CA2392238A1

CA2392238A1 - Modular storage shed

Info

Publication number: CA2392238A1
Application number: CA002392238A
Authority: CA
Inventors: Brian K. Zeilinger
Original assignee: Individual
Current assignee: Playstar Inc
Priority date: 1999-11-23
Filing date: 2000-11-22
Publication date: 2001-05-31
Also published as: EP1144776A4; WO2001038669A1; AU1800501A; EP1144776A1

Abstract

The present invention is directed to a modular storage shed (10) that is configured to be stronger, less expensive to manufacture, and easier to assemble. The modular storage shed (10) is designed to its overall length changed by inserting addition floor sections (41), roof sections (31) and pairs of sidewalls (21).

Description

MODULAR STORAGE SHED
FIELD OF THE INVENTION
This invention relates to an improved storage shed, and more particularly to a modular storage shed that is easily assembled and readily adapted to be formed into different configurations.
BACKGROUND OF THE INVENTION
Modular sheds are used for storing items such as lawn and garden implements.
Individual sheds are typically purchased in the form of unassembled kits that are readily transported to a desired location where the shed is assembled together. A
typical shed includes four walls and a roof with one of the walls including doors that provide access to the interior of the shed.
The walls of the modular storage sheds are commonly made up of one or more subpanels such that the overall size of the shed may be adjusted by adding or subtracting subpanels from the walls, floor and roof. The length of the sheds is the most commonly adjusted dimension and is increased or decreased by adding or subtracting subpanels to/from the sidewalk, the roof and the floor (if one is present).
SUMMARY OF THE INVENTION
The present invention is directed to a modular storage shed that is configured to be stronger, less expensive to manufacture, and easier to assemble. The modular storage shed is designed to have its overall length changed by inserting additional floor sections, roof sections and pairs of sidewalk.
In one form, the modular storage shed includes a roof, sidewall and door. The sidewall includes an extension that protrudes from an edge of the sidewall.
The extension includes an outer section and an inner section with the inner section extending from the edge of the sidewall. The door includes a channel that mates with the outer section of the extension such that the door rotates relative to the sidewall in order to allow access into the interior of the shed.
In one embodiment, the channel on the door is parallel to an edge of the door and a slot extends inward from the edge of the door into communication with the channel. The extension is T-shaped and the slot is sized to allow the inner section of the T-shaped extension to pass through the slot until the outer section is aligned with the channel in the door. Once the outer section of the T-shaped extension is positioned within the channel, the T-shaped extension prevents the door from being separated from the sidewall.
It should be noted that the orientation of the T-shaped extension on the sidewall and the channel in the door may be reversed (i.e., the sidewall may include the channel and the door may include the T-shaped extension) without departing from the scope of the present invention. In addition, there may be channels and T-shaped extensions on both the door and the sidewall.
In another form, the modular storage shed includes a roof, a plurality of sidewalls and an interlocking floor positioned below the sidewalk. The interlocking floor includes a first section having a tenon and a second section having a mortise such that the tenon on the first section is inserted into the mortise on the second section.
The first and second sections are assembled together by twisting one, or both, of the first and second sections. Twisting one, or both, of the first and second sections allows the mortise that is in communication with the mating edge of the second section to receive the tenon that is in communication with the mating edge of the first section (see Figs. 5-8).
In a preferred form, the tenon and mortise have a dovetail configuration.
In still another form, the modular storage shed includes a roof, a bracket and a plurality of sidewalls. The bracket includes a tenon that extends from an edge of the bracket as well as a projection positioned near the tenon. One of the sidewalk includes a mortise that is adapted to receive the tenon on the bracket as well as an indentation that receives the projection on the bracket. The projection on the bracket abuts an edge of the indentation and prevents the tenon from sliding relative to the mortise in the sidewall once the tenon is inserted into the mortise and the projection is inserted into the indentation.
The mortise preferably includes an open end such that the tenon on the bracket is inserted into the mortise from the open end.
In yet another form, the modular storage shed includes a plurality of sidewalls and a roof secured to the sidewalls. The roof includes a first subpanel and a second subpanel with each subpanel having edges that mate with one another to form a water-tight seal.
The edge on the first section includes a first projection and an undercut section and the edge on the second section includes a second projection that fits within the undercut section on the first section. In addition, the mating edges are preferably arc-shaped and the roof is connected to the sidewalk by a snap-fit connection.
In another form, the modular storage shed includes a roof and a plurality of sidewalls where one of the sidewalls includes an extension projecting from a portion of an edge on the sidewall. The extension preferably includes a cylindrical insert that is inserted into a cylindrical slot which is in communication with an edge of an adjacent sidewall.
Once the cylindrical insert is positioned within the slot, the adjacent sidewalls are rotatably connected together. The adjacent sidewalk are preferably assembled together by forcing the insert into the slot.
In still another form, one of the sidewalls includes a plurality of extensions projecting from an edge of the sidewall with each extension preferably including a cylindrical insert. The edge of the adjacent sidewall includes a plurality of cylindrical slots that receives one of the cylindrical inserts. The slots and the inserts are preferably evenly spaced along the entire edges of the sidewalk. The sidewalls are assembled together by snapping the inserts on one of the sidewalk into the slots on an adjacent sidewall. Once the extensions are inserted into the slots, the sidewalk are rotatably connected.
The adjacent sidewalls include side surfaces and the rotatable movement of the sidewalls relative to one another is limited in one direction by contact between one of the edges and one of the side surfaces and limited in an opposite direction by contact between the edges. The sidewalls preferably have 90° of rotatable movement while the cylindrical insert in one sidewall is positioned within the slot of an adjacent sidewall.
In yet another form, the modular storage shed includes a plurality of sidewalls and a roof secured to the sidewalls. The roof includes a back section, a front section and an arcuately shaped extension section positioned between the back section and the front section. The arcuately shaped extension section is used to extend the length of the roof and includes a support header extending between opposing ends. The extension section also includes opposing edges that are adapted to mate with edges on the front and back sections to form a water tight seal between the back section, the front section and the extension section. The header in the extension section allows the extension section to support a snow load when one or more extension sections are added to the roof between the front section and the back section. The extension sections are also preferably assembled to the front and back sections and/or other extension sections without using fasteners.
In still another form, the modular storage shed includes a roof having a void and a sidewall having an extension that is adapted to be inserted into the void in the roof. The extension on the sidewall includes a projection that is snap-fit into an indentation within the void in order to secure the roof to the sidewall. The void is larger than the extension in order to permit a tool to be inserted into the void to facilitate removing the roof from the shed. In a preferred form, the extension protrudes from one end of the sidewall and the void extends inward at one edge of the roof. The sidewall may also include one or more additional extensions and the roof may include one or more additional voids to receive each of the additional extensions in order to provide additional connections between the roof and the sidewalk.
It should be noted the orientation of the extension and the void in the roof and the sidewall may be reversed (i.e., the roof may include the extension and the sidewall may include the void) without departing from the scope of the present invention.
In addition, there may be voids and extensions on the same sections of the roof and sidewall.
In another form, the modular storage shed includes a plurality of sidewalls, a roof extending above the sidewalls and a floor positioned below the sidewalk. The plurality of sidewalls include outer surfaces and the floor extends outwardly past each of the outer surfaces on the sidewalls such that a lawn mower is able to snugly cut grass around the entire shed.
A principle advantage of the invention is to provide a modular storage shed that includes a hinge configuration between a door and a side wall where the mid-portion of the door is prevented from becoming separated from the wall through 180° of articulation as the door is rotated relative to the rest of the shed.
Another advantage of the invention to provide a modular storage shed that includes a floor which may be assembled together with minimal mounting hardware.
Yet another advantage of the invention is to provide a modular storage shed that includes brackets which are readily and securely connected to the walls of the storage shed.
Still another advantage of the invention is to provide a modular storage shed that includes roof panels that are joined together in a simple and secure manner without the use of mounting hardware.
Another advantage of the invention is to provide a modular storage shed that includes sidewall subpanels which are readily and securely mounted together to form sidewalls in the modular storage shed.
Still another advantage of the invention is to provide a modular storage shed with a roof extension section that includes a header which allows the roof extension section to support a snow load when the roof extension section is used in conjunction with an additional floor section and a pair of sidewalls to extend the length of the shed.

