Modular panel construction system

Information

  • Patent Grant
  • 6185878
  • Patent Number
    6,185,878
  • Date Filed
    Wednesday, May 27, 1998
    26 years ago
  • Date Issued
    Tuesday, February 13, 2001
    23 years ago
Abstract
A utility shed is disclosed comprising modular side panels (30) which are connected together by corner connectors (26) and in-line connectors (28) to form sidewalls. The connectors (26, 28) have an I-beam cross section and comprise U-shaped ends (106, 80) which engage relatively wide channels (62, 64) to securely hold the wall panels together. A door assembly is provided for engaging the corner connectors (26) and include pivot pin members (202) which attached to the vertical channel (114) of corner connectors (26) and allow pivotal door panels (164) to be suspended therefrom. Floor panels (116, 118) and lid panels (154) are provided compatible with the I-beam edge configuration of the side panels (30) such that the lid, floor and sidewalls mutually interlock with high structural integrity. The modularity of the side panels (30) allow for enclosures of larger or smaller size to be created using the same panel componentry.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates generally to structural panel systems combining a plurality of panel members with connector joining members to create an enclosure and, more specifically, to such systems wherein the components are modular so as to enable the construction of variably sized enclosures using the same components.




2. The Prior Art




Panel systems, or kits, comprising connector members and cooperating panels for forming a wide variety of products are well known. Applications include the construction of: building partitions and, therefrom, enclosures such as utility sheds; furniture; toy activity playsets; and containers for the storage or shipment of goods. Typically, such systems include connector members having a specific cross-sectional geometry that facilitates an engagement between such members and one or more panels having a complementary edge configuration.




A particularly common structure for the connector members in such systems is an 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 state of the art I-beam connector members. The I-beam sides of the connector engage with 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 I-beam connector members are also included in the kits to join panels in a coplanar relationship, whereby creating walls of varying length.




The aforementioned systems can also incorporate roof and floor panels to form a freestanding enclosed structure such as a 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, however, while working well, have not met all of the needs of consumers from a structural standpoint. Paramount among such needs is a panel and connector system for creating enclosure walls which resists panel separation, buckling, racking and weather infiltration. A further problem is that the wall formed by the panels and connectors must tie into the roof and floor in such a way as to unify the entire enclosure. Also from a structural standpoint, a door system must be present which is compatible with the panel and connector sidewalls and which provides dependable pivoting door access to the enclosure.




There 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, cost effective fabrication techniques; and the system must be capable of being packaged and shipped in a knocked-down state. Further, the system ideally 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 also 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 hand tools. The system must further 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 negatively affect the utility of the structure.




SUMMARY OF THE INVENTION




The subject invention satisfies the market's needs by providing a system, or kit, of panels and connectors which combine to form an enclosure, commonly in the form of a utility shed. The panels are formed by blow molded plastic and overlap with one another to form the sidewalls of the enclosure. A connector strip, of generally, I-beam cross section is provided to joint adjacent panels together either at the corners of the structure or inline. The connector strip forms a channel for receiving a free peripheral edge of the panel, and includes inwardly directed flanges which are received within slots of the panel. The connector strip flanges are U-shaped, filling the wide slots within the panels which are created by the blow molding process. The filling of such slots creates a tight fit between the component parts and, thereby, in the resulting structure. The overlap between vertically oriented panels and engagement between detents and detent flanges formed within the panels serve to rigidly connect the components together and counter forces that would otherwise act to separate the components or cause the components to buckle or rack.




The system further includes a door assembly comprising a plurality of pivot pin members which slide into the channel of a corner connector strip and present a vertical pivot pin on which door panels may be suspended. A roof panel and a floor panel tie together through the connector strips and sidewall panels to create mutually reinforced and unitary 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.




Accordingly, it is an objective of the present invention to provide a modular panel and connector system for creating enclosures of varying dimension using common components.




A further objective is to provide a panel and connector system which accommodates blow molding plastic formation of the panel components without degradation in structural integrity.




Yet a further objective is to provide a panel and connector enclosure in which sides, roof, and floor are integrally interlocked.




Another objective is to provide a panel and connector enclosure system having an integral door system which is readily assembled and installed.




An additional objective is to provide a panel and connector enclosure system having a minimal number of component parts and which requires minimal assembly hardware and a minimum number of assembly tools.




