Patent Application
20070107326
This invention relates generally to a cupola device constructed of plastic structural panels. More specifically, the present invention relates to a cupola kit utilizing modular injection molded plastic panels. The cupola kit is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola assembly upon a desired site.
Permanent structures such as utility sheds or garages are often utilized for storage of household items such as gardening tools, children's toys, barbeque accessories and the like. A common addition to the roof of such structures is the cupola. Cupolas have been part of architectural design for many years. Most cupolas are constructed of wood, with metal or shingle roofs, and may include windows to admit light or louvers to vent hot air out of the structure to which they are attached.
Wooden cupolas are generally custom made for a particular roof and thus assembly and installation require a great deal of time and expertise. Because these structures are made of wood they also require a great deal of maintenance to prevent degradation during the life of the structure to which they are attached.
Metal cupolas are also known in the art. Metal cupolas generally include a plurality of metal panels having turned up edges that are assembled by aligning the turned up edges and thereafter sliding a U-shaped retainer over the joint to hold the panels in position. For example, Nystrom U.S. Pat. No. D413,170 discloses an ornamental design for a metal cupola. Post Jr. Discloses a pre-fabricated cupola and mounting bracket. Forsman et al. Discloses a cupola having and adjustable mount.
Also known in the art of metal cupolas are panels with snap-fit edges. For example, Coolman U.S. Pat. No. 6,170,206 discloses a cupola roof having panels with snap-fit edges. Each combination cupola roof panel has a female snap-fit edge on one side and a female snap-fit edge on the other side.
It is also known to combine metal panels and plastic panels into a cupola structure. For example, Wilhelmson discloses a satellite dish housing and roof ventilation device. The device includes panels constructed of radio-frequency transparent material so that television reception is not impaired.
Another cupola construction known in the art utilizes a roto-molded construction wherein all four sides of the cupola are formed as a single piece. See Van Gilst et al. U.S. Pat. No. 6,422,936.
Such prior art systems, while working well, have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped or the needs of consumers requiring structural integrity combined with modularity and aesthetic appearance.
For example, the metal structures of the prior art include numerous sharp edges and are difficult to assemble. In addition, the thin sheet metal panels are easily bend during shipping and assembly. The combination plastic and metal structures do not include any integrated fasteners and thus require substantial skill as well as numerous tools to assemble. The roto-molded structures do not break down into small components and thus are expensive and difficult to ship.
In addition, due to the nature of the manufacturing processes utilized for constructing the prior art cupolas, the panel components cannot be formed with the intricate shapes and/or cross sections required for integrated connectors. Therefore, these systems require a substantial number of fasteners in combination with connector members having a specific cross-sectional geometry that facilitate an engagement between the panels to complete the structure.
Therefore, what is needed in the art is an injection molded modular cupola assembly. The modular cupola assembly should achieve objectives such as lightweight single walled panel construction. The construction of the panels should eliminate the need for additional connectors to create a cupola assembly which resists panel separation, buckling, and racking. The cupola assembly should be capable of withstanding the snow and wind loads typically associated with enclosures. Also, from a convenience standpoint, the cupola assembly should include features constructed to cooperate with lighting and/or fans or other enhancements. In addition, the cupola assembly should include convenience features that allow the cupola to be easily attached to an enclosure.
There are also commercial considerations that must be satisfied by any viable cupola assembly or kit; considerations which are not entirely satisfied by state of the art products. The cupola assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques, such as injection molding. The cupola assembly must also be capable of being packaged and shipped in a knocked-down state. In addition, the cupola assembly must be modular and facilitate the creation of a family of cupola assemblies for enclosures that vary in size but which share common, interchangeable components.
Finally, there are ergonomic needs that a cupola assembly must satisfy in order to achieve acceptance by the end user. The cupola assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the cupola assembly must not require excessive strength to assemble or include heavy component parts. Moreover, the cupola assembly must assemble together in such a way so as not to detract from the appearance or function of the resulting enclosure, or otherwise negatively affect the utility of the structure.
The assignee of the instant invention is also the assignee of various other plastic enclosure systems, U.S. Pat. No. 6,892,497 entitled Plastic Panel Enclosure System, U.S. patent application Ser. No. 10/729,689 filed Dec. 5, 2003, entitled Low Profile Plastic Panel Enclosure, and U.S. patent application Ser. No. 10/674,103 filed Aug. 29, 2003, entitled Plastic Expandable Utility Shed, the contents of which are incorporated herein in their entirety.
The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form a roof mountable cupola. The panels are formed of injection molded plastic to interlock with one another without the need for separate fasteners or connectors. The system incorporates a minimum number of components to construct a cupola by integrally forming the connectors into the injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the cupola. The integrated connection of the side walls and cover components also simplifies cupola construction. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or extruded panels. The same side wall and cover panel components may be used to create a variety of cupolas and the assembly thereof requires minimal hardware and a minimum number of hand tools.
The front and rear wall panels have outwardly projecting locking posts for interlocking cooperative engagement with sockets in the left and right side wall panels. The engagement between the locking posts and the sockets serve to rigidly connect the components together. The system further includes a cover which slides into place after the front, rear, left and right wall panels have been fully assembled. The cover may include spring locks for engagement with the side panels or alternatively may be held in place with suitable fasteners. The system is constructed to allow various cover panels to be utilized further increasing the utility of the assembled cupola.
Accordingly, it is an objective of the present invention to provide a modular cupola assembly having integrated connectors for creating various cupolas using common components.
A further objective is to provide a modular cupola assembly wherein the panels include integrated connectors accommodated by injection molding plastic formation for increased structural integrity.
Yet a further objective is to provide a modular cupola assembly in which the side walls and cover panels are integrally interlocked without separate connectors or fasteners.
Another objective is to provide an cupola assembly constructed of modular panels having a cover panel which allows interchangeability after all other parts are assembled.
Yet another objective is to provide a kit for a cupola that is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola upon a desired site.
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.
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.
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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.