Yet another advantage of the present invention is provide a modular storage shed that permits a tool to be inserted between the top of the sidewalls and the roof to facilitate separating the roof from the sidewalk.
Other features and advantages of the invention are set forth in the following drawings, detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of an assembled modular storage shed of the present invention.
Fig. 2 is a perspective view similar to Fig. 1 illustrating another form of the modular storage shed shown in Fig. 1.
Fig. 3 is a perspective view of the modular storage shed shown in Fig. 1 with one of the shed doors open.
Fig. 4 is a section view of the modular storage shed shown in Fig. 1 taken along line 4-4.
Fig. S is a top plan view illustrating a partially assembled interlocking floor used in the modular storage shed of the present invention.
Fig. 6 is a section view of the interlocking floor of Fig. 5 taken along line 6-6.
Fig. 7 is a front view illustrating one technique for assembling two sections of the interlocking floor shown in Fig. 5.
Fig. 8 is a perspective view illustrating one of the connections between two sections of the interlocking floor shown in Fig. 5.
Fig. 9 is a section view of the modular storage shed of Fig. 1 taken along line 9-9.
Fig. 10 is a section view similar to Fig. 9 illustrating another form of the connection between a sidewall and the floor of the modular storage shed.
Fig. 11 is a plan view illustrating a pair of sidewalk that are used to form the walls of the modular storage shed.
Fig. 12 is a plan view illustrating a portion of the adjacent sidewalls of Fig. 11 assembled to one another.
Fig. 13 is a section view of the assembled adjacent sidewalls of Fig. 1 taken along line 13-13 illustrating the connection between adjacent sidewalk.
Fig. 14 is a section view similar to Fig. 13 illustrating another portion of the assembled adjacent sidewalls.