A further objective is provide connector members for a panel enclosure system having enhanced structural integrity and means for securely and rigidly adjoining adjacent panels.




Yet a further objective is to provide a panel and connector enclosure sidewalls which resist buckling or racking.




Another objective is to provide a panel and connector enclosure system formed of modular components useful in various enclosure configurations.




A further objective is to provide a panel and connector enclosure system which is economically and readily produced, capable of being shipped in a knock-down state, and which is easily assembled by the end user.




These and other objectives, which will be apparent to one skilled in the art, are achieved by a preferred embodiment which is described in detail below and illustrated by the accompanying drawings.











DESCRIPTION OF THE ACCOMPANYING DRAWINGS





FIG. 1

is a front perspective view of a utility shed incorporating the subject panel and connector system.





FIG. 2

is a front top perspective view thereof with one of the roof panels removed.





FIG. 3

is an enlarged fragmentary perspective view of a straight connector and two panels connected thereby.





FIG. 4

is an enlarged fragmentary perspective view of a corner connector and two panels connected thereby.





FIG. 5

is an exploded fragmentary perspective view of a straight connector and two panels which are joined thereby.





FIG. 6

is an exploded fragmentary perspective view of a corner connector, panel, and a pivot pin member.





FIG. 7

is a cross-sectional view through a corner connector.





FIG. 8

is a cross-sectional view through a straight, or in-line, connector.





FIG. 9

is a front plan view of a side panel.




FIG.


10


. is rear plan view of a side panel.





FIG. 11

is a transverse section view through a side panel taken along the line


11





11


of FIG.


10


.





FIG. 12

is a transverse section view through a side panel taken along the line


12





12


of FIG.


10


.





FIG. 13

is a transverse section view through a side panel taken along the line


13





13


of FIG.


10


.





FIG. 14

is a longitudinal section view through a side panel taken along the line


14





14


of FIG.


10


.





FIG. 15

is a top plan view of two mating floor panels.





FIG. 16

is a transverse section view through a door panel edge strip.





FIG. 17

is a perspective view of a partial door panel edge strip.





FIG. 18

is a perspective view of a door pivot pin member.





FIG. 19

is an enlarged fragmentary perspective view of a door handle and door panel.





FIG. 20

is a front perspective view of a door panel.





FIG. 21

is a top plan view of a roof panel.





FIG. 22

is a front fragmentary perspective view of a roof panel.





FIG. 23

is a front top fragmentary perspective view of the floor panel overlap joint.





FIG. 24

is a front bottom perspective view of the floor panel overlap joint.





FIG. 25

is a rear perspective view of the door panel.





FIG. 26

is a front perspective view of the front nose strip.











DESCRIPTION OF THE PREFERRED EMBODIMENT




Referring initially to

FIGS. 1 and 2

, the subject invention is shown embodied in the form of a utility shed enclosure


10


, comprising a top panel assembly


12


, a floor assembly


14


, opposite side assemblies


16


,


17


, adjacent door assemblies


18


,


19


, a pair of handles


20


, and a back panel assembly


22


. In the preferred embodiment, the panels are formed of conventional plastic such as polyethylene, through the process of blow molding conventional in the industry. The result is that the panels comprising the sides, lid, floor, and doors of the subject shed


10


are hollow and have a relatively thick dimensional section. Elongate depressions


24


are formed within the inner surfaces of such panels in order to enhance the rigidity of the panels while leaving the external surface in a smooth condition for aesthetic purposes, as shown in FIG.


2


.




The subject system further includes a plurality of elongate corner connectors


26


and a plurality of in-line, or straight, connectors


28


. The connectors


26


and


28


may be formed of suitable conventional plastics material such as polyethylene, or other suitable plastic, by either an extrusion molding process or by injection molding.




Referring to

FIGS. 9

,


10


and


11


, one side panel


30


is shown. Side panel


30


constitutes one of a plurality of like-configured panels in the system and represents a central building block in the formation of the sides and back panel assemblies. The side panel


30


is configured to overlap and mate on the top and bottom with other like-configured panels, and comprises an upper overlap flange


32


for such purpose. The flange


32


steps inward as a protrusion


34


at a location midway across, and an elongate male detent flange


36


is formed within the protrusion


34


and projects upwardly. A complimentary overlap flange


38


is formed along a bottom edge of the panel


30


and provides a detent


40


positioned midway across, dimensioned to receive the male detent flange


36


of a like-configured second panel. A ledge protrusion


42


extends from a central location on an inward surface of the panel


30


, and provides with protrusions of other side panels, support for a shelf (not shown).




