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

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.

Sti

Images