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 posts 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:
REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation-in-part of Ser. No. 10/404,281, filed Mar. 31, 2003, the contents of which are herein incorporated by reference in their entirety. This application is also a continuation of provisional application 60/469,440, filed May 12, 2003, the contents of which are herein incorporated by reference in their entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    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 larger sized enclosures using the same components.  
         BACKGROUND INFORMATION  
         [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 and the like consume a great deal of the garage floor space available, forcing the homeowner to park his automobile outside.  
           [0004]    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.  
           [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]    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.  
           [0007]    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 interfitting 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 and electrical outlets.  
           [0008]    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.  
           [0009]    Finally, there are ergonomic needs that an enclosure system must satisfy in order to achieve acceptance by the end user. The system must be easily and quickly assembled using 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  
         [0010]    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 pillars, 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 pillars and wall panels have receptacles to accept both roof and floor bosses for interlocking cooperative engagement to rigidly connect the components together.  
           [0011]    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 pillars, wall, roof, floor and door components also minimizes component shapes and simplifies enclosure construction. The heavy duty interlocking construction of the corner pillars 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 a 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.  
           [0012]    In one embodiment, the enclosure system utilizes interlocking corner pillars, roof headers, and floor panels to create a structural frame. Two types of wall panel construction are integrated into the structural frame: the first being utilized for the side walls, and the second being used for the rear wall and the door assembly. The side walls are constructed to allow clear or opaque portions for natural lighting and also include provisions for standard electrical current hookup. 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 slides into place after the walls and roof have been fully assembled. The floor of the system is constructed to allow optional floor joists to be added to the plastic floor panels to further increase the structural integrity of the enclosure. The same components are used to create sheds of varying size, and the assembly of the system requires minimal hardware and a minimum number of hand tools.  
           [0013]    Accordingly, it is an objective of the present invention to provide a plastic structural frame and panel system having integrated connectors for creating larger enclosures of varying dimension using common components.  
           [0014]    A further objective is to provide a structural frame and panel system with integrated connectors which accommodates injection molding plastic formation of the panel components for increased structural integrity.  
           [0015]    Yet a further objective is to provide a structural frame and panel system enclosure which utilizes structural L-shaped corner pillars for increased enclosure rigidity.  
           [0016]    Another objective is to provide a structural frame and panel system enclosure constructed with side panels having interlocking ridge and groove edges to increase rigidity and prevent panel bowing or separation.  
           [0017]    Yet another objective is to provide a structural frame and panel system enclosure which reduces the number of components required to assemble an enclosure and simplifies construction.  
           [0018]    Still yet another objective is to provide a structural frame and panel system enclosure constructed and arranged with panels that allow wood and/or steel supports to be easily incorporated therein.  
           [0019]    An even further objective is to provide a structural frame and panel system enclosure constructed and arranged to allow airflow through the enclosure while preventing weather related moisture from entering the enclosure.  
           [0020]    Yet a further objective is to provide a structural frame and panel system enclosure which may be optionally configured with translucent windows thereby allowing natural light to enter the enclosure.  
           [0021]    Still yet a further objective is to provide a structural frame and panel system enclosure that is constructed and arranged for connection to standard electrical power.  