Continuing with regard to

FIGS. 9

,


10


and


11


, the outer surface


43


of the panel


30


is convoluted or rippled for added strength. A pair of elongate detent recesses


44


are provided within the top overlap flange


32


, located on opposite sides of the protrusion


34


. Positioned above and extending along the detent recesses


44


are detent ribs


46


. In the lower overlap flange


38


, complimentary located and configured recesses


44


and interlocking detent flanges, or ribs,


46


are incorporated. The flanges


46


have a beveled lead in surface


48


along an outward side and a flat stop surface


50


formed along an inward side.




It will be appreciated that the purpose of the protrusion


34


is to align two panels together vertically to facilitate their mechanical connection. The panels, so aligned, are brought into overlapping relationship as the top overlap flange


32


of one panel overlaps the lower overlap flange


38


of the other. The detent flange


36


of the lower panel enters into the detent


40


of the superior panel. Likewise, the detent ribs


46


of the lower panel upper flange


32


ride over the ribs


46


in the upper panel lower flange


38


and into detent recesses


44


therein. The result is a mechanically secure connection between the two panels.




The overlap joint between panels so aligned and connected as described above provides a secure connection and offers several advantages. First, the overlap prevents rain from entering the enclosure from between top and bottom panels. Secondly, the ramped lead in surface


48


on locking flange rib


46


easily rides over the rib


46


of the second panel, minimizing the force require by the user to effect clearance. As rib


46


enters appropriately into the channel


44


of the opposite panel, flat surface


50


of the rib abuts flat surface


50


of the opposite rib. This creates a positive lock and prevents inadvertent separation of the panels. The detent channels


44


and detent rib flanges


46


prevent separation of the panels from tensile forces and also prevent in-plane rotational movement of one panel relevant to the other.




The engagement between bumps or detent flange s


36


of one panel into detent


40


of the opposite also acts to secure the connection between panels. Also, the engagement keeps the panels in the same plane and prevents bowing of either panel. The protrusion


34


of one panel aligns against the protrusion


34


of the opposite panel and serves to reinforce the connection against racking, or transverse movement of one panel relative to the other. Thus, from the above, it will be appreciated that the structural overlap and redundant detent and detent flange connections between the panels effects resistance to undesirable movement of one panel to the other in any direction. That is, separation in transverse or longitudinal directions is prevented, as is rotational movement and bowing deformation of either panel. The resultant wall created by the combination of interlocking panels as taught herein accordingly benefits from a high structural integrity.




Referring to

FIGS. 5

,


6


and


14


, the peripheral lateral edge of each panel member


30


further is structured to provide an I-beam sectional configuration. Edge flanges


54


,


56


extend from opposite sides of the panel


30


from top flange


32


to bottom overlap flange


38


. Beveled surfaces


58


,


60


of extend along leading sides of the flanges


54


,


56


. A pair of channels


62


,


64


extend adjacent flanges


54


,


56


, respectively. The process of blow molding panel member


30


from plastics material requires that the channels


62


,


64


be relatively wide, approximately as wide as deep.




The connector members which comprise component parts of the subject system will be understood from a consideration of

FIGS. 3

,


5


and


8


. A straight, or in-line, connector


28


is shown as having, essentially, an I-beam cross-sectional configuration. The connector


28


comprises parallel side walls


68


bisected by a transverse divider wall


70


. Arms


72


,


74


,


76


and


78


are thus defined to extend from divider wall


70


, each arm terminating in an inward directed U-shaped end


80


. Each U-shaped arm end


80


is defined by an outer flange


82


and an inner flange


84


, separated by a bight channel


86


. It will be appreciated that the width dimension “A” of U-shaped end


80


is preferably approximately equal to the depth dimension “B”, as shown in

FIG. 8

as a result of the blow molding process. A pair of elongate channels


88


,


90


are, accordingly, defined along each connector


66


on opposite sides of the divider wall


70


. Each channel


88


,


90


is partially enclosed along an outward side by the inward directed U-shaped ends


80


of respective arms which define the sides of the channels


88


,


90


.





