Patent Grant
11674302
This disclosure relates generally to modular enclosures, structures, and components thereof, and relates specifically to modular storage enclosures and structures, such as sheds and containers, and components thereof.
Modular enclosures and structures are known that allow users to connect and configure various panels to form assemblies suitable for storage. For example, storage sheds and outdoor storage containers, or boxes, are known.
Various improvements to such assemblies are described herein, to provide improved properties and features of such assemblies.
The present disclosure describes modular enclosures, structures, and components thereof. In embodiments according to the present disclosure, a modular enclosure includes a plurality of enclosure panels defining an enclosed storage volume. At least one of the plurality of enclosure panels is a first roof panel, the first roof panel including a dormer opening. The modular enclosure may further include a plurality of dormer wall panels extending from the first roof panel about the dormer opening. The modular enclosure may further include at least one dormer roof panel transverse to the plurality of dormer wall panels. The plurality of dormer wall panels and the dormer roof panel collectively define a dormer. The dormer includes at least one window configured to allow light external to the modular enclosure to enter the storage volume.
In embodiments according to the present disclosure, a modular assembly includes a first panel having a first edge, the first edge including at least one bore. The modular assembly further includes a second panel having a second edge, the second edge including at least one bore. The modular assembly may further include an elongated structural reinforcing member sized and shaped for positioning between the first and second edges. The modular assembly may further include at least one connector pin having two prongs. The connector pin is sized and shaped such that a first prong of a connector pin is positionable within the bore of the first edge and a second prong of the connector pin is positionable within the corresponding bore of the second edge, such that the connector pin connects the first and second panels.
In embodiments according to the present disclosure, a modular assembly includes a first molded panel including an elongated channel formed on a first surface thereof. The elongated channel includes two molded blind bores at opposite ends thereof. The blind bores extending in substantially the same direction as the elongated channel. The modular assembly may further include an elongated reinforcing member positioned in the channel. The elongated reinforcing member includes pins extending from opposite ends thereof. The pins are sized and shaped to be retained within the blind bores. The modular assembly may further include at least one fastener configured to retain the elongated reinforcing member within the channel. The elongated reinforcing member provides structural reinforcement to the first molded panel.
The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar to identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale.
The present disclosure includes non-limiting embodiments of modular assemblies having various improved features, such as connection means, reinforcing means, and/or a dormer. The embodiments are described in detail herein to enable one of ordinary skill in the art to practice the assemblies and structures and associated methods of making, although it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the scope of the disclosure. Throughout the disclosure, depending on the context, singular and plural terminology may be used interchangeably.
Various modular enclosures, assemblies and structures, as well as the components and features thereof, are described herein. As used herein, the term “modular” is used to refer to assemblies formed by sections or components (e.g., panels) that are configured for connection and assembly into an enclosure by a user.
Modular enclosures and structures are known that allow users to connect and configure various panels to form assemblies suitable for storage. For example, storage sheds and outdoor storage containers, or boxes, are known. Various improvements to such assemblies are described herein, to provide improved properties and features of such assemblies.
Connection Means for Modular Assemblies
Embodiments of the modular assemblies described herein may include connected abutting or otherwise adjacent panels. For example, modular assemblies such as sheds, fences, and containers such as storage boxes, may utilize such connection means to provide a secure attachment of adjacent panels. The panels may be any suitable panels, and in some embodiments are substantially planar.
Traditional methods of connecting such adjacent panels may utilize overlapping joints with threaded fasteners (e.g., screws) used to connect the overlap, or may utilize overlapping joints that employ a structural member engaged to one of the adjacent panel edges. Such connections may suffer from insecure attachments or other structural issues.
In certain embodiments, a modular assembly includes a first panel having a first edge including at least one bore, a second panel having a second edge including at least one bore, an elongated structural reinforcing member sized and shaped for positioning between the first and second edges, and at least one connector pin having two prongs, wherein the connector pin is sized and shaped such that a first prong of a connector pin is positionable within the bore of the first edge and a second prong of the connector pin is positionable within the corresponding bore of the second edge, such that the connector pin connects the first and second panels. Such connection means may incorporate relevant aspects of U.S. Pat. No. 6,668,514, which is incorporated by reference herein in its entirety.