           [0022]    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  
       [0023]    [0023]FIG. 1 is a perspective view of an enclosure constructed using the instant enclosure system;  
         [0024]    [0024]FIG. 2 is an exploded view of the enclosure shown in FIG. 1;  
         [0025]    [0025]FIG. 3 is a perspective view of one embodiment of the floor assembly utilized in the instant invention;  
         [0026]    [0026]FIG. 4 is an exploded perspective view of the floor assembly shown in FIG. 3;  
         [0027]    [0027]FIG. 5 is a perspective view of the floor assembly illustrating the sliding engagement of the floor panels;  
         [0028]    [0028]FIG. 6 is a bottom view of the floor assembly illustrating the cross-bracing;  
         [0029]    [0029]FIG. 7 is a perspective view illustrating one of the corner pillars utilized in the instant invention;  
         [0030]    [0030]FIG. 8 is a perspective view illustrating assembly of a side wall panel to a corner pillar and the floor assembly;  
         [0031]    [0031]FIG. 9 is a perspective view of the T-connector utilized in the instant invention;  
         [0032]    [0032]FIG. 10 is a cross sectional view illustrating the locking engagement between the T-connector(s) and adjacent wall panels;  
         [0033]    [0033]FIG. 11 is a perspective view illustrating one of the panels utilized for the rear wall and door assemblies of the instant invention;  
         [0034]    [0034]FIG. 12 is a perspective view illustrating assembly of the rear wall of the instant invention;  
         [0035]    [0035]FIG. 13 is a partial perspective view of the enclosure with enlarged partial views illustrating assembly of the hinges;  
         [0036]    [0036]FIG. 14 is an exploded perspective view of the roof assembly utilized in the instant invention;  
         [0037]    [0037]FIG. 15 is a partial cross sectional view illustrating the cooperation between the weatherstrip seal and the roof ridge cap panels;  
         [0038]    [0038]FIG. 16 is a perspective view illustrating the cooperation between the roof support beams and the roof assembly;  
         [0039]    [0039]FIG. 17 is a partial exploded view illustrating the door assembly of the instant invention;  
         [0040]    [0040]FIG. 18 is a partial view illustrating assembly of one of the door latch housings utilized in the instant invention;  
         [0041]    [0041]FIG. 19 is a partial view illustrating assembly of one of the door latch pins utilized in the instant invention;  
         [0042]    [0042]FIG. 20 is a partial view illustrating assembly of one of the door handles utilized in the instant invention;  
         [0043]    [0043]FIG. 21 is a partial view illustrating assembly of one of the door handles utilized in the instant invention;  
         [0044]    [0044]FIG. 22 is a partial sectioned view illustrating the cooperation of the optional shelves with the side panels in the instant invention;  
         [0045]    [0045]FIG. 23 illustrates an alternative embodiment of the instant invention;  
         [0046]    [0046]FIG. 24 is an exploded view of the alternative embodiment shown in FIG. 25.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0047]    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.  
         [0048]    [0048]FIGS. 1 and 2 which are now referenced show an isometric and exploded view of the heavy duty structural frame and panel system enclosure, generally referenced as  10 , 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 pillars  300 , roof assembly  400 , rear wall and door assemblies  500 . In the preferred embodiment, the panels comprising the assemblies are formed of but not limited to a suitable plastic such as polystyrene or polyethylene, through the process of long core injection molding. The result is that the panels comprising the floor  100 , pillars  300 , side walls  200 , roof  400 , rear wall and doors  500  of the enclosure  10  are formed as unitary panels with integral connectors, and cross bracing. Strengthening ribs  204  and gussets  206  are formed within the inner surfaces of the wall panels  202 - 502  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 pillars  300 , roof assembly  400 , and rear wall and door assemblies  500  using a minimal number of components.  
         [0049]    Referring to FIGS. 3-6, the enclosure includes two pair of like-constructed floor panels  102 . Each panel has a top surface  104 , bottom surface  106 , a closed edge  108 , a ramp edge  110 , a first locking edge  112 , and a second locking edge  114 . Adjacent to the closed edge  108  and the ramp edge  110  is a 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 ,  310  and  510  located at each longitudinal end of the structural wall panels  202 ,  502  and the structural L-shaped pillars  302 . Adjacent to each of the ramp edges  110  is a pair of generally cylindrical hinge pins  128  extending upwardly. The hinge pins  128  cooperate with the wall panels  502  to allow pivotal movement. A series of spaced apart tubes  118  extend through each floor panel  102  under the top surface  104  and between the locking edge  112  and the ramp edge  110 . The tubes  118  are constructed and arranged to add increased weight capacity and stability to the enclosure  10 . Along the locking edges  112 ,  114  of each floor panel  102  is a series of spaced apart fingers  122  and recesses  124  for attaching the panels together into a floor assembly  100 , each of the fingers being provided with at least one countersank aperture  123  for receiving a fastener (not shown). The fingers  122  and recesses  124  are constructed and arranged so that the fingers  122  overlap and mateably engage the recesses  124 . The fasteners secure the panels together in an inter-fitting engagement with their respective top surfaces  104  in a co-planar arrangement. The bottom surface  106  (FIG. 6) 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.  