Fig. 15 is a section view similar to Fig. 13 illustrating another portion of the assembled adjacent sidewalls.
Fig. 16 is an exploded perspective view illustrating the connection between a door, a sidewall and the floor of the modular storage shed illustrated in Fig. 1.
Fig. 17 is a front plan view illustrating a portion of the door that is connected to an adjacent sidewall on the modular storage shed shown in Fig. 1.
Fig. 18 is a side plan view illustrating a portion of a sidewall that is connected to the door on the modular storage shed shown in Fig. 1.
Fig. 19 is a plan view illustrating a portion of the door in the modular storage shed that is adapted to be connected to a T-shaped extension on an adjacent sidewall.
Fig. 20 is a section view similar to Fig. 19 illustrating the door connected to a T-shaped extension on an adjacent sidewall.
Fig. 21 is a perspective view illustrating one form of the connection between a sidewall and a roof section of the modular storage shed.
Fig. 22 is a section view illustrating the form of the connection between the roof and the sidewall shown in Fig. 21.
Fig. 23 is a top plan view illustrating a front section of the roof on the modular storage shed.
Fig. 24 is a front plan view illustrating the front section of the roof shown in Fig.
23.
Fig. 25 is a section view illustrating the front section of the roof shown in Fig. 23 taken along line 25-25.
Fig. 26 is a section view illustrating the front section of the roof shown in Fig. 23 taken along line 26-26.
Fig. 27 is a side plan view illustrating the front section of the roof shown in Fig.
23.
Fig. 28 is a top plan view illustrating an arcuately shaped extension section in the roof of the modular storage shed shown in Fig. 1.
Fig. 29 is a front plan view of the extension section shown in Fig. 28.
Fig. 30 is a section view of the extension section shown in Fig. 28 taken along line 30-30.
Fig. 31 is a section view of the extension section shown in Fig. 28 taken along 31-31.
Fig. 32 is a side plan view of the extension section shown in Fig. 28.

Fig. 33 is a section view illustrating a connection between a bracket and a sidewall where the bracket is used to support a shelf in the modular storage shed of the present invention.
Fig. 34 is a section view similar to Fig. 33 illustrating the attachment of the bracket to the sidewall in the modular storage shed.
Fig. 35 is a section view of the connection between the bracket and the door shown in Fig. 34 taken along line 35-35.
DETAILED DESCRIPTION
A modular storage shed 10 of the present invention is shown in Figs. 1-4. Fig.