FIGS. 4 and 7

best show the configuration of the corner or right angle connector


26


, which takes the general cross-section of two I-beams intersecting at a right angle. Connectors


26


include spaced apart and parallel side walls


92


,


94


extending in a first direction and spaced apart and parallel side walls


96


,


98


extending at a right angle to the first direction. a curved outer wall


100


connects the two I-beam components of connector


26


. An inner wall


102


defines with the side walls


96


,


98


a channel


114


and an inner wall


104


defines with the sidewalls


92


,


94


a like channel


114


on the opposite side. The side walls


92


,


94


,


96


,


98


, similar to the straight connector


28


, have inward directed U-shaped ends


106


, each defined by an outward flange


108


and an inward flange


110


separated by a bight channel


112


. The relative depth to width dimension of U-shaped ends


106


to the corner connector


26


is the same as described above in reference to the straight connector


28


.




The connectors


26


,


28


serve to join side panels


30


to form the side wall assemblies


16


,


17


and back assembly


22


. It will be seen from

FIGS. 1

,


2


,


3


and


4


, that, for the size enclosure represented therein, the side walls comprise three stacked side panels


30


and the back assembly


22


comprises six panels


30


. The side wall assemblies


16


,


17


are formed by sequentially feeding the I-beam peripheral edges


52


of three panels


30


into the channels of two corner connectors


26


. The channels


114


of connectors


26


are sized to receive edges


52


as U-shaped ends


106


of connector


26


enter into the channels


62


,


64


of the edges


52


. The opposite panel edges


52


of the first side panel


30


are fed downward into the connector channels


114


of two connectors


26


to the bottom. Thereafter, the second of three side panels


30


is fed downward into the connector channels


114


to an overlapping engagement with the first panel


30


. The engagement between overlapping panels and their respective detent flanges and detents is as described previously. The third panel


30


is assembled in like manner until all three panels of one side of the enclosure are in overlapping formation.




Assembly of the back assembly


22


proceeds in like manner except that one edge


52


of three panels


30


are assembled in overlapping formation to one connector


26


and the opposite edge


52


of the panels are assembled into a connector


28


. The connector


28


thus acts to double the length of the back wall relative to the side wall of the enclosure. It will be appreciated that the U-shaped ends


106


(connector


26


) and


80


(connector


28


) are wide enough to substantially fill the relatively wide channels


62


,


64


in the panel edges


52


. The U-shaped configuration thus effects a tight fit between the connectors and the side panels


30


. Moreover, material used in the formation of the U-shaped ends is substantially less than would otherwise be necessary were the ends of the connector arms made of solid material to a thickness equivalent to the width of channels


62


,


64


. The subject connectors


26


,


28


, accordingly, effectuate a positive connection to relatively wide channels which are a natural consequence of the blow molding process, yet do so in a cost effective manner.




Referring next to

FIGS. 15

,


23


and


24


, the subject enclosure includes a pair of identical floor panels


116


,


118


. Panels


116


,


118


are configured identically. Each panel


116


,


118


has a top surface


120


and a peripheral channel


122


extending about three sides. Channel


122


is defined along an outer side by a serpentine mating upright flange wall


124


and along an inward side by flat vertical wall


126


. Six locking flanges, each dimensioned and configured identically to the locking flanges


46


of the side panels


30


, are positioned about the periphery of the panels


116


,


118


within the channel


122


. A series of spaced apart edge apertures


130


extend through each panel


116


,


118


to the outside of flange wall


124


. Positioned along and extending forward from each of the panels


116


,


118


are spaced apart finger flange projections


132


with adjacent projections


132


being separated by recesses


134


. As best seen from

FIGS. 23 and 24

, each projection


132


has a pair of flange protrusions


136


extending therefrom, and a each protrusion


136


is formed having a pair of sockets


138


in an underside. The body


140


of projections


132


further has two additional sockets


142


formed in an underside.




A ledge


144


is formed inside each recess


134


and a pair of spaced apart sockets


146


are formed therein. Each socket


146


has a detent flange projecting upward therefrom. Stepped above the ledge


144


within each recess


134


is a second pair of sockets


150


, each likewise having a detent flange


152


which projects upward therefrom. It will be appreciated that the floor section panels


116


,


118


mateably engage as the projections


132


of the one fit within and overlap the recesses


134


. The detent flanges


148


of the underlying recess resiliently snap into the sockets


142


of the upper panel and the detent flanges


152


resiliently snap into the sockets


138


. The panels


116


,


118


are thus secured together in an interfitting engagement and their respective top surfaces


120


are coplanar.