         [0050]    Referring to FIG. 7 a structural corner pillar  302  is shown. The corner pillar  302  constitutes one of a plurality of like-configured structural pillars in the system used to add significant strength and rigidity to the enclosure  10 . The corner pillars  302  are generally L-shaped having one leg extending at least partially along the front or rear wall of the enclosure and one leg extending at least partially along a side wall of the enclosure. The structural corner pillars  302  are each configured having a first longitudinal end  304  and a second longitudinal end  308  each including an integrally formed attachment means illustrated as a plurality of sockets  310 . The sockets are generally constructed and arranged to cooperate with either a floor assembly  100  or a roof assembly  400  in a generally perpendicular relationship. To facilitate mechanical connection with other structural panel members  202  in a co-planar relationship the pillars are provided a first horizontal edge  314  constructed with an attachment means illustrated as a ridge or groove portion  316  extending from about the first longitudinal end  304  to about the second longitudinal end  308  of the edge  314 . The ridge or groove  316  is arranged to cooperate with a side-panel member  202  having a complimentary ridge or groove in a interlocking coplanar relationship. To facilitate mechanical connection with rear wall panel or door panel members  502  the second horizontal edge  322  of the corner pillars  302  are constructed with a semi-circular conduit  306  extending from about the second longitudinal end  308  to about the middle portion of the edge. Centrally located within the semi-circular conduit  306  is a generally circular aperture  318  for accepting a dowel pin  220 . The conduits  306  are arranged to cooperate with other panel members having a complimentary semi-circular conduit in a co-planar, perpendicular, or pivotable relationship. The outer surface  328  (FIG. 1) of the corner pillars  302  are constructed generally smooth having a plurality of inwardly bowed surfaces  324  for added strength and aesthetic appearance. The inwardly bowed surfaces  324  increase the structural integrity of the enclosure  10  by preventing the corner pillars  302  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure  10 .  
         [0051]    The L-shaped corner pillars  302  are attached to the interconnected floor-panels  102  by sliding the first longitudinal end  304  over a plurality of the bosses  116  extending outwardly from the floor panels  102 . The pockets  310  in each end of the panels  302  correspond in shape and size to that of the bosses  116  and spring tabs  126  (FIG. 3) integrally formed into the bosses  116  align with apertures  334  in the pockets  310  to engage the side wall panel  302 . The result is a positive mechanical connection between the corner pillars  302  and the floor assembly  100 .  
         [0052]    Referring to FIGS. 8 and 9 a structural side wall panel  202  is shown. The structural side wall panel  202  constitutes one of a plurality of like-configured panels in the system used to construct the left and right side wall assemblies  200 . The structural side wall panels  202  are each configured having a first longitudinal end  208  including an integrally formed attachment means illustrated as a plurality of sockets  210 . A second longitudinal end  212  also including an integrally formed attachment means illustrated 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. To facilitate mechanical connection with other structural panel members  200  in a co-planar relationship the panels are provided a first horizontal edge  214  constructed with an attachment means illustrated as an outwardly extending ridge  216 . The ridge  216  extends from about the first longitudinal end  208  of the panel to about the second longitudinal end  212  of the panel. The ridge  216  is arranged to cooperate with a corner pillar member  302  or a side-panel member  202  having a complimentary groove in an interlocking coplanar relationship. The second horizontal edge  222  is constructed generally flat having an inwardly depending groove  226 . The groove  226  extends from about the first longitudinal end  208  of the panel to about the second longitudinal end  212  of the panel. The groove  226  is arranged to cooperate with a corner pillar member  302  or a side-panel member  202  having a complimentary ridge in an interlocking coplanar relationship. For additional structural rigidity between the side wall panels, the first and second horizontal edge attachment means may also include at least one T-connector  250  (FIG. 9). The T-connector is generally constructed having a first end portion  254  and a second end portion  256 . The first end portion  254  is constructed and arranged for insertion through at least one slot  258  extending along the first horizontal edge  214  of the wall panels  200 . The second horizontal edge  222  of the wall panels  200  are constructed and arranged with at least one key-hole slot  260  for insertion of said second end portion  256  of said at least one T-connector  250 . In operation, the first end portion  254  is inserted into a first horizontal edge slot  258  and rotated about ninety degrees to secure the T-connector in place within the first horizontal edge of the side wall panel  214  or corner pillar  314 . The outwardly extending second end portion  256  of the T-connector  250  is brought into an interlocking relationship with a corresponding key-hole slot  260  in an adjacent corner pillar or wall panel and slid downwardly resulting in a mechanically secure connection between the panels.  
