US20070107326A1 - Modular cupola assembly - Google Patents

Modular cupola assembly Download PDF

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Publication number
US20070107326A1
US20070107326A1 US11/264,574 US26457405A US2007107326A1 US 20070107326 A1 US20070107326 A1 US 20070107326A1 US 26457405 A US26457405 A US 26457405A US 2007107326 A1 US2007107326 A1 US 2007107326A1
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US
United States
Prior art keywords
side panel
cupola
panel
assembly
kit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/264,574
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English (en)
Inventor
Michael Uffner
Jed Richardson
Torrence Anderson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Suncast Corp
Original Assignee
Suncast Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Suncast Corp filed Critical Suncast Corp
Priority to US11/264,574 priority Critical patent/US20070107326A1/en
Assigned to SUNCAST CORPORATION reassignment SUNCAST CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANDERSON, TORRENCE, RICHARDSON, JED, UFFNER, MICHAEL
Priority to CA002565428A priority patent/CA2565428A1/fr
Publication of US20070107326A1 publication Critical patent/US20070107326A1/en
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/028—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of structures of pyramidal or conical shape
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/026—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of prefabricated modules, e.g. box-like or cell-like units

Definitions

  • This invention relates generally to a cupola device constructed of plastic structural panels. More specifically, the present invention relates to a cupola kit utilizing modular injection molded plastic panels.
  • the cupola kit is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola assembly upon a desired site.
  • Cupolas have been part of architectural design for many years. Most cupolas are constructed of wood, with metal or shingle roofs, and may include windows to admit light or louvers to vent hot air out of the structure to which they are attached.
  • Wooden cupolas are generally custom made for a particular roof and thus assembly and installation require a great deal of time and expertise. Because these structures are made of wood they also require a great deal of maintenance to prevent degradation during the life of the structure to which they are attached.
  • Metal cupolas are also known in the art. Metal cupolas generally include a plurality of metal panels having turned up edges that are assembled by aligning the turned up edges and thereafter sliding a U-shaped retainer over the joint to hold the panels in position.
  • Nystrom U.S. Pat. No. D413,170 discloses an ornamental design for a metal cupola.
  • Post Jr. Discloses a pre-fabricated cupola and mounting bracket.
  • Forsman et al. Discloses a cupola having and adjustable mount.
  • Coolman U.S. Pat. No. 6,170,206 discloses a cupola roof having panels with snap-fit edges.
  • Each combination cupola roof panel has a female snap-fit edge on one side and a female snap-fit edge on the other side.
  • Wilhelmson discloses a satellite dish housing and roof ventilation device.
  • the device includes panels constructed of radio-frequency transparent material so that television reception is not impaired.
  • Another cupola construction known in the art utilizes a roto-molded construction wherein all four sides of the cupola are formed as a single piece. See Van Gilst et al. U.S. Pat. No. 6,422,936.
  • the metal structures of the prior art include numerous sharp edges and are difficult to assemble.
  • the thin sheet metal panels are easily bend during shipping and assembly.
  • the combination plastic and metal structures do not include any integrated fasteners and thus require substantial skill as well as numerous tools to assemble.
  • the roto-molded structures do not break down into small components and thus are expensive and difficult to ship.
  • the panel components cannot be formed with the intricate shapes and/or cross sections required for integrated connectors. Therefore, these systems require a substantial number of fasteners in combination with connector members having a specific cross-sectional geometry that facilitate an engagement between the panels to complete the structure.
  • the modular cupola assembly should achieve objectives such as lightweight single walled panel construction.
  • the construction of the panels should eliminate the need for additional connectors to create a cupola assembly which resists panel separation, buckling, and racking.
  • the cupola assembly should be capable of withstanding the snow and wind loads typically associated with enclosures.
  • the cupola assembly should include features constructed to cooperate with lighting and/or fans or other enhancements.
  • the cupola assembly should include convenience features that allow the cupola to be easily attached to an enclosure.
  • the cupola assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques, such as injection molding.
  • the cupola assembly must also be capable of being packaged and shipped in a knocked-down state.
  • the cupola assembly must be modular and facilitate the creation of a family of cupola assemblies for enclosures that vary in size but which share common, interchangeable components.
  • a cupola assembly must satisfy in order to achieve acceptance by the end user.
  • the cupola assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the cupola assembly must not require excessive strength to assemble or include heavy component parts. Moreover, the cupola assembly must assemble together in such a way so as not to detract from the appearance or function of the resulting enclosure, or otherwise negatively affect the utility of the structure.
  • the present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form a roof mountable cupola.
  • the panels are formed of injection molded plastic to interlock with one another without the need for separate fasteners or connectors.
  • the system incorporates a minimum number of components to construct a cupola by integrally forming the connectors into the injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the cupola.
  • the integrated connection of the side walls and cover components also simplifies cupola construction. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or extruded panels.
  • the same side wall and cover panel components may be used to create a variety of cupolas and the assembly thereof requires minimal hardware and a minimum number of hand tools.
  • the front and rear wall panels have outwardly projecting locking posts for interlocking cooperative engagement with sockets in the left and right side wall panels.
  • the engagement between the locking posts and the sockets serve to rigidly connect the components together.
  • the system further includes a cover which slides into place after the front, rear, left and right wall panels have been fully assembled.
  • the cover may include spring locks for engagement with the side panels or alternatively may be held in place with suitable fasteners.
  • the system is constructed to allow various cover panels to be utilized further increasing the utility of the assembled cupola.
  • a further objective is to provide a modular cupola assembly wherein the panels include integrated connectors accommodated by injection molding plastic formation for increased structural integrity.
  • Yet a further objective is to provide a modular cupola assembly in which the side walls and cover panels are integrally interlocked without separate connectors or fasteners.
  • Another objective is to provide an cupola assembly constructed of modular panels having a cover panel which allows interchangeability after all other parts are assembled.
  • Yet another objective is to provide a kit for a cupola that is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola upon a desired site.
  • FIG. 1 is a perspective view of one embodiment of the cupola assembly
  • FIG. 2 is a perspective view of the inner surface of a wall panel utilized in the instant invention
  • FIG. 3 is a perspective view of the front and rear panels of embodiment shown in