Foldable Plastic Shed Panels With Interlocking Joints Against Water Ingress
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Solution Overview
Problem
Existing outdoor storage sheds face issues with structural instability, water ingress, and high transportation and installation costs due to traditional materials and assembly methods.
Innovation Solution
The use of molded plastic panels with interlocked teeth couplings, foldable corner panels, and integrated strengthening ribs, along with innovative coupling mechanisms, provides a durable and stable shed structure that minimizes seams and reduces packaging and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional materials and assembly methods are used for outdoor storage sheds, then manufacturing and installation are straightforward, but structural stability is poor and water ingress occurs
Solution Approach 1:
The shed is divided into modular panels (wall panels, floor panels, roof panels) that can be assembled together. Each panel is a self-contained unit with standardized coupling mechanisms, allowing for systematic construction while maintaining overall structural integrity and weather tightness through the interlocking joints between segments.
Solution Approach 2:
Multiple functions are combined into the panel structures: the panels provide both structural support and weather protection, the coupling mechanisms simultaneously join panels and seal joints, and the foldable corners integrate structural articulation with weather sealing capabilities in a single integrated component.
2Strength
If traditional rigid materials are used, then structural strength is sufficient, but transportation cost is high due to weight
Solution Approach 1:
The material properties are optimized by using molded plastic with specific density and structural characteristics. The panels incorporate strengthening ribs and optimized thickness variations to achieve high strength-to-weight ratio, maintaining structural integrity while significantly reducing weight compared to traditional materials like wood or metal.
3Stability of the object's composition
If complex assembly mechanisms are used, then structural stability improves, but installation complexity increases
Solution Approach 1:
The coupling mechanisms are designed to be self-aligning and self-latching. The interlocking teeth and recesses automatically engage when panels are brought together, and the foldable corner panels self-lock into position through their hinge mechanisms, eliminating the need for complex fastening procedures or specialized installation tools while maintaining robust structural connections.
4Ease of manufacture
If non-foldable panels are used, then manufacturing is simpler, but packaging volume and transportation cost increase
Solution Approach 1:
The corner panels incorporate foldable hinges that allow the panel to change its configuration from a flat, extended position during manufacturing and packaging to a three-dimensional corner position during installation. This dynamic capability enables compact stacking and reduced packaging volume while maintaining the ability to form proper corner structures for the shed.
Data Source
AI summary
The present subject matter discloses an outdoor storage shed utilizing molded plastic components or panels. A storage shed structure can comprise foldable corner panels and one or more interlocked teeth couplings. The foldable corner panel can pivot at integrated folding grooves to serve as corners. The interlocked teeth couplings comprise a plurality of protrusions and matched recesses arranged on both sides of engaged panels. Furthermore, the storage shed can come with pre-constructed shelf grooves in the foldable corner panels. The storage shed can have a concaved door frame and a recessed door.