illustrates a smaller version of the modular storage shed 10. The smaller version includes a pair of sidewalls 21 (only one is visible in Fig. 2), a roof 31, a floor 41 and doors 50.
The back wall 12 (not visible in Fig. 2) of the shed 10 is made up of three sidewalls 21.
As shown in Figs. 1, 3 and 4, the length of the modular shed 10 can be increased by adding additional pairs of sidewalk 21B, 21C, additional floor sections 41B, 41C and additional roof sections 31B, 31C to the pair of sidewalls 21A, floor section 41A and roof section 31A. It should be understood that length of the modular storage shed 10 could be increased even further by adding additional floor sections, roof sections and pairs of sidewalls that are similar to the pair of side panels 21B, roof panels 31B and floor panels 41B shown in Figs. 1, 3 and 4.
The modular storage shed 10 illustrated in Figs. l, 3 and 4 is assembled by first fabricating the floor 41. As shown most clearly in Fig. 5, the floor 41 includes a first section 41A, a second section 41C and an intermediate section 41B inserted between the first section 41A and the second section 41C when the length of the shed 10 is extended.
It should be noted that although the first section 41A and the second section 41C are shown as having identical configurations, the sections may have different designs depending on the application where the modular storage shed 10 is used.
Although there is a similar connection between the first section 41A and the intermediate section 41B, only the connection between the second section 41C
and intermediate section 41B will be explained in detail with reference to Figs.
5, 7 and 8. The second section 41C includes dove-tailed tenons 42 that are in communication with a lower surface 43 on the second section 41C. The tenons 42 extend out from a mating edge 44 of the second section 41C and are adapted to be inserted into mortises 45 on one end of the intermediate section 41B to form a connection between the intermediate section 41B and _g_ the second section 41C. The mortises 45 extend inward from a mating edge 46 on the intermediate section 41B and are in communication with a lower surface 47 on the intermediate section 41B.
The second section 41C and the intermediate section 41B are also connected on an opposing end in a manner similar to the connection between the intermediate section 41B
and the second section 41C on the end described above except the intermediate section 41B includes dove-tailed tenons 48 that are in communication with the lower surface 47 of the intermediate section 41B. The tenons 48 extend outward from the mating edge 46 of the intermediate section 41B and are adapted to be inserted into mortises 52 within the second section 41C. The mortises 52 on the second section 41C extend inward from the mating edge 44 and are in communication with the lower surface 43 of the second section 41C.
The second section 41C and the intermediate section 41B (as well as any other floor sections) are assembled by (i) twisting one, or both, of the sections, (ii) abutting the mating edges 44, 46 together, and (iii) inserting the tenons 42, 48 into the appropriate mortises 45, 52 (see Figs. 7 and 8). Fasteners are not required to assemble the tenons 42, 48 and the mortises 45, 52 together, although as shown in Figs. 6 and 8, a fastener 95 could be used to provide a more secure connection between the sections of the floor 41.
The floor sections 41A-C preferably include a raised pattern that serves to provide an improved gripping surface on the floor 41 of the modular shed 10. Although the raised pattern is shown in a square configuration in Figs. 5 and 8, it should be understood that the raised pattern can take any conventional form that provides a superior gripping surface.
Once the floor 41 is assembled together, the sidewalk 21 are assembled to the floor 41 and one another. As shown most clearly in Fig. 9, the sidewalk 21 are snap-fit into one of the sections that make up floor 41. In a preferred form, the sidewalk 21 includes a projection 19 having an undercut section 22. The projection 19 is sized so that it must be forced through a narrowed section within an opening 42 in the floor 41. As the projection 19 passes through the narrowed section of the opening 42, the undercut section 22 engages a lateral edge 43 within the opening 42. Once the undercut section 22 engages the lateral edge 43, the sidewall 21 is prevented from exiting the opening 42 thereby securing the sidewall 21 to the floor 41. The projection 19 on the sidewall 21 and opening 42 in the floor section 41 are preferably sized so that a bottom edge 24 on the sidewall 21 engages a top surface 74 on the floor 41 once the undercut section 22 engages the lateral edge 43.
The floor 41 extends outwardly past any of the sidewalk 21 and the doors 50 that make up the modular storage shed 10 (see Figs. 1 and 2) a sufficient distance such that a conventional lawn mower can be maneuvered around the entire modular storage shed in order to cut any grass growing around the modular storage shed.
It should be understood that the snap-fit configuration between the sidewall 21 and the floor section 41 could be any configuration that is commonly known in the art. In addition, the snap-fit configuration may be eliminated entirely and/or may also be used in combination with a fastener 45 (see Fig. 10).
Figs. 11 and 12 illustrate a pair of sidewalls 21A, 21B (shown assembled in Fig.
12) that each include an upper edge 25 and a bottom edge 24. As stated previously, projections 19 extend downward from the bottom edge 24 while similar projections 19 extend upward from the upper edge 25. One of the lateral edges 27 on each of the sidewalk 21A, 21B includes an outwardly projecting extension 23. The opposing lateral edge 28 includes either (i) a slot 29 that is aligned with the extension 23 (Fig. 12); or includes T-shaped extensions 51 that are adapted to mate with one of the doors 50 on the modular storage shed 10 (Fig. 11).
The extension 23 on the sidewall 21B is adapted to be inserted into the slot 29 on the lateral edge 28 of the adjacent sidewall 21A in order to connect the adjacent sidewalk 21A, 21B together. The sidewall 21B is assembled to sidewall 21A by positioning the extension 23 adjacent to the slot 29 and snapping the extension 23 into the slot 29. Once the extension 23 is inserted into the slot 29, the projections 19 on the bottom edge 24 of the sidewall 21B are snap-fit into the openings 42 in the floor 41.
