Modular Plastic Shed Panels with Folding Grooves and T-Connectors
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Solution Overview
Problem
Existing modular storage sheds lack efficient assembly and disassembly mechanisms, and often require complex hinge structures and numerous fasteners, which can be labor-intensive and prone to structural instability.
Innovation Solution
A modular storage shed design utilizing blow-molded plastic panels with embedded seamless folding grooves and T-shaped connectors for secure assembly, along with pivotable frame brackets for enhanced door stability and support columns with reinforcement ribs for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional hinge structures and numerous fasteners are used for assembly, then the shed can be assembled, but the assembly process becomes labor-intensive and structurally unstable
Solution Approach 1:
The shed is divided into modular panels (wall panels, floor panels, roof panels) that can be independently manufactured and assembled. Each panel is a self-contained unit with integrated connection features, eliminating the need for complex hinge structures and numerous separate fasteners. The segmentation allows for simple snap-fit or interlocking assembly mechanisms.
Solution Approach 2:
Multiple functions are merged into single components. For example, wall panels integrate both structural support and connection features in one element. The panels combine framing, cladding, and attachment mechanisms into unified modular units, reducing the total number of parts and simplifying the assembly process while improving structural stability.
2Weight of moving object
If molded plastic panels are used, then transportation cost is reduced due to lighter weight, but structural stability may be compromised
Solution Approach 1:
The patent utilizes molded plastic panels that combine lightweight properties with enhanced structural characteristics. The plastic material is engineered to provide adequate strength-to-weight ratio, and the panels incorporate internal reinforcement structures or ribbing to maintain structural stability while keeping weight low for cost-effective transportation.
Solution Approach 2:
The molded plastic panels incorporate curved or arched structural elements rather than purely flat surfaces. These curved geometries provide inherent structural strength and rigidity, allowing the lightweight plastic material to resist external loads and maintain structural stability without requiring additional heavy reinforcement.
3Adaptability or versatility
If molded plastic panels are used, then design flexibility is improved, but manufacturing precision requirements increase
Solution Approach 1:
The molded plastic panels are designed with standardized dimensions and geometric parameters that can be easily varied. By changing key parameters such as panel size, thickness, rib spacing, or connection feature locations, a wide range of design configurations can be achieved using the same basic manufacturing process and mold tools, maintaining precision while providing flexibility.
Solution Approach 2:
The patent employs universal connection features and standardized panel interfaces that work across different panel types and configurations. This allows the same manufacturing precision standards to serve multiple design purposes, reducing the complexity of maintaining precision across varied designs while still enabling design flexibility through different panel arrangements and configurations.
Data Source
AI summary
The present subject matter discloses a prefabricated modular shed constructed from modular plastic components or panels. The modular storage shed can be installed onsite with pre-constructed modular panels. The shed features embedded seamless folding grooves such as in the door panels and the central roof panel. Furthermore, a pivotable frame bracket can encase the edge of the rotating panels, enhancing both strength and durability. The wall and floor panels are secured with T-shaped connectors to further improve stability. The structural integrity of the shed's walls is reinforced by support columns with built-in reinforcement ribs, which are designed for simple installation. In addition, the modular storage shed can be expandable depending on the preferred size.