Modular Enclosure Using Segmented Plastic Panels
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Solution Overview
Problem
Conventional sheds are cumbersome to build, difficult to disassemble, and require significant time, labor, and maintenance due to their heavy and bulky construction from materials like wood and metal, which also leads to high shipping costs and practicality issues for consumers.
Innovation Solution
A modular shed constructed from lightweight blow-molded plastic components that are easily assembled, disassembled, and reconfigured, featuring interlocking panels and a design that minimizes the number of parts and requires less maintenance, with features like ultraviolet inhibitors for durability and integrated patterns for strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sheds are constructed from wood or metal, then structural strength is achieved, but weight and bulk increase making them difficult to assemble and ship
Solution Approach 1:
The shed is divided into multiple modular panels (wall panels, roof panels, floor panels) that can be separately manufactured and assembled. Each panel is a discrete component that can be easily handled and connected through interlocking mechanisms, reducing the weight burden on individual components while maintaining overall structural integrity.
Solution Approach 2:
The patent employs composite construction combining plastic materials with metal fastening systems. The panels are primarily plastic which is lightweight, while metal fasteners provide the necessary structural connection strength. This composite approach allows the shed to achieve required strength without relying on heavy traditional materials throughout the entire structure.
2Stability of the object's composition
If conventional sheds use numerous interconnected parts, then structural integrity is maintained, but assembly time and complexity increase
Solution Approach 1:
The shed structure is segmented into standardized panels with uniform connection interfaces. Each panel has identical mounting holes and interlocking features positioned at consistent locations, allowing for rapid assembly through repetitive connection operations rather than custom fitting of unique components.
Solution Approach 2:
The connection system uses universal fastening mechanisms that serve multiple purposes: securing panels to each other, providing structural stability, and enabling easy disassembly. The same type of fastener and connection interface is used throughout the entire shed, simplifying the assembly process compared to varying connection methods.
3Reliability
If conventional sheds are built with heavy materials, then durability is achieved, but shipping costs and consumer handling difficulty increase
Solution Approach 1:
By dividing the shed into separate panels, each component becomes lighter and easier for consumers to handle during delivery and assembly. The modular design allows panels to be packed compactly and transported in smaller units, reducing shipping complexity and cost while maintaining the durability of the complete assembled structure.
Solution Approach 2:
The patent changes the material parameters from heavy traditional materials to lightweight plastic while compensating for strength through optimized panel design, interlocking mechanisms, and distribution of structural loads across multiple connection points. This parameter change reduces weight for easier handling while preserving necessary durability.
4Stability of the object's composition
If conventional sheds use traditional construction methods, then structural stability is achieved, but adaptability for reconfiguration and relocation is reduced
Solution Approach 1:
The connection system is designed to be dynamically adjustable, allowing panels to be connected, disconnected, and reconnected in different configurations. The reversible fastening mechanisms enable the shed to transition between assembled and disassembled states, providing adaptability for relocation and reconfiguration while maintaining structural stability when assembled.
Solution Approach 2:
The modular panel design with standardized interfaces enables flexible reconfiguration of the shed structure. Panels can be rearranged in different configurations or completely disassembled and relocated, providing adaptability that traditional monolithic construction methods do not allow while maintaining structural integrity through consistent connection protocols.
Data Source
AI summary
A modular enclosure, such as a shed, may include sidewalls and a roof. The roof, for example, may include one or more roof panels. The roof may also include a truss that is sized and configured to support the roof panels. The shed may also include one or more support beams that may be connected to the truss and may be connected to one or more panels. The shed may include one or more brackets used to connect a pair of panels that are positioned at an angle to form a corner of the shed. The shed may also include a cover, which may include one or more receiving portions sized and configured to receive at least a portion of the brackets. A plurality of roof panels may be positioned within a shipping container to form storage areas or cavities sized and configured to receive all or at least a portion of one or more floor panels.