Plastic utility shed flooring system

Abstract

The present invention provides a system which includes 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.

Description

RELATED APPLICATIONS [0001] 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. FIELD OF THE INVENTION [0002] 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. 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 blo...

AI Technical Summary

Benefits of technology

[0014] 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.

[0015] 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.

[0018] 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.

[0019] 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.

[0022] 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.

Problems solved by technology

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.

Another drawback associated with blow molded panels is the requirement of an inner and an outer wall.

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.

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.

Due to the nature of the manufacturing process, the conduits are difficult to extrude in long sections for structural panels.

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.

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.

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