         [0053]    Continuing with regard to FIG. 8, the outer surface  228  of the panels  202  are constructed generally smooth having a plurality of inwardly bowed surfaces  230  for added strength and aesthetic appearance. The inside of the panel  232  (FIG. 2) is constructed with a plurality of ribs  204  extending from the first edge  214  across the panel  202  to the second edge  222 . Each of the ribs  204  being provided with a plurality of gussets  206  to further strengthen the panel  202 . The ribs  204  and gussets  206  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 . The reinforced ribs also provide support for optional shelves  600  (FIG. 22). The construction of the ribs  204  allow shelving to extend across the span of the shed thereby dividing the load between two walls and eliminating the cantilever effect of attaching a shelf to a single wall surface.  
         [0054]    The left and right side wall panels  202  are attached to the interconnected floor-panels  102  and corner pillars  302  by sliding the first longitudinal end  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. 2) integrally formed into the bosses  116  align with apertures  234  in the pockets  210  to engage the side 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 pillar  302  with the first longitudinal end  208  downward interlocking the two panels via the ridge, groove and T-connector 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 T-connector arrangement extending along the sides of the wall panels.  
         [0055]    It will be appreciated that the purpose of the ridge  224  and the groove  226  arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The ridge  224  and the groove  226  are brought into an interlocking relationship wherein the ridge  224  enters the corresponding groove  226  (FIG. 10). 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.  
         [0056]    Referring to FIGS. 11-13, the structural rear wall and door panel is shown. The rear wall panel  502  constitutes one of a plurality of like-configured panels in the system used to construct the rear wall assembly and the door assembly. The rear wall panels  502  are each configured having a first longitudinal end  508  and a second longitudinal end  512  each including an integrally formed attachment means illustrated as a plurality of sockets  510 . The sockets  510  are generally constructed and arranged to cooperate with either a floor assembly  100  or a roof assembly  400  for generally perpendicular connection thereof. To facilitate pivotable mechanical connection with corner pillar members  302 , the panels  502  are provided a first horizontal edge  514  constructed with a semi-circular conduit  516  extending from about the first longitudinal end  508  to about the middle portion of the edge. The conduit  516  is arranged to cooperate with other panel members having a complimentary semi-circular conduit in a co-planar, a perpendicular, or a pivotable relationship. Centrally located within the semi-circular conduit  516  is an integrally formed C-shaped annular hinge portion  552  for cooperation with adjacent semi-circular conduits. Also integrally formed on the first horizontal edge  514  at about the second longitudinal end  512  of the panels  502  is a C-shaped annular hinge portion  524  constructed and arranged to cooperate with a roof assembly hinge pin  128 . For connection to a floor hinge pin  128  a hinge cap  336  is inserted into a socket  510  provided in the first end of the panel  502 . The socket is generally constructed and arranged with a C-shaped annular portion to cooperate with a floor hinge pin  128 . The second horizontal edge  522  of the panel  502  is constructed generally flat and may include an optional overlapping seal  550  to prevent moisture from entering the enclosure  10 .  
         [0057]    Continuing with regard to FIGS. 11-13, the outer surface  528  of the panels  502  are constructed generally smooth having a plurality of inwardly bowed surfaces  530  for added strength and aesthetic appearance. The inside of the panel  532  (FIG. 2) is constructed with a plurality of ribs  504  extending from the first edge  514  across the panel  502  to the second edge  522 . Each of the ribs  504  being provided with a plurality of gussets  506  to further strengthen the panel  502 . The ribs  504  and gussets  506  increase the structural integrity of the enclosure  10  by preventing the panels  502  from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure  10 .  
         [0058]    The rear panels  502  are attached to the interconnected floor panels  102  and the installed corner pillars  302  by inserting a hinge cap  336  into a corresponding cavity  510  located in the first longitudinal end  508  of the panel  502  for engagement with the floor assembly  100 , the first edge  514  of a rear wall panel is slid inward over dowels  220  and hinge pins  128  aligning the semi-circular conduits and engaging the respective hinge clips  540  (FIG. 12). The body of the hinge clip  540  (FIG. 13) is generally concave and rectangular and includes spring tabs  542  located at each end adapted to fit within the respective hinge caps to secure the door panels to the hinge and dowel pins and facilitate independent pivotal movement of each panel  502 . To prevent the panel  502  from pivoting the rear panel is inserted over a floor panel connector  554  (FIG. 1). Spring tabs  556  integrally formed into the floor panel connector  554  align with apertures  534  in the panels  502  for engagement. The result is a positive mechanical connection between the corner pillars  300 , rear panels  500  and the floor assembly  100 . In this manner the panel members  502  can be configured as a fixed panel using the floor panel connector  554  or a pivotable panel by omitting the floor panel connector  554 .  