The sidewalk 21 are inserted around the edges of the floor 41 until the walls of the modular storage shed 10 are formed. One edge of the floor 41 does not include sidewalk because that side of the shed 10 includes doors 50 (see Figs. 1 and 3) which are assembled to lateral edges 28 that are similar to one included in sidewall 21B.
The configuration for the connection between the extension 23 and the slots 29 in the adjacent sidewalk 21A, 21B is further shown in Figs. 13-15. The extension projects from the lateral edge 27 of the sidewall 21B and includes a cylindrical insert 25.
The slot 29 in the adjacent sidewall 21A include a cylindrical section 9 that is sized to receive the cylindrical insert 25. Once the cylindrical insert 25 is positioned within the slot 29, the adjacent sidewalk 21A, 21B can be rotated 90° relative to one another unless both of the sidewalk 21A, 21B are secured to the floor 41.
Figs. 13-15 show the adjacent sidewalk 21A, 21B positioned 180°
apart. When the adjacent sidewalk 21A, 21B are in this position, the lateral edges 27, 28 of the adjacent sidewalk 21A, 21B are positioned against one another to form part of a common wall on the modular storage shed 10. When the adjacent sidewalk 21A, 21B are positioned at 90°
relative to one another, the lateral edge 27 of the sidewall 21B is positioned against a side surface 8 of the adjacent sidewall 21A such that the sidewalk 21A, 21B are on different sides of the modular storage shed 10.
In one embodiment, the extensions 23 on the sidewalk 21 extend along the entire length of the lateral edges 27. The sidewalk 21 are assembled according to one of two methods. The first method includes inserting the extension 23 up or down through the open ends (usually the upper end) on one of the slots 29. In the second and more practical method, the cylindrical insert 25 is forced into the cylindrical portion 9 within the slot 29 because the relative sizes of the cylindrical insert 25 and the cylindrical portion 9 allow the cylindrical insert 25 to be snap-fit into the slot 29. The adjacent sidewalk 21A, 21B are preferably positioned about 135° apart relative to one another when the cylindrical insert 25 is forced into the slot 29 (shown in phantom in Fig. 13).
The extension 23 on each sidewall 21 includes intermittently and evenly spaced relief sections 24 extending along the length extension 23 (see Fig. 11). The relief sections 24 facilitate molding the sidewalk 21 from plastic.
Referring to Figs. 11-13, one or more recesses 26 are positioned adjacent to the extension 23 on the sidewall 21B. The sidewall 21A includes a corresponding number of projections 36 that are inserted into the recesses 26 when the sidewalls are assembled together and positioned 180° apart. As stated previously, the sidewalk 21A, 21B are preferably snapped together when they are 135° apart relative to one another and as the sidewalk are moved so that they are 180° apart the projections 36 on sidewall 21A move into the recesses 26 on sidewall 21B. Once the projections 36 are inserted into the recesses 26 the sidewalk 21A and 21B are prevented from moving vertically relative to one another.
Once the sidewalk 21 are secured to one another and the floor 41, each of the doors 50 is assembled to the floor 41 and one of the sidewalk 21. As shown most clearly in Figs. 16-20, the particular sidewalls 21 that are connected to the doors 50 include extensions 51 that project from a lateral edge 29 of a sidewall 21. The extensions are preferably T-shaped and include an outer section 53 and an inner section 54.
The outer section 53 fits within a channel 55 in the door 50. Once the outer section 53 is inserted all of the way into the channel 55, the door 50 is able to rotate more than 180° relative to the sidewall 21. The T-shaped extension 51 restrains the door 50 from moving laterally relative to the sidewall 21.
The door 50 is assembled to the sidewall 21 by inserting the outer section 53 of the T-shaped extension 51 into the channel 55 in the door 50 and rotating the door 50 until the inner section 53 passes through the slot 56. The slot 56 is in communication with both the channel 55 and a lateral edge 57 of the door 50.
Figs. 16-18 illustrate that the door 50 includes a cylindrical extension 58 which projects from a bottom edge 59 of the door 50. The cylindrical extension 58 is adapted to fit within an opening 40 (see Fig. 16) in the floor 41. Once the cylindrical extension 58 is inserted into the opening 40 in the floor 41, the door 50 is able to rotate relative to the floor 41.
Once the sidewalk 21 and the doors 50 are assembled to the floor 41, the roof 31 is assembled to the modular storage shed 10. The shed 10 illustrated in Figs. 1, 3 and 4 includes three sidewalk 21A, 21B, 21C on each side of the modular storage shed 10. The three sidewalk 21A, 21B, 21C are adapted to mate with three separate sections 31A, 31B, 31C of the roof 31. Specifically, the roof 31 includes a front section 31A, a back section 31C and an extension section 31B positioned between the front section 31A and the back section 31C. As stated previously, when it is desired to increase the length of the modular storage shed 10 additional floor sections 41B, pairs of sidewalls 21B and roof extension sections 31B are added to the modular storage shed 10.
Each of the roof sections 31A-C includes voids 34 that are adapted to receive the projections 19 which extend upward from the upper edges 25 of the sidewalk 21 (see Figs.
9, 21 and 22). The voids 34 include indentations that are adapted to receive the projections 19 on each of the sidewalk 21 via a snap-fit connection. The snap-fit connections between the projections 19 on the sidewalk 21 and the indentations within each void 34 in the roof 31 are similar to the connections between the floor 41 and each of the projections 19 extending from the lower edges 26 of the sidewalk 21.
An alternative form of the connection between the sidewalk 21 and the roof 31 is illustrated in Fig. 22. In this form, the sidewall 21 is connected to the roof 31 by using a fastener 71 instead of a snap-fit connection.
The voids 34 in the roof sections 31A-C are longer than the individual projections 19 on the sidewalk 21 so that a tool 35 (see Fig. 21) can be inserted into that portion of the void 34 that is not occupied by the projection 19. The ability to insert a tool in such a manner facilitates removing a particular roof section 31 from a sidewall 21.

