Patent Application
20100122509
The present invention relates generally to wall and wall panel structures and to enclosures made from such panel structures. The invention finds particular application and advantage in the construction of screen enclosures.
It is well known that easily assembled and disassembled wall panel structures have significant utility. It is also well known that such panel structures can be useful in the construction of various forms of enclosures, such as screened porches and patios, lanais and gazebos. Other enclosures with panels fabricated from lightweight materials other than screens, such as tool and garden sheds and hunting and fishing blinds, also benefit from construction designs that permit easy assembly and disassembly. The technical literature shows a wide variety of designs useful in such applications, yet there still exists a need for a light weight, inexpensive wall panel design which may be easily assembled and disassembled with few if any tools. Such a design facilitates cleaning, maintenance and repair of the enclosures and makes them much more suitable for use in climates where winter snowfalls require annual removal of the enclosure roof panels.
The present invention is directed to a wall panel structure which is easily assembled and disassembled and is constructed from a plurality of frame assemblies, each frame assembly comprising a first frame component having a first wall and an adjacent second wall, the first wall having an externally accessible abutment surface; and a second frame component having an angled cross section defined by first and second arms, the first arm having an inwardly extending flange configured to engage said abutment surface of the first frame component, and the second arm configured to engage the second wall of the first frame component.
In one disclosed embodiment the wall panel structure includes at least one tubular wall frame member and first and second panel frame members. The tubular wall frame member is formed to have a generally rectangular cross section defined by four sides, one side having a pair of opposing abutment surfaces. The first and second panel frame members each have two arms defining a generally L shaped cross section. The first arm of the first panel frame member terminates at a distal end having a retaining lip adapted to engage one of the abutment surfaces on the frame member, and the second arm of the first panel frame member is positioned and configured to engage a second side of the wall frame member which is adjacent to the side with the abutment surfaces. The first arm of the second panel frame member also terminates at a distal end having a retaining lip adapted to engage the other abutment surface on the wall frame member, and the second arm of the second panel frame member is positioned and configured to engage a third side of the wall frame member opposite to said second side. The first and second panel frame members also have spline channels configured to receive a spline and a border of a panel sheet member. One or more retainers engage the wall frame member and the panel frame members to maintain said members in assembled relation.
The novel features which are characteristic of the present invention are set forth in the appended claims. However, the invention's preferred embodiments, together with further objects and attendant advantages, will be best understood by reference to the following detailed description taken in connection with the accompanying drawings in which:
As illustrated in
The screened enclosure 10 is constructed with a plurality of panels 12 which make use of a unique wall panel structure allowing the enclosure to be easily assembled and disassembled. The wall panel structure includes a skeleton of wall frame components 14 which support the many screened panels 12. In some cases, for example on the side walls of the enclosure, the screen panels may be assembled directly to the wall frame components, using a conventional spline recess and spline. In other cases, for example on the roof of the enclosure, the screen panels may be assembled to the wall frame components 14 using the novel frame assembly of the present invention.
The wall frame components 14 may also include spline grooves 38 so that the screen material may be assembled directly to the wall frame in a more permanent fashion, if that is desired, without the use of the panel frame components 30.
As shown in
The wall frame component 14 and the panel frame component 30 may be advantageously constructed from extruded plastic or aluminum, both of which afford a light weight and durable enclosure. The fittings may be constructed from molded plastic or elastomer.
It will be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. For example, the sheet material forming the panels need not be screen, but may comprise other sheeting such a plastic film. All such modifications and changes are intended to be covered by the appended claims.