As illustrated in these figures, a modular assembly 1100 includes a first panel 1102 having a first edge 1102a including at least one bore 1112, a second panel 1104 having a second edge 1104a including at least one bore 1112, an elongated structural reinforcing member 1108 sized and shaped for positioning between the first and second edges 1102a, 1104a, and at least one connector pin 1108 having two prongs 1108a, 1108b, wherein the connector pin 1108 is sized and shaped such that a first prong 1108a of a connector pin 1108 is positionable within the bore 1112 of the first edge 1102a and a second prong 1108b of the connector pin 1108 is positionable within the corresponding bore 1112 of the second edge 1104a, such that the connector pin 1108 connects the first and second panels 1102, 1104.
The elongated structural reinforcing member 1108 may be any suitable size, shape, and material to provide the desired structural reinforcement for the joint of the first and second panels 1102, 1104. For example, the elongated structural reinforcing member 1108 may be tubular, with any suitable cross-sectional shape (e.g., circular, oval, elliptical, rectangular, square). The reinforcing member may be hollow or solid in construction. In some embodiments, the structural reinforcing member is a metal tube.
In certain embodiments, as shown in the right-hand view of
As shown in the left-hand view of
The bores 1112 may have any suitable size, shape, and position to securely receive the prong 1108a, 1108b of a connector pin 1108. In certain embodiments, the bores are blind bores. In other embodiments, as shown in the figures, the bores are through-holes. In certain embodiments, the bores extend in a direction substantially parallel to a direction in which the elongated structural reinforcing member extends; however, any suitable direction of the bores may be used. In certain embodiments, the bores 1112 include an interference feature to prevent movement of a connector pin 1108 positioned therein. Such interference feature may be mechanical, such as a notch, or similar retention feature, or may be due to the geometry of the bore with respect to the connector pin (e.g., an angled bore). Thus, the interference feature may prevent the pin from moving out of the connecting position. The bores may be manufactured through methods such as described in U.S. Pat. No. 6,808,674, which is incorporated by reference herein in its entirety.
In certain embodiments, such as shown in
As shown in
In certain embodiments, the bores 1112 and the connector pin 1108 are sized and shaped to provide secure attachment of the first and second panels 1102, 1104 in a direction parallel to and/or perpendicular with the first and second panels 1102, 1104.
Thus, these assemblies and connection means may provide an improved joining method, along with improved structural performance of the joined panels. The configuration of these components may provide secure attachment in directions parallel and perpendicular to the wall construction. The elongated reinforcing member may provide greater structure versus a joint that only has panels in combination with traditional connectors and/or fasteners. That is, the application of a structural member between adjacent panels held in place by connectors, creating a captured joint assembly, may provide an improved structural connection for such modular panels.
In certain embodiments, methods of constructing a modular assembly such as described above are also provided. Such methods may include positioning the elongated structural reinforcing member in a recess formed between the first and second edges, and positioning the prongs of the at least one connector pin in the corresponding bores of the first and second edges, to securely connect the first and second panels.
Reinforcing Means for Modular Assemblies
In certain embodiments, as shown in
In certain embodiments, a modular assembly includes a first molded panel having an elongated channel formed on a first surface thereof and having two molded blind bores at opposite ends thereof, the blind bores extending in substantially the same direction as the elongated channel, an elongated reinforcing member positioned in the channel and including pins extending from opposite ends thereof, the pins being sized and shaped to be retained within the blind bores, and at least one fastener configured to retain the elongated reinforcing member within the channel, wherein the elongated reinforcing member provides structural reinforcement to the first molded panel.
While embodiments of these reinforced panels are described and illustrated with respect to panels forming the lid for a container and panels forming the door of a shed, it should be understood that the reinforcing means may be applied to any suitable panel type.
As shown in
In certain embodiments, the first panel 102, the elongated channel 110, and the blind bores 108 are blow molded in a single blow-molding step. For example, relevant teachings regarding blow-molding methods that may be used for the manufacture of such parts may be found in U.S. Pat. No. 6,808,674, which is incorporated by reference herein in its entirety.
Thus, in certain embodiments, the first panel 102 is formed of a molded plastic material. In certain embodiments, the reinforcing member 104 and pins 106 are formed of metal. The pins 106 may be associated with the reinforcing member 104 by any suitable direct or indirect coupling means (e.g., welding, adhesives, mechanical connection means), or the pins 106 may be formed as a solid member with the reinforcing member 104.