The front section 31A of the roof 31 is illustrated more clearly in Figs. 23-27. The front section 31A includes a sloped forward surfaces 35, 36 that extend downward from an upper arcuate surface 37 to the front one of the substantially flat surfaces 38 that are on three sides of the front section 31A (see Fig. 23). An arcuately shaped back edge 39 extends across the front section 31A on the remaining side. The surfaces 38 preferably include a gradual one-quarter inch rise as they move inwardly from the outside edges of front section 31A. The rise on the surfaces 38 facilitates molding the roof with plastic.
The arcuately shaped edge 39 is adapted to mate with an arcuately shaped front edge 78 on the extension section 31B shown in Figs. 28-32.
The arcuately shaped back edge 39 on the first section 31A include a projection 60 that extends upwardly from the upper arcuate surface 37. A channel 61 extends along the length of the projection 60 and is adapted to receive an adhesive or some type of seal that facilitates maintaining the water-tight integrity of the roof 31 once its is assembled. The extension section 31B includes a C-shaped projection 62 that extends along the arcuately shaped edge 78 of the extension section 31B. The interior side of the projection 62 includes an undercut section 63 that is adapted to fit over the projection 60 when the extension section 31B is assembled to the front section 31A so that the arcuately shaped edges 39, 78 form a water tight seal without the use of fasteners (see Figs. 4 and 31).
The extension section 31B is shown most clearly in Figs. 28-32. The extension section 31B includes substantially flat surfaces 76 that are positioned on opposing sides of the extension section 31B (see Figs. 28 and 29) and further includes an arcuately shaped surface 75 that extends upward from the substantially flat surfaces 76. The flat surfaces 76 preferably include a one-quarter inch rise similar to the substantially flat edges 38 on the front section 31A. The arcuate surface 75 on the extension section 31B has a curvature that matches the arcuate surfaces 37 on the front and back sections 31A, 31C
so that the surface of the roof 31 provides a smooth appearance. The extension section 31B
further includes a header 73 that is positioned near the middle of the extension section 31B and extends along substantially the entire length of the extension section 31B
(see Figs. 29-31).
The header 73 supports the roof 31 when one or more extension sections 31B are added to the modular storage shed 10 to increase the length of the modular storage shed 10. The header 73 also helps the roof 31 to handle a snow load when the modular storage shed 10 is used in colder environments.
The extension section 31B also includes an areuately shaped back edge 79 that has a configuration similar to the arcuately shaped back edge 39 of the front section 31A (see Fig. 31). The back edge 79 of the extension section 31B is configured similar to the back edge 39 on the front section 31A so that either of the back edges 39, 79 on the front section 31A and the extension section 31B are adapted to mate with a front arcuately shaped edge 89 on the back section 31C (see Fig. 4).
When the modular storage shed 11 does not include an extension section 31B, the back edge 39 on the front section 31A mates directly with the front edge 89 on the back section 31C to form a water tight seal. When additional extension sections 31B
are added to the modular storage shed 10, the front edge 78 on each extension section 31B mates with either the back edge 39 of the front section 31A, or the back edge 79 of an adjacent extension section 31B, and the back edge 79 on each extension section 31B
mates with either the front edge 89 on the back section 31C or the front edge 78 of an adjacent extension section 31B.
The front section 31A of the roof is connected to a top edge of the door 50 in a manner similar to the connection between the door 50 and the floor 41.
Specifically, the front section 31A of the roof 31 includes a pair of openings that are similar to the openings 40 in the floor 41. These openings are adapted to receive a cylindrical extension that projects from the top edge of the door 50. The cylindrical extension that projects from the top edge of the door 50 is similar to the cylindrical extension 58 that projects from the bottom edge 59 of the door. Once the cylindrical extension that projects from the top edge of the door is positioned within the opening in the front section 31A of the roof, the door 50 is able to rotate relative to the roof 31.
The back section 31C of the roof 31 is similar to the front section 31A except that the front section includes the openings that are adapted to receive the cylindrical extensions projecting from the top edge of the door 50. The arcuately shaped edges 39, 89 on each section are also different because they are configured to mate with one another (or opposing sides of an extension section 31B).
Another form of the modular storage shed 10 is shown in Figs. 33-35. In this form, the modular storage shed 10 includes a bracket 90 that is adapted to support a shelf 91 or some other device that is commonly used to store items. The bracket includes a tenon 92 and a projection 93 both of which extend from an edge 94 of the bracket 90.
During assembly of the bracket 90 to the sidewall 21, the tenon 92 on the bracket 90 is inserted into a mortise 96 that extends inward from a side surface 95 of the sidewall 21. The mortise 96 includes an open end (partially defined by a void 97 in the sidewall 21), and the tenon 92 on the bracket 90 is inserted into the open end of the mortise 96. As the tenon 92 is inserted into the mortise 96, the projection 93 on the bracket 90 comes into alignment with an indentation 99 in the sidewall 21. Once the projection 93 and the indentation 99 are aligned, the projection 93 is inserted into the indentation thereby preventing the bracket 90 from moving relative to the sidewall 21. As the tenon 92 is inserted into the mortise 96, an edge 100 on the tenon 92 comes into contact with a closed edge 101 of the mortise 96 thereby limiting any further insertion of the tenon 92 into the mortise 96.
In another form, the indentation 99 in the sidewall 21 may be much larger than the projection 93 on the bracket 90 (e.g., where the indentation is a channel that extends along the width of a sidewall 21). When the indentation 99 is much larger than the projection 93, the indentation 99 is only able to prevent movement of the bracket 90 relative to the sidewall 21 in one direction, usually the direction opposite to the direction limited by the mating edges 100, 101 of the tenon 92 and the mortise 96.
It should be noted that the bracket 90 could be any device that is commonly hung within the interior of a modular storage shed (e.g., a hook for hanging lawn and garden implements) without departing from the scope of the present invention. In addition, although the tenon 92 and mortise 96 are shown with a dove-tail configuration, the configuration of the connection could be any type that is commonly known in the art.
The foregoing description of the present invention has been presented for purposes of illustration and description. The description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the prior art, are within the scope of the present invention. The embodiments described herein are intended to explain the best modes for practicing the invention and to enable other skilled in the art to utilize the invention in the disclosed or other embodiments, and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by prior art.
Various features and advantages of the present invention are set forth in the following claims.