The side assemblies


16


,


17


are attached to the interconnected floor panels


116


,


118


by inserting the lower edge of the side panel


30


into the channel


122


of the floor. The shape of the outer surfaces of the side panels


30


align against the shape of the outer wall


124


of channel


122


and the flat inward surface of the side panels


30


against flat channel wall


126


. The detent flanges


128


of the panels


116


,


118


align with and extend over the locking detent flanges


46


of the side panels and ride over such flanges into the detent channels


44


located thereabove. The result is a positive mechanical connection between the preassembled wall side assemblies


16


,


17


and the floor surface.




Continuing with reference to

FIGS. 21

,


22


, each lid panel


154


is shown to comprise a generally flat tack off bottom surface


156


. A series of six sockets


158


of generally rectangular shape extend into the surface


156


, positioned two to a side. The detail of each socket


158


, as best seen in

FIG. 22

, includes a detent flange


160


configured and dimensioned identically with the locking detent flanges


46


of the side panels


30


. Positioned adjacent each flange


160


is a detent channel


162


correspondingly sized and configured as channels


44


of the side panels


30


. It will be readily understood that the side panel assemblies


16


,


17


interconnect along their upper overlap edge flange


32


into the lid panels


154


in like manner as panel assemblies


16


,


17


interconnect along their lower overlap edge flange


38


into the floor panels


116


,


118


. That is, the locking detent flanges


46


along the upper side panel


30


engage over the detent flange


160


of each socket


158


until entering into the channel


162


. Accordingly, the side assemblies


16


,


17


are mechanically connected simultaneously into the lid panels and the floor panels. The resultant enclosure is structurally tied together as floor and lid panels both connect in with the opposite top and bottom edges of the side assemblies


16


,


17


.




The enclosure representing the preferred embodiment is configured having two door panels


164


, each being configured as the mirror image of the opposite. While one panel is represented in

FIGS. 20

,


25


, it will be readily appreciated that the other panel member (not shown) is of identical mirror configuration. The panel


164


is configured having a flat front side


166


into which a series of oval, spaced apart handle depressions


168


are formed.

FIG. 20

shows the panel


164


in an inverted condition. An upper pivot pin bore


172


is formed at the upper left hand corner of the panel


164


and a lower pivot pin bore


170


is formed at a lower left hand corner. A free leading edge


174


of the door panel


164


is opposite the pivot pin bores


170


,


172


and is substantially of I-beam cross sectional configuration. Formed along an outward surface of panel


164


proximate edge


174


is an elongate, outward projecting detent flange


176


extending from top to bottom. Adjacent flange


176


and co-extensive therewith is a detent channel


178


. Opposite flange


176


and channel


178


on the opposite side of the edge


174


are detent flange


180


and detent channel


182


. The I-beam edge


174


extends to an upper overlap flange


184


.




The flange


184


at the top of the door panels


164


is substantially configured as the top flange


32


of each side panel


30


described previously. The flange


184


has a rectangular protrusion


186


midway across and a detent projection


188


therein. A locking detent flange and detent channel


190


,


192


, respectively, are on opposite sides of the protrusion


186


.




The forward edge


174


of the door panel


164


is intended to engage a edge strip


194


as will be apparent from

FIGS. 16

,


17


. The edge strip


194


is fabricated by extrusion or injection molding and has one side of substantial I-beam cross section with which to engage door panel edge


174


. A channel


196


is formed and is enclosed partially across an outer side by U-shaped ends


198


in like manner to connectors previously described. The strip


194


provides a flat surface


200


at the side opposite the I-beam for abutting against a like-configured surface


200


of the opposite door panel. The strip


194


is reversible such that it can be used on both the right and left door panels


164


, whereby avoiding the cost of a separate part for each door side.




A pivot pin member


202


is shown in

FIGS. 6 and 18

intended to attach to the front corner connectors


26


of the enclosure and to pivotally suspend the door panels


164


, both right and left, therefrom. The member


202


is configured at one side


204


to have a generally I-beam sectional configuration dimensioned and adapted to allow member


202


to slide down channel


114


of the corner connector


26


. The I-beam section is defined by oppositely extending detent flanges


206


,


208


and channels


210


,


212


adjacent thereto, respectively. The member


202


further includes a generally circular horizontal flange


214


extending from side


204


. An upward extending pivot pin


216


and a depending pivot pin


218


extend from the flange


214


. Pivot pin member


202


is integrally formed of conventional plastic material, preferably by the injection molding process. Pin members


202


can be interchangeably used on either the right or the left door panels.




