Modular cupola assembly

Abstract

The present invention relates to kit for a cupola assembly. The cupola assembly utilizes injection molded plastic panels having integrally formed connectors. The cupola is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola.

Description

FIELD OF THE INVENTION [0001] This invention relates generally to a cupola device constructed of plastic structural panels. More specifically, the present invention relates to a cupola kit utilizing modular injection molded plastic panels. The cupola kit is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola assembly upon a desired site. BACKGROUND INFORMATION [0002] Permanent structures such as utility sheds or garages are often utilized for storage of household items such as gardening tools, children's toys, barbeque accessories and the like. A common addition to the roof of such structures is the cupola. Cupolas have been part of architectural design for many years. Most cupolas are constructed of wood, with metal or shingle roofs, and may include windows to admit light or louvers to vent hot air out of the structure to which they are attached. [0003] Wooden cupolas are generally custom made for a particular roof and thus assembly an...

AI Technical Summary

Benefits of technology

[0015] The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form a roof mountable cupola. The panels are formed of injection molded plastic to interlock with one another without the need for separate fasteners or connectors. The system incorporates a minimum number of components to construct a cupola by integrally forming the connectors into the injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the cupola. The integrated connection of the side walls and cover components also simplifies cupola construction. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or extruded panels. The same side wall and cover panel components may be used to create a variety of cupolas and the assembly thereof requires minimal hardware and a minimum number of hand tools.

[0016] The front and rear wall panels have outwardly projecting locking posts for interlocking cooperative engagement with sockets in the left and right side wall panels. The engagement between the locking posts and the sockets serve to rigidly connect the components together. The system further includes a cover which slides into place after the front, rear, left and right wall panels have been fully assembled. The cover may include spring locks for engagement with the side panels or alternatively may be held in place with suitable fasteners. The system is constructed to allow various cover panels to be utilized further increasing the utility of the assembled cupola.

[0018] A further objective is to provide a modular cupola assembly wherein the panels include integrated connectors accommodated by injection molding plastic formation for increased structural integrity.

Problems solved by technology

Wooden cupolas are generally custom made for a particular roof and thus assembly and installation require a great deal of time and expertise.

Because these structures are made of wood they also require a great deal of maintenance to prevent degradation during the life of the structure to which they are attached.

Such prior art systems, while working well, have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped or the needs of consumers requiring structural integrity combined with modularity and aesthetic appearance.

For example, the metal structures of the prior art include numerous sharp edges and are difficult to assemble.

In addition, the thin sheet metal panels are easily bend during shipping and assembly.

The combination plastic and metal structures do not include any integrated fasteners and thus require substantial skill as well as numerous tools to assemble.

The roto-molded structures do not break down into small components and thus are expensive and difficult to ship.

In addition, due to the nature of the manufacturing processes utilized for constructing the prior art cupolas, the panel components cannot be formed with the intricate shapes and / or cross sections required for integrated connectors.

There are also commercial considerations that must be satisfied by any viable cupola assembly or kit; considerations which are not entirely satisfied by state of the art products.

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