In certain embodiments, a panel 102 contains more than one channel 110 and thereby is configured to receive more than one reinforcing member 104. In certain embodiments, at least one elongated channel 110 is at or adjacent an edge of the first molded panel 102, with the elongated channel 110 extending substantially parallel to the edge. Beneficially, such design may provide an improved method to capture the ends of a structural member to a plastic part (e.g., panel), thereby providing greater resistance to distortions closer to the edges of the plastic part (e.g., plastic panel).
As shown throughout the figures, the elongated reinforcing member 104 may be formed of a sheet-like material that has been shaped to conform to and provide the required support to the panel 102 and channel 104. That is, the surface of the reinforcing member 104 may generally correspond in shape to the surface of the elongated channel 110 that it supports. For example, the reinforcing member 104 may have a cross-sectional shape that is curved, serpentine, S-shaped, J-shaped (see
The bores 108 are encapsulated holes (i.e., blind bores) and are sized and shaped to receive the pins 106 of the reinforcing member 104. In certain embodiments, as shown in
In certain embodiments, the reinforcing member 104 is fastened to the panel 102 by at least one fastener 112, such as a threaded fastener (e.g., screw, bolt/nut).
It has been found that this reinforcing support means provides an improved method for attaching structural components to plastic parts, while also reducing the required fastening steps (e.g., reduces the number of threaded fasteners needed). Additionally, these assemblies provide more support structures to the assembly while simultaneously reducing the number of parts/screws needed. Further, these assemblies increase rigidity of the panels by allowing the metal (e.g., pin) to extend further in a slot. In the embodiment of
As shown in
As shown in
Thus, these assemblies provide a metal reinforcement to support the handle-edge of the blow molded shed doors, the reinforcement having pins affixed or coupled at each end, the pins engaging into the enclosed areas of the blow molded article to secure the top and bottom of the door thus providing resistance to deflection due to heat histories (e.g., warp induced by heating/cooling cycles from sunlight). Further securing of the reinforcement component to the blow molded door panel may be provided by the exterior door handle (a separate component) attachment/fixed to/through the door reinforcement component.
Methods of constructing the modular assemblies described with reference to
Modular Enclosures with a Dormer
Also provided herein are modular enclosures having a dormer. As used herein, the term “dormer” is used to refer to a roofed structure that projects vertically, relative the ground, beyond the plane of the roof or other surface plane from which it extends.
In certain embodiments, a modular enclosure includes a plurality of enclosure panels defining an enclosed storage volume, wherein at least one of the plurality of enclosure panels is a first roof panel having a dormer opening, a plurality of dormer wall panels extending from the first roof panel about the dormer opening, and at least one dormer roof panel transverse to the plurality of dormer wall panels, the plurality of dormer wall panels and the dormer roof panel collectively defining a dormer. In certain embodiments, the dormer contains at least one window configured to allow light external to the modular enclosure to enter the storage volume. For example, as shown in
In certain embodiments, the panels of the modular enclosure are configured to provide resistance to water intrusion into the enclosed storage volume. That is, the panel orientation, installation, and assembly may be configured in a manner that provides water intrusion management.
In certain embodiments, at least one of the roof panels 1908 is slanted, pitched, or otherwise angled with respect to the base panel 1906. In other embodiments, one or more of the roof panels 1908 are substantially flat or parallel to the base panel 1906. In embodiments having at least one slanted roof panel 1908, the modular enclosure may further include gable panels 1912 positioned between the side wall panels and the slanted roof panels.
As seen in
As shown in
In certain embodiments, the dormer 1902 contains at least one window 1920 configured to allow light external to the modular enclosure 1900 to enter the storage volume. For example, the window(s) 1920 may be disposed in any of the panels forming the dormer 1902, to provide the desired amount of light exposure to the enclosed storage volume.
In certain embodiments, as shown in
As described herein, the various enclosure panels (e.g., side wall, base, and roof panels), the dormer wall panels, and dormer roof panels may all be formed of a plastic material. Suitable connection means, such as those described herein, may be used to connect and configured the panels to form the enclosure assembly. Suitable fixtures (e.g., handles) and other features may be provided.
Thus, various modular enclosures, assemblies, and structures have been provided having improved structural and other properties.
While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not described herein, but which are commensurate with the spirit and scope of the disclosure. Conditional language used herein, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
This application claims the benefit of U.S. Provisional Application No. 62/977,584 filed on Feb. 17, 2020, which is incorporated herein in its entirety by reference.
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| Entry |
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| Number | Date | Country | |
|---|---|---|---|
| 20210254327 A1 | Aug 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62977584 | Feb 2020 | US |