The handle body


220


of the enclosure is represented in FIG.


19


. The body is generally concave and rectangular and includes a mounting boss


222


,


224


at opposite end adapted to fit within respective ones of depressions


168


in the door panels


164


. Thereupon, screws (not shown) may be inserted through the bottom surface of depressions


168


and into the handle bosses


222


,


224


to attach the handle securely to the door. An outer edge


226


of the handle body


220


provides the user with an edge for grasping the handle to open the door.




A front nose member


228


is shown in

FIG. 26. A

member


228


mounts to a forward side of each of the floor panels


116


,


118


. Member


228


comprises a ramped forward surface


230


and a raised support boss


232


at an outward end. Extending upwardly from the support boss


232


is a pivot pin


234


. A series of four attachment finger flanges


236


are spaced along and extend outward form a rear side of the nose member


228


. It will be apparent from

FIG. 15

that the finger flanges


236


of member


228


are positioned to align with the edge apertures


130


of floor panels


116


,


118


and include detent flanges (not shown) in an undersign which snap through the apertures


130


and securely affix nose member


228


to the floor panels


116


,


118


.




Assembly of the door to the enclosure will appreciated from

FIGS. 6

,


18


,


20


, and


26


. A first door panel


164


is aligned with the edge of a forward corner connector


26


and lower pivot pin bore


170


of the panel


164


is lowered onto the upwardly directed pivot pin


234


of the nose member


228


. Thereafter, one of the pivot pin members is inserted into the same corner connector


26


from the top and slid down in the I-beam channel until the lower pin


218


enters the top bore


172


of the first panel


164


. A second panel is then aligned with the same corner connector


26


and lower bore


170


receives the upper pin


216


of the pivot pin member. A second pivot pin member


202


follows into the connector


26


until received within the second panel


164


. A third and final panel


164


is then aligned with the connector


26


and receiving the upper pin


216


. A third and final pin member


202


is inserted into the top bore


172


of the third panel and the top pin


218


thereof is captured within the top lid panel. The edge extrusion


194


is then assembled to the door forward edge as channel


196


receives the forward edges of panels


164


therein. Extrusion


194


assists in holding the three stacked door panels


164


together. In the preferred embodiment, three panels


164


and three pivot pin members


202


are deployed per door side.




So assembled, the door assembly is supported by the pivot pin


234


of the nose member


228


and the three of pivot pin members


202


to freely pivot thereabout. The door members may thus be freely opened and closed at both sides of the enclosure.




From the foregoing, it will be understood that the subject invention is composed of modular components. For the size structure depicted in the preferred embodiment, as shown in

FIGS. 1 and 2

, the sides of the utility shed comprise three side panels


30


, connected at opposite edges to two corner connectors


26


. The back of the structure comprises six side panels


30


, three high. A straight connector


28


bisects the back of the enclosure with two stacks of three side panels


30


each connected together thereby. The outer edges of the side panels connect into the same rear corner connectors as the sides. The roof or top comprises two of the lid panels


154


and the floor comprises two bottom panels


116


. Each door side comprises three stacked panels connected to a front corner connector


26


by the pivot pin members


202


described above. Two nose members


228


are provided, across the lower front edge of the enclosure.




The subject modularity means that the same side panel


30


is used in the formation of the sides and back. Also, the floor panels are identical, reducing the number of molds required to make the component parts. A minimal number of parts need be formed and shipped to the end user. It will be appreciated that assembly of the enclosure as described above is relatively simple and can be accomplished without a large number of fasteners or hand tools. The component parts, moreover, can be shipped disassembled in a “knock-down” state, whereby reducing packaging and shipping costs.




In addition, the panels comprising the enclosure are all preferably formed by the blow molding process. As such, a thickness and strength can be achieved in the resultant hollow panels with minimal use of plastic material. The corner and in-line connectors can effectively join blow molded panels along channels which are necessarily wide due to the manufacturing process. Connectors


26


,


28


accomplish such a connection by means of unique U-shaped I-beam ends which fill the wide channels in the panel edge portions. The U-shaped fingers rigidly connect to the panels in a tight manner, and do not detract from the structural integrity of the enclosure.




