the inner wall  316 . 
   Referring to  FIGS. 14-17 , engagement of the bosses  334  and sockets  330  is illustrated. The wall panels  202  are 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 surface  254  to flex the inner wall  316  until the ramp-lock  250  slips through aperture  252  allowing 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 to  FIGS. 15-17 , and  20 , a door frame  750  member is attached to a wall panel  202 . The door frame member includes at least one hinge pin conduit  718  and a pair of hinge pin clearance pockets  728  integrally formed thereto. The door frame member also includes a door seal  752  integrally formed thereto to provide a weather resistant seal to the door assembly  700 . The wall panel  202  and the door frame member  750  are attached together by sliding the bosses of the panel into the sockets of the adjacently positioned door frame member, as shown in  FIG. 15 , and thereafter sliding the wall panel downward to engage the hook-locks, as shown in  FIG. 16 . In addition to engagement of the hook-locks, the downward motion preferably causes the ramping surface  254  to flex the inner wall  316  until the ramp-lock  250  slips through aperture  252  allowing 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 member  750 . 
   Referring to  FIGS. 21-23 , the wall panels  202  are attached to the interconnected floor-panels  102  and corner post assemblies  300  by sliding the first longitudinal end of a wall panel  208  over a plurality of the bosses  116 . The pockets  210  in each end of the panels  202  correspond in shape and size to that of the bosses  116  and spring tabs  126  ( FIG. 8 ) integrally formed into the bosses  116  align with apertures  234  in the pockets  210  to engage the wall panel  202 . The result is a positive mechanical connection between the wall-panels  200  and the floor assembly  100 . The first wall panel being attached to the floor assembly  100  and the corner post assembly  300  with the first longitudinal end  208  downward 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 ridge  180  and the groove  216  arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The ridge  180  and the groove  216  are brought into an interlocking relationship wherein the ridge  180  enters the corresponding groove  216  ( 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 to  FIGS. 18-19 , a wall panel reinforcement channel  701  is illustrated. The side wall reinforcement channel is generally C-shaped and includes a first end  740 , a second end  742 , an inner surface  746 , and an outer surface  747 . The inner surface includes a plurality of formed flexible hooks  748 . Each flexible hook includes a barb  749 . In operation the reinforcement channel is attached to the inner socket wall  316  of a pair of assembled wall panels  202  by inserting the flexible hooks through apertures  254  until the barbs  710  engage the inner surface of the socket  330 . 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 panels  202  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure  10 . Still yet, the reinforced ribs provide support for optional cantilever shelves  800  ( FIG. 45-46 ) or stackable shelves  900  ( FIGS. 47-50 ) by distributing any load applied to the shelves across the length of the wall panels. 
   Referring to  FIGS. 3 ,  24  and  25 , the door assembly  700  is illustrated. The door assembly includes a pair of door panels  702 , a pair of door frame members  750 , a hinge means  720 , a door handle assembly  726 , 728 , and a latch assembly  724 . The door panel  702  constitutes one of a plurality of like-configured panels in the system used to construct the door assembly. The door panels  702  are configured each having a first longitudinal end  708 , a second longitudinal end  712 , an inner surface  704 , an outer surface  706 , a first edge  714 , and a second edge  716 . To facilitate mechanical connection with door frame members  750  in a pivoting, relationship the first edge of the panels are provided with a pair of circular hinge conduits  718  and a hinge pin  720 . The hinge conduits and hinge pin are constructed and arranged to cooperate with hinge pins and conduits integrally formed onto the door frame members  750  to allow pivoting movement of the door panel. The second horizontal edge  716  is constructed generally flat with the exception of an optional overlapping seal  722  ( FIG. 3 ) extending the full length of the panel. The optional overlapping seal  722  may be attached by any suitable fastening means well known in the art or may be integrally formed with the panel. The door panels  702  are also provided with an upper and lower sliding latch mechanism  724  ( FIGS. 24-25 ) as well as left and right door handles  726 ,  728  ( FIG. 3 ). 
   Continuing with regard to  FIGS. 3 ,  24  and  25 , the outer surface  706  of the panels  702  are constructed generally smooth having a plurality of raised panels  726  for added strength and aesthetic appearance. The inside surface of the panel  704  is constructed with a plurality of raised panels  726  for added strength and aesthetic appearance. The raised panels  726  increase the structural integrity of the enclosure  10  by preventing the panels  702  from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure  10 . 
   Referring to  FIGS. 26-27 , the door panels  702  are attached to the interconnected floor panels  100 , left and right corner post assemblies  300 , and front wall assembly  600  by sliding the respective hinge pin  720  into the corresponding hinge conduits  718  located along the edge of the door frame  750  and the front end member of the floor assembly. Either door panel  702  is 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 latches  724 , left door handle  726  and right door handle  728  ( FIG. 3 ). 