         [0059]    Referring to FIGS. 14-16 the roof assembly  400  includes two like constructed headers  430 . The header is a truss like structure molded with an aesthetically pleasing generally smooth wall on its outer surface  432  and integrally formed cross bracing  436  and a plurality of pockets  438  constructed and arranged to accept reinforcement beams on its inner surface  434 . The header also includes an upper surface  440  and a lower surface  444 . The upper surface  440  includes a plurality of vents  442  that are constructed and arranged to allow airflow through the enclosure  10  but prevent weather related moisture from entering. The lower surface  444  includes a plurality outwardly extending bosses  446  constructed and arranged to cooperate with sockets located in the second end  308  of the corner pillars  302 . The bosses  446  are slid into the respective corner pillar sockets  310  until the integrally formed spring tabs  448  engage corresponding apertures  334  formed in the corner pillar sockets. At least two and preferably six support beams  450  are inserted into their respective pockets  438  in each of the headers and secured in place with suitable fasteners. The support beams  450  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. 17 is shown with a portion of the enclosure omitted for clarity, illustrating the placement of the support beams  450  in the preferred embodiment. The roof assembly  400  also includes two like constructed ridge caps  418  and two pair of like-constructed roof panels  402 . The ridge caps  418  generally include at least one outwardly extending boss  422  and at least one socket  424  for securing the ridge caps together. The ridge cap  418  are slid together until the spring tabs  448  integrally formed into the bosses  422  engage corresponding apertures  438  (not shown) formed in the sockets  424 . The assembled ridge cap is slid into place over the headers and fastened in cooperative engagement with the support beams  450  utilizing the anti-lift strapping  464 . A weatherstrip  452  is utilized to seal the ridge cap assembly seam against leakage. Starting at one side of the ridge cap assembly, the weather strip  452  is fed into the groove  454  (FIG. 16) formed by connecting the two ridge caps  418  until it is centered.  
         [0060]    Each roof panel has a top surface  404 , bottom surface  406 , a first locking edge  408 , a second locking edge  410  and two closed edges  412  and  414 . Along the bottom surface  406  adjacent to the closed edge  412  is a plurality of sockets  450  (not shown) constructed and arranged to receive roof connectors  452 . 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  450  located on the lower surface  406  of the roof panels  402 . A series of spaced apart structural tubes  418  (FIG. 15) extend through each roof panel  402  under the top surface  404  and between the first locking edge  408  and the first closed edge  412 . The first locking edge  408  of each roof panel  402  is configured as an interlocking sleeve  416  constructed and arranged to cooperate with a ridge cap  418  having a conjugately shaped projection  420  to create a weather resistant seal. The roof panels  402  are slid over the projection  420  until the integrally formed spring tabs (not shown) engage corresponding apertures formed in the ridge cap  418 .  
         [0061]    [0061]FIG. 15 shows the resilient weatherstrip seal  452 , which takes the general cross section of a flared U with an arrow extending downwardly from the apex of the radius. The weatherstrip seal  452  is constructed from a resilient material allowing the free edges  456  to be spread outwardly as the strip  452  is slid into the place creating a watertight seal between the top surface of the ridge caps  418  and the weatherstrip  452 . Moreover, the ridge cap  418  construction provides an elevated position for the weatherstrip  452  allowing water to be quickly directed away from the weatherstrip. It is also understood and anticipated that other suitable types of weatherstrips and/or sealants well known in the art could replace the illustrated weatherstrip seal.  
         [0062]    It should be appreciated that Assembling the roof assembly onto the enclosure is performed before the doors are assembled to the enclosure. This eliminates the tedious task of aligning the doors as the roof is attached to the structure, thereby simplifying assembly over the prior art.  