Moreover, the interlocking detents and detent flanges in the side panels


30


reinforce the sides and back of the enclosure from separation, buckling, racking and weather infiltration. The integrity of the resultant enclosure is enhanced.




While the preferred embodiment shows a utility shed of intermediate proportion, the modularity of the components used therein enable a shed of larger or smaller proportion to be made, if desired, using the same components. By way of example, a larger enclosure can be made by doubling the shed sidewalls to two panels wide, joined by an in-line connector


28


. Additional roof panel and floor panels would be required (not shown) but the same side panels


30


as described above may be used. Alternatively, the shed can be made smaller by reducing the sides, front, and back to two panels high. Shorter connectors (not shown) at the corners and inline along the back would be necessary.




Finally, the subject invention has been described in the preferred embodiment as an utility shed. However, the invention need not be so limited. Other applications for enclosures formed by the teachings herein set forth, are intended as well. By way of example, the modular side panels and connector system may be useful in the creation of partitions, fencing, or in the creation of other types of products such as playground activity toys. Other uses and applications, which will be apparent to one skilled in the art, and which utilize the teachings herein set forth, are intended to be within the scope and spirit of the subject invention.



Claims
  • 1. A construction panel assembly for enclosures, comprising:a first and a second panel member, the first panel member having a lower edge flange and the second panel member having an upper edge flange which overlap to place the panel members into a stacked and overlapped relationship; at least one protrusion and at least one recess in the overlapping edge flanges of the first and second panel member which engage to join the overlapping edge flanges together; a connector strip having a longitudinal channel for receiving lateral edges of the first and second panel members and maintaining the edges in an aligned relationship.
  • 2. A panel assembly according to claim 1, wherein the connector strip comprises a second longitudinal channel for receiving lateral edges of a like-configured third and a fourth panel member.
  • 3. A panel assembly according to claim 1, wherein the connector strip longitudinal channel is defined by spaced-apart sidewalls, at least one of said sidewalls having an inward extending outer edge portion which at least partially encloses an outer side of the channel.
  • 4. A panel assembly according to claim 3, wherein the lateral edges of the first and second panel members are dimensioned for close receipt within the connector strip channel and the first and second panel members further comprise at least one longitudinal slot positioned and dimensioned to receive therein the outer edge portion of the connector strip channel one sidewall.
  • 5. A panel assembly according to claim 4, wherein the outer edge portion of the connector strip channel one sidewall is substantially U-shaped and comprises spaced apart flanges defining therebetween a bight slot.
  • 6. A panel assembly according to claim 5, wherein the flanges are spaced apart a distance substantially equivalent to the width of the one longitudinal slot within the first and second panel members.
  • 7. An enclosure comprisingat least one pair of like-configured side panels joined together by an elongate connector, the connector having at least a first longitudinal channel dimensioned to receive a respective lateral edge of each of the side panels and maintain the panels in an aligned relationship, and the first and second panel member each having an edge flange overlapping the edge flange of the opposite panel member and the overlapping edge flanges having at least one protrusion and at least one recess which engage to join the overlapping edge flanges together and; a roof connected to the side panels and enclosing a top of the enclosure; a door connected to the side panels and enclosing a forward side of the enclosure.
  • 8. An enclosure according to claim 7, wherein the longitudinal channel is defined by spaced apart sidewalls, and at least one sidewall has a remote edge portion extending inward to at least partially enclose a forward side of the channel.
  • 9. An enclosure according to claim 7, wherein further comprising at least one floor panel having a peripherially located channel for receiving a lower edge portion of at least one of said side panels.
  • 10. An enclosure according to claim 9, wherein the roof comprises at least one roof panel having an underside and engagement means therein for receiving and engaging an upper edge portion of at least one of said side panels.
  • 11. An enclosure according to claim 7, wherein further comprising:at least one corner connector located at a forward corner of the enclosure and having an elongate channel substantially open along an outward side; at least one pivot pin member comprising a rearward portion dimensioned for receipt within the corner connector channel and a further comprising a forward portion extending outward from the corner connector channel and the forward portion having an upwardly directed pivot pin affixed thereto; the door comprising at least one door panel having a bore extending along an outward edge portion dimensioned to receive the pivot pin therein, the door being pivotally supported by the pivot pin member and pivoting about the pivot pin between a closed position and an open position.