   Referring to  FIGS. 24-25 , installation of the upper and lower slide latches  724  is illustrated. The slide latches are constructed and arranged to allow simple push-in installation. The latch housings  730  are merely pushed into apertures  732  located adjacent to edge  716  in the door panels  702  until the spring clips (not shown) engage an inner surface of the panel. Thereafter the one end of the door latch pin  734  is inserted through the housing  730  and downwardly until spring clip  736  is 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 pin  734  to extend it outwardly to engage the roof assembly  400  or the floor assembly  100 , the contents contained within the enclosure  10  are secured. The door handles  726 ,  728  are constructed and arranged to allow simple push-in installation. The handles are merely pushed into apertures  738  contained in door panels  702  until the spring clips (not shown) engage an inner surface of the panel  702 . 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 to  FIGS. 28-32  the roof assembly  400  includes a pair of like constructed header assemblies  450 . The header assembly is a truss like structure molded with an aesthetically pleasing generally smooth wall on its outer surface  452  and integrally formed box bracing  454  and a plurality of pockets  456  constructed and arranged to accept roof support beams on its inner surface  454 . In the preferred embodiment the header is constructed of a center member  472  and a pair of outer members  474 . 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 surface  458  and a lower surface  460 . The lower surface  460  includes a third means of connection illustrated herein as a plurality of inwardly extending engagement sockets  462  constructed and arranged to cooperate with removable and replaceable bosses  464  and/or door hinge pins  466 . The bosses  464  or hinge pins  466  are slid into their respective engagement sockets  462  until the integrally formed spring tabs  468  engage corresponding apertures  470  formed in the engagement sockets. The end surfaces  476 ,  478  of the members include a ninth means of connection illustrated herein as a plurality of outwardly extending inter-fitting tubes  480 . 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 pins  466  into their respective hinge conduits  718  while simultaneously sliding the locking bosses  464  into the wall sockets  210  until the integrally formed spring clips engage the apertures  234  formed 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 to  FIGS. 28 ,  33 , at least three and up to five roof supports  482  are inserted into their respective pockets  456  in each of the headers and secured in place with suitable fasteners. The support beams  482  are 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. 33  is shown with a portion of the enclosure omitted for clarity, illustrating the placement of the support beams  482  in the preferred embodiment. The roof assembly  400  also includes a plurality of like constructed ridge cap members  484  and a plurality of like-constructed roof panels  402 . Each ridge cap member  484  includes a tenth means of connection illustrated herein as at least one outwardly extending boss  486  and at least one socket  488  for securing the ridge cap members together. The ridge cap members  484  are slid together until the ramp-locks  490  integrally formed into the bosses  486  engage corresponding apertures (not shown) formed in the sockets  488 . The assembled ridge cap is slid into place over the headers and fastened in cooperative engagement with the support beams  482  and the headers  450 . Ramp-locks  490  ( FIG. 38B ) integrally formed into the front surface  452  of the headers  450  cooperates with apertures  492  formed into a front depending wall  494  ( 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 aperture  492  snaps over the ramp-lock to secure the ridge cap assembly in place. 
   Referring to  FIGS. 28-41 , each roof panel has a top surface  404 , bottom surface  406 , a first locking edge  408 , a second locking edge  410 , a third locking edge  412  and a closed edge  414 . Along the bottom surface  406  adjacent to the closed edge  412  is a fifteenth means of connection illustrated herein as a plurality of sockets  416  constructed and arranged to receive roof connectors  418 . The roof connectors are constructed and arranged to cooperate with pockets  210  located at second longitudinal end  212  of the structural wall panels  202  as well as the sockets  416  located on the lower surface  406  of the roof panels  402 . A series of spaced apart structural ribs  420  extend across the lower surface of each roof panel  402  to provide increased weight carrying capacity to the roof assembly  400 . The first and second locking edges of the roof panel  402  include a thirteenth and fourteenth means of connection illustrated herein as a W-shaped overlapping connection  416  ( FIG. 40 ). The distal portion  418  of the first edge overlapping connection including a plurality of ramp-locks  490  arranged to cooperate with apertures  492  formed 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 edge  408  of each roof panel  402  includes a twelfth means of connection illustrated herein as an interlocking tube  422  constructed and arranged to cooperate with a ridge cap  484  having a conjugately shaped receiver  424  ( FIG. 41 ) to create a weather resistant seal. The roof panels  402  are slid into the receiver  424  until the integrally formed ramp-locks  490  engage corresponding apertures formed in the ridge cap  484 . For interlocking cooperation between the roof panels  402  and the roof supports  482  a sixteenth means of connection is provided. The sixteenth means of connection is illustrated herein as a second roof connector  420 . The second roof connector includes a first boss end  423  constructed and arranged to cooperate with sockets  416  and a second end  424  constructed and arranged to cooperate with the roof supports  482 . 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 to  FIGS. 42-44  a cupola  800  is illustrated. The cupola includes a pair of side walls  802  and a front and rear wall  804 . 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 to  FIGS. 45-46  installation and assembled views of cantilever type modular shelving  800  are illustrated. The cantilever shelving includes cantilever wall mounts  802  constructed and arranged to cooperate with wall panels  202  for snap-in engagement. The cantilever shelf  804  is constructed and arranged to snap into engagement with the wall mounts. This arrangement permits assembly without the need for fasteners. The plurality of apertures  254  formed 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&#39;s needs. 
     FIGS. 47-50  illustrate assembly of stackable shelving  850 . The stackable shelving includes at least two horizontal members  852 , at least two vertical members  854 , and a shelf member  856 . The horizontal members are constructed and arranged to cooperate with aperture  254  formed into the inner surface of the wall panels at a first end and the vertical members  854  at a second end. The bottom portion of the vertical members include an integrally formed projection for interlocking cooperation with an indentation  856  ( FIG. 47 ) formed into the upper surface of the floor panels  102 . Additional shelves may be added to the assembly in a vertical manner by engaging additional vertical members into sockets  858  formed into the upper surface of the horizontal member  852  and thereafter assembling additional horizontal members thereto. 
   Referring to  FIGS. 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. 
   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. 
   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. 
   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.

Technology Classification (CPC): 4