         [0063]    Referring to FIGS. 17-21, the enclosure door assembly includes a pair of door panels, a hinge means, a door handle assembly, and a latch assembly. The door panel  502  constitutes one of a plurality of like-configured panels in the system used to construct the back wall assembly and the door assembly. The door panels  502  are configured each having a first longitudinal end  508  including at least one integrally formed socket  510 . The socket  510  is generally constructed and arranged to cooperate with a hinge cap  336  having a C-shaped annular portion. A second longitudinal end  512  including an integrally formed C-shaped annular hinge portion  524 . To facilitate mechanical connection with corner pillar members  302  in a pivoting relationship the panels are provided a first horizontal edge  514  constructed with a semi-circular conduit  516  extending from about the first longitudinal end  508  to about the middle portion of the edge. The hinge cap  336 , integrally formed hinge portion  524 , and the semi-circular conduit  516  each containing at least one hinge means illustrated as a C-shaped annular portion  518  having an open side  520  constructed and arranged to accept a hinge pin  128  or a dowel pin  220  and to cooperate with a hinge clip  540  to close the annular cavity  518  and allow pivoting movement of the door panel  502 . The second horizontal edge  522  is constructed generally flat with the exception of a optional overlapping seal  550  extending the full length of the panel. The optional overlapping seal  550  may be attached by any suitable fastening means well known in the art or may be integrally formed with the panel. The door panels  502  are also provided with an upper and lower sliding latch mechanism  534  (FIGS. 18-19) and a left and right door handles  536 ,  538  (FIGS. 20-21).  
         [0064]    Continuing with regard to FIGS. 17-21, the outer surface  528  of the panels  502  are constructed generally smooth having a plurality of inwardly bowed surfaces  530  for added strength and aesthetic appearance. The inside of the panel  532  (FIG. 2) is constructed with a plurality of ribs  504  extending from the first edge  514  across the panel  502  to the second edge  522 . Each of the ribs  504  may be provided with a plurality of gussets (not shown) to further strengthen the panel  502 .  
         [0065]    The ribs  504  increase the structural integrity of the enclosure  10  by preventing the panels  502  from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure  10 .  
         [0066]    The door panels  502  are attached to the interconnected floor panels  100 , left and right corner pillars  300 , and roof panels  400  by sliding the respective hinge cap  336  into the corresponding cavity  510  located in the first end  508  of the door panels. Either door panel  502  is aligned with the hinge pins by sliding it horizontally into place over the respective pins and engaging the hinge clips  540  (FIGS. 12 and 13). The body of the hinge clip  540  is generally concave and rectangular and includes spring tabs  542  located at each end adapted to fit within the respective hinge caps to secure the door panels to the hinge pins and facilitate independent rotational movement of each door. It should be appreciated that this construction allows the doors to be installed or removed without disassembling or partially disassembling other components from the enclosure  10 . The construction also provides economic advantage allowing inexpensive hinge components to be easily removed and replaced in the event they become damaged while reusing the same panel. The door panels are also provided with removable and replaceable door latching mechanisms including slide latches  534 , left door handle  536  and right door handle  538  (FIG. 20).  
         [0067]    Referring to FIGS. 18-19, installation of the upper and lower door latches is illustrated. The door latches are constructed and arranged to allow simple push-in installation. The latch housings  552  are merely pushed into apertures  546  located adjacent to edge  522  in the door panels  502  until the spring clips  548  engage the back surface  532  of panel  502 . Thereafter the one end of the door latch pin  554  is inserted through the housing  552  and downwardly until spring clip  550  is snapped into place. In this manner the door latches can be installed and removed as need without the need for tools or screw type fasteners. By sliding the latch pin  554  to extend it outwardly to engage the roof assembly  400  or the floor assembly  100  the contents contained within the enclosure  10  are secured.  
         [0068]    Referring to FIGS. 20-21, installation of the left door handle  536  and right door handle  538  are illustrated. The door handles are constructed and arranged to allow simple push-in installation. The handles are merely pushed into apertures  544  contained in door panels  502  until the spring clips  542  engage the back surface  532  of panel  502 . 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  546  allowing the contents contained within the enclosure to be secured with a padlock or the like.  
         [0069]    Referring to FIGS. 23-24, an alternative embodiment of the present invention is shown wherein the enclosure is made larger by adding floor panels, roof panels, and adding additional side wall panels. The enlarged enclosure 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.  
         [0070]    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.  
         [0071]    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.  
         [0072]    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