  • 12. An enclosure according to claim 11, wherein the corner connector channel is defined by sidewalls, at least one of said sidewalls having an inwardly directed end portion for enclosing at least a portion of said channel outward side, and the pivot pin member rearward portion comprising a slot dimensioned to receive the one sidewall end portion therein to connect the pivot pin member to the corner connector.
  • 13. An enclosure according to claim 7, wherein further comprising:at least one elongate door connector located at a forward side of the enclosure and having an elongate channel substantially open along an outward side; a plurality of pivot pin members, each comprising a rearward portion dimensioned for receipt within the door connector channel and further comprising a forward portion extending outward from the connector channel and the forward portion having an upwardly directed upper pivot pin affixed thereto and a downwardly directed lower pivot pin affixed thereto in axial alignment with the upper pivot pin; the door comprising a plurality of door panels, each having an upper and a lower bore extending along an outward edge portion, the door panels and pivot pin members being alternately positionable along the door connector channel with the upper and lower bores of each said door panel receiving therein the pivot pins of the respective pivot pin members positioned proximate thereto, whereby the door panels are pivotally supported by the pivot pin members and pivot between a closed position and an open position.
  • 14. An enclosure according to claim 13, wherein further comprising a free edge connector connected to forward edge portions of the door panels, the free edge connector comprising an elongate channel dimensioned to receive the forward edge portions of the door panels therein.
  • 15. An enclosure according to claim 14, wherein the free edge connector channel is defined by spaced apart sidewalls and at least one of said sidewalls has an inwardly projecting end portion for at least partially enclosing a forward side of the free edge connector channel; and the door panels each comprise an elongate slot located along said forward edge portions for receiving the end portion of the free edge connector channel one sidewall.
  • 16. An enclosure according to claim 15, wherein the end portion of the free edge connector channel is substantially U-shaped and dimensioned in width to be substantially equivalent to the door panel elongate slot.
  • 17. An enclosure comprisingat least one pair of like-configured side panels joined together by an elongate connector, the connector having at least a first longitudinal channel dimensioned to receive a respective lateral edge of each of the side panels and maintain the panels in an aligned relationship; a roof connected to the side panels and enclosing a top of the enclosure; a door connected to the side panels and enclosing a forward side of the enclosure; the longitudinal channel is defined by spaced apart sidewalls, and at least one sidewall has a remote edge portion extending inward to at least partially enclose a forward side of the channel and the remote edge portion is substantially U-shaped and comprises first and second spaced apart flanges defining a bight slot therebetween which opens toward the opposite sidewall.
  • 18. An enclosure according to claim 17, wherein the lateral edge of at least one of the side panels comprises a longitudinal slot sized to closely receive the U-shaped remote edge portion of the connector.
  • 19. A door assembly for an enclosure comprising:an elongate connector having an elongate channel substantially open along an outward side; a plurality of pivot pin members, each comprising a rearward portion dimensioned for receipt within the connector channel and further comprising a forward portion extending outward from the connector channel and the forward portion having an upwardly directed upper pivot pin portion affixed thereto and a downwardly directed lower pivot pin portion affixed thereto in axial alignment with the upper pivot pin portion; a plurality of door panels, each panel having an upper and a lower bore extending along an outward edge portion, the door panels and pivot pin members being alternately positionable along the connector channel with the upper and lower bores of each said door panel receiving therein the pivot pin portions of respective pivot pin members disposed proximate thereto, whereby the door panels are pivotally supported by the pivot pin members and pivot between a closed position and an open position.
  • 20. A door assembly according to claim 19, wherein further comprising a free edge connector connected to forward edge portions of the door panels, the free edge connector comprising an elongate channel dimensioned to receive the forward edge portions of the door panels therein.
  • 21. A door assembly according to claim 20, wherein the free edge connector channel is defined by spaced apart sidewalls and at least one of said sidewalls has an inwardly projecting end portion for at least partially enclosing a forward side of the free edge connector channel; and the door panels each comprise an elongate slot located along said forward edge portions for receiving the end portion of the free edge connector channel one sidewall.
  • 22. A door assembly according to claim 21, wherein the end portion of the free edge connector channel is substantially U-shaped and dimensioned in width to be substantially equivalent to the door panel elongate slot.
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Entry
“item Industrietechnik” promotional materials, bearing a designation “0.4.106.31 05/95”.