Claims

What is claimed is:

1. A modular storage shed comprising:
a sidewall including an extension protruding from an edge of the sidewall the extension including an outer section and an inner section with the inner section extending from the edge of the sidewall;
a roof extending above the sidewall; and a door having a channel mating with the outer section of the extension such that the door is able to pivot relative to sidewall, wherein the channel is parallel to an edge of the door and further includes a slot extending inwardly from the edge of the door into communication with the channel.

2. The modular storage shed of claim 1 wherein the extension projects from a midportion of the edge on the sidewall.

3. The modular storage shed of claim 1 wherein the slot is sized to allow the inner section of the extension to pass through the slot.

4. The modular storage shed of claim 1 wherein the extension is T-shaped.

5. A modular storage shed comprising:
a plurality of sidewalls;
a roof extending above the sidewalls;
an interlocking floor positioned below the sidewalls, the interlocking floor including a first section and a second section, wherein the first section includes a first tenon and the second section includes a first mortise such that the first tenon is inserted into the first mortise.

6. The modular storage shed of claim 5 wherein the first section and the second section each include an upper surface, a lower surface and a mating edge and the first tenon and first mortise are in communication with the lower surface and the mating edge.

7. The modular storage shed of claim 5 wherein the first section includes a second tenon and the second section includes a second mortise such that the second tenon is inserted into the second mortise.

8. The modular storage shed of claim 5 wherein the first section includes a second mortise and the second section includes a second tenon such that the second tenon is inserted into the second mortise.

9. The modular storage shed of claim 5 wherein the first section and the second section are assembled without using fasteners.

10. The modular storage shed of claim 5 wherein the first tenon has a dovetail configuration.

11. A modular storage shed comprising:
a bracket including a tenon extending from an edge of the bracket, the bracket further including a projection positioned near the tenon;
a plurality of sidewalls, one of the sidewalls including a mortise for receiving the tenon on the bracket and an indentation for receiving the projection on the bracket; and a roof extending above the sidewall.

12. The modular storage shed of claim 11 wherein the projection on the bracket also extends from the edge of the bracket.

13. The modular storage shed of claim 11 wherein the projection on the bracket prevents the tenon on the bracket from sliding relative to the mortise on the sidewall once the tenon is inserted into the mortise and the projection is inserted into the indentation.

14. The modular storage shed of claim 13 wherein the indentation in the sidewall is much larger than the projection on the bracket such that the projection abuts an edge of the indentation.

15. The modular storage shed of claim 11 wherein the mortise in the sidewall includes an open end such that the tenon on the bracket is inserted into the mortise from the open end.

16. A modular storage shed comprising:
a plurality of sidewalls, and a roof secured to the sidewalls, the roof including a first subpanel having a first edge and a second subpanel having a second edge mated with the first edge, wherein the first edge includes a first projection and an undercut section, and the second edge includes a second projection that fits within the undercut section.

17. The modular storage shed of claim 16 wherein the first projection is C-shaped.

18. The modular storage shed of claim 16 wherein the roof is connected the sidewalk by a snap-fit.

19. The modular storage shed of claim 16 wherein the first edge and the second edge are arc-shaped.

20. The modular storage shed of claim 16 wherein no fasteners are used to secure the first subpanel to the second subpanel.

21. A modular storage shed comprising:
a plurality of sidewalls, one of the sidewalls including an extension projecting from a portion of an edge on the sidewall;
a roof extending above the sidewall; and wherein an adjacent side wall includes a slot in communication with an edge of the adjacent sidewall the slot receiving the extension such that the sidewalls are pivotally connected.

22. The modular storage shed of claim 21 wherein the extension further includes a cylindrical insert and the slot further includes a cylindrical section for receiving the cylindrical insert.

23. The modular storage shed of claim 22 wherein the cylindrical insert is substantially parallel to the edge of the sidewall.

24. The modular storage shed of claim 22 wherein the cylindrical insert is snap-fit into the slot in the adjacent sidewall.

25. The modular storage shed of claim 24 wherein the entire length of the cylindrical insert is forced into the slot.

26. The modular storage shed of claim 21 wherein the sidewalk have 90 degrees of rotatable movement while the extension is positioned within the slot in the adjacent sidewall.

27. The modular storage shed of claim 21 wherein the sidewalls include side surfaces and the rotatable movement of the sidewalls relative to one another is limited in one direction by the edges coming into contact, and limited in an opposite direction by one of the edges coming into contact with one of the side surfaces.

28. The modular storage shed of claim 21 wherein each of the sidewalls includes a slot on one edge and an extension on an opposing edge.

29. The modular storage shed of claim 21 wherein the sidewall that includes the extension projecting from a portion of an edge on the sidewall further includes a recess and the adjacent side wall that includes a slot in communication with an edge of the adjacent sidewall further includes a projection that is positioned within the recess when the sidewalls are assembled together.

30. The modular storage shed of claim 29 wherein the recess and the projection are parallel to the edges of sidewalls.

31. A modular storage shed comprising:
a plurality of sidewalls, one of the sidewalls including a plurality of extensions projecting from an edge of the sidewall;
a roof extending above the sidewall; and wherein an adjacent side wall includes a plurality of slots in communication with an edge of the adjacent sidewalk each of the slots receiving one of the extensions such that the sidewalls are rotatably connected.

32. The modular storage shed of claim 31 wherein each extension further includes a cylindrical insert and the slot further includes cylindrical sections, each cylindrical section receiving one of the cylindrical inserts.

33. The modular storage shed of claim 32 wherein the cylindrical inserts and the cylindrical sections are evenly spaced apart along the entire edges of the adjacent sidewalls.

34. The modular storage shed of claim 31 wherein each of the slots includes an open end and the adjacent sidewalls are assembled by positioning the extensions on one of the sidewalls between the slots on an adjacent sidewall and then inserting the extensions into the open ends of the slots.

35. The modular storage shed of claim 34 wherein the extensions are slightly shorter in length than the spacing between slots.

36. A modular storage shed comprising:
a plurality of sidewalls; and a roof secured to the sidewalls, the roof including a back section, a front section and an arcuately shaped extension section positioned between the back section and the first section, the extension section including a support header extending between opposing ends of the extension section.

37. The modular storage shed of claim 36 wherein the front section includes a first edge and the back section includes a second edge, the first and second edges mating with opposing edges on the extension section to form a water-tight seal between the back section, the front section and the extension section.

38. The modular storage shed of claim 37 wherein the first edge on the front section mates with the second edge on the back section to form a water-tight seal between the back section and the front section when there is no extension section in the modular storage shed.

39. The modular storage shed of claim 36 wherein the roof further includes one or more additional extension sections to extend the roof.

40. The modular storage shed of claim 36 wherein the front section, the back section and any additional extension sections are assembled without using fasteners.

41. A modular storage shed comprising:
a sidewall including an extension;
a roof including a void adapted to receive the extension;
and wherein the extension on the sidewall includes a projection that is snap-fit into an indentation within the void in the roof to secure the roof to the sidewall, the void being larger than the extension to permit a tool to be inserted into the void to facilitate removing the roof from the sidewall.

42. The modular storage shed of claim 41 wherein the sidewall includes an end and the extension protrudes from the end of the sidewall.

43. The modular storage shed of claim 42 wherein the roof includes an end and the void extends inward from the end of the roof.

44. The modular storage shed of claim 41 wherein the sidewall includes one or more additional extensions with each extension including a projection, and the roof includes additional voids to receive each of the additional extensions.

45. The modular storage shed of claim 44 wherein the additional extensions are evenly spaced along an end of the sidewall.

46. The modular storage shed of claim 41 wherein the extension is part of the roof instead of sidewall and the void is part of the sidewall instead of the roof.

47. A modular storage shed comprising:
a plurality of sidewalls having outer surfaces;
a roof extending above the sidewalls;
a floor positioned below the sidewalls, the floor extending outwardly past the outer surfaces of each of the sidewalls such that a lawnmower is able to cut grass around the entire shed.

48. The modular storage shed of claim 47 wherein the floor includes beveled edges.