This application is a continuation of utility patent application entitled Plastic Expandable Utility Shed filed Aug. xx, 2005, the contents of which are herein incorporated in their entirety. This application is also related to Ser. No. 29/230,885 filed May 27, 2005, the contents of which are herein incorporated by reference in their entirety. This application is also related to Ser. No. 29/230,978 filed May 27, 2005, the contents of which are herein incorporated by reference in their entirety.
This invention relates generally to expandable plastic utility sheds, and more specifically to a modular flooring system constructed of injection molded plastic panels for creating utility shed floors of various sizes from standardized components.
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, lawn tools and the like are stored within utility sheds for the convenience of the homeowner.
The prior art has proposed a number of different panel systems, or kits, comprising blow molded and/or extruded panels which are combined with connector members for forming storage structures, e.g. utility sheds. Unfortunately, blow molding and/or extrusion of panels for utility sheds has resulted in shortcomings within the state of the art products. For example, due to the nature of the manufacturing process, blow molded and/or extruded plastic components cannot be formed with the intricate shapes and/or sharp corners required for integrated connectors. Therefore, these systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitate an engagement between the blow molded or extruded panels to complete the structure.
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.
Another drawback associated with blow molded panels is the requirement of an inner and an outer wall. The inner and outer walls are a necessary product of the blow molding manufacturing process. While the inner wall may add some rigidity to the panels, it also adds a significant amount of weight and dramatically increases the volume of plastic necessary to form a panel of a given size when compared to other methods of manufacturing, such as injection molding.
In addition, because the blow molding process does not generally allow for supports to extend between the inner and the outer walls for load distribution, blow molded panels make weak floor structures. The panels are generally only connected around the perimeter, leaving the center area free of support. Therefore, when a heavy object such as a garden tractor traverses a blow molded panel, the center portion of the panel flexes downwardly distorting the floor structure. If a heavy object is left in place for an extended period of time the floor structure may be permanently distorted.
Still yet another drawback associated with blow molded panels relates to accurate control of wall thickness throughout the panels. The blow molding process does not allow the wall thickness of the panels to be accurately controlled; once the molten plastic is conveyed to the tooling, there is minimal control over where the plastic flows during formation of the panel. In addition, the blow molding process does not allow the intentional formation of thick and thin sections within a single panel for engineered rigidity at the points of high stress or high load concentration.
Extruded panels 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 also require connectors to achieve adequate length for utility shed floors. A common structure for connecting extruded members has a center I-beam with upper and lower protrusions for engaging the conduits. Floor panels utilizing these connectors are vulnerable to buckling under loads and may have an aesthetically unpleasing appearance. Moreover, loads from lawn tractors and the like may cause such floors to flex downwardly 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.
Therefore, what is needed in the art is an injection molded modular floor system for utility enclosures. The modular floor system should achieve objectives such as lightweight single wall construction. The construction of the panels should eliminate the need for extruded I-beam connectors to create a floor assembly which resists panel separation, buckling, and racking. The floor assembly should be capable of withstanding the loads typically associated with utility enclosures. Also, from a convenience standpoint, the floor assembly should include features constructed to cooperate with shelving and/or other storage enhancements. In addition, the floor assembly should include convenience features that allow the doors to be latched in open, as well as closed, positions for easy loading and/or unloading of the enclosure.
There are also commercial considerations that must be satisfied by any viable utility shed floor assembly or kit; considerations which are not entirely satisfied by state of the art products. The floor assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques, such as injection molding. The floor assembly must also be capable of being packaged and shipped in a knocked-down state. In addition, the floor assembly must be modular and facilitate the creation of a family of floor assemblies for enclosures that vary in size but which share common, interchangeable components.
Finally, there are ergonomic needs that a floor assembly must satisfy in order to achieve acceptance by the end user. The floor assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the floor assembly must not require excessive strength to assemble or include heavy component parts. Moreover, the floor assembly 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.
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 including injection molded floor panels having integrated connectors which combine to form a family of variously sized floor assemblies for utility enclosures. The floor panels are formed of injection molded plastic to create light-weight panels having integrally formed ribs and gussets for strength and integrity. The injection molding also facilitates integrally formed connectors so that the panels interlock with one another without the need for separate connectors. The outer ends of the floor panels have integrally formed apertures constructed for interlocking cooperative engagement with a plurality of wall bosses to rigidly connect the wall panels together with the floor assembly in a perpendicular relationship.
The system incorporates a minimum number of components to construct a large heavy duty enclosure floor 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 floor panels also minimizes component shapes and simplifies enclosure construction by not requiring the floor panels to be assembled into sub-assemblies. The heavy duty interlocking construction of the floor panels and the locking bosses create a structural floor assembly that allows construction of larger enclosures. Injection molding the floor panels allow them to be formed with various consumer convenience features such as anti-skid surfaces, shelving and bench alignment pockets, anchoring apertures and the like. Injection molding also allows the panels to be formed with integral cross-bracing, ribs, and gussets beneath the top surface for increased rigidity when compared to blow molded or extruded panels.
The floor assembly is primarily constructed of a single type of floor panel in combination with front and rear edge assemblies to permit construction of sheds having various predetermined lengths and widths. The same floor components may be used to create an entire family of utility enclosures of varying size, and the assembly of the system requires minimal hardware and a minimum number of hand tools.
Accordingly, it is a primary objective of the instant invention to provide a plastic utility enclosure flooring assembly.
It is a further objective of the instant invention to provide a plastic flooring assembly which utilizes floor panels having single wall construction with integrally formed ribs and gussets for a lightweight yet robust floor assembly.
It is yet another objective of the instant invention to provide a plastic flooring system which accommodates injection molding plastic formation of the panel components for increased structural integrity.
It is a still further objective of the instant invention to provide a flooring system in which the floor panel members include integrally formed connectors.
Still another objective of the instant invention is to provide a flooring assembly which includes floor panels having predetermined sizes for creating enclosures of varying dimensions using common components.
Yet another objective of the instant invention is to provide a flooring assembly which reduces the number of components required to assemble an enclosure and simplifies construction.
Still yet another objective of the instant invention is to provide a floor assembly that includes removable and replaceable locking bosses.
Still yet another objective of the instant invention is to provide a floor assembly having removable and replaceable front and rear end members.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein 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 and any drawings/figures included herein.
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.