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Plastic utility shed wall systemPlastic utility shed wall system description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070175108, Plastic utility shed wall system. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATIONS [0001] This application is a continuation of utility patent application entitled Plastic Expandable Utility Shed filed Aug. 30, 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; and Ser. No. 29/230,978 filed May 27, 2005, the contents of which are herein incorporated by reference in their entirety. FIELD OF THE INVENTION [0002] This invention relates generally to utility sheds, and more specifically to a modular wall system constructed of injection molded plastic panels for creating utility shed walls and doors of various sizes from standardized components. BACKGROUND OF THE INVENTION [0003] 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. [0004] 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 various metal or plastic connector members having a specific cross-sectional geometry that facilitates an engagement between the blow molded or extruded panels to complete the structure. [0005] A particularly common structure for the connector members includes a member having cross section in the form of an I-beam. The I-beam defines free edge portions of the connector member which fit within appropriately dimensioned and located slots in the edges of the panel members. U.S. Patent 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 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. [0006] Another shortcoming 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. [0007] A further shortcoming 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. Also, 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. [0008] 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 walls. A common structure for connecting extruded members has a center I-beam with upper and lower protrusions for engaging the conduits. Wall panels utilizing these connectors are vulnerable to buckling under loads, such as those produced by snow and wind, and may have aesthetically unappealing appearance. 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 panel sections to create the height needed for utility shed walls. [0009] Larger structures must perform differently than small structures. Large structures must withstand increased wind and snow loads when compared to smaller structures. Paramount to achieving these needs is a panel system which eliminates the need for extruded connectors to create enclosure walls which resist panel separation, buckling, and racking. A further problem is that the wall formed by the panels must tie into the roof and floor in such a way as to unify the entire enclosure. Also, from a structural standpoint, the enclosure should include components capable of withstanding the increased wind, snow, and storage loads required by large structures. From a convenience standpoint, a door must be present which is compatible with the sidewalls, and which provides dependable pivoting access to the enclosure. [0010] Therefore, what is needed in the art is an injection molded modular wall system for utility enclosures. The modular wall system should achieve objectives such as lightweight single wall construction. The construction of the panels should eliminate the need for I-beam type connectors to create a wall assembly which resists panel separation, buckling, and racking. The wall assembly should be capable of withstanding the loads typically associated with utility enclosures. Also, from a convenience standpoint, the wall assembly should include various design features to enable cooperation with shelving and/or other storage enhancements. [0011] There are also commercial considerations that must be satisfied by any viable utility shed enclosure system or kit; considerations which are not entirely satisfied by state of the art products. The wall assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The wall assembly must also be capable of being packaged and shipped in a knocked-down state. In addition, the wall assembly must be modular and facilitate the creation of a family of wall assemblies that vary in size but which share common, interchangeable components. [0012] Finally, there are ergonomic needs that a wall assembly must satisfy in order to achieve acceptance by the end user. The wall assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the wall components must not require excessive strength to assemble or include heavy component parts. Moreover, the wall components must assemble together in such a way so as to not detract from the internal storage volume of the resulting enclosure, or otherwise negatively affect the utility of the structure. SUMMARY OF THE INVENTION [0013] The present invention provides a system including injection molded wall panels having integrated connectors which combine to form a family of variously sized wall assemblies for utility enclosures. The wall 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 or fasteners. These integrally formed connectors also allow the wall panels to be utilized for door frames as well as corner sections. The wall panels are also constructed to accept windows for natural lighting, and may include provisions for standard electrical current hookup. The internal surfaces of the wall panels include integrally formed connectors for easy assembly of added components such as shelving, baskets, slat wall storage and the like. The wall assembly further includes a door assembly which may be locked in an open or closed position. The wall assembly eliminates the need for extruded connectors to create enclosure walls which resist panel separation, buckling, racking; and a roof system which allows ventilation while preventing weather infiltration. The walls formed by the panels must tie into the roof and floor in such a way as to unify the entire enclosure. [0014] Accordingly, it is an objective of the instant invention to provide a plastic wall assembly which utilizes wall panels having single wall construction with integrally formed ribs and gussets for a lightweight yet robust wall assembly. [0015] It is yet another objective of the instant invention to provide a plastic wall assembly which accommodates injection molding plastic formation of the panel components for increased structural integrity. [0016] It is a still further objective of the invention to provide a plastic wall assembly which utilizes structural corner assemblies for increased enclosure rigidity. [0017] Still another objective of the instant invention is to provide a wall system in which the wall panel members include integrally formed connectors. [0018] Yet another objective of the instant invention is to provide a wall assembly which includes wall panels having predetermined sizes for creating enclosures of varying dimensions using common components. [0019] Still yet another objective of the instant invention is to provide a wall assembly which may be optionally configured with clear windows thereby allowing natural light to enter the enclosure. [0020] Still yet another further objective of the instant invention is to provide a wall assembly which reduces the number of components required to assemble an enclosure and simplifies construction. Continue reading about Plastic utility shed wall system... Full patent description for Plastic utility shed wall system Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Plastic utility shed wall system patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Plastic utility shed wall system or other areas of interest. ### Previous Patent Application: Self-adhered flange for use with non-flanged windows Next Patent Application: Observation shelter Industry Class: Static structures (e.g., buildings) ### FreshPatents.com Support Thank you for viewing the Plastic utility shed wall system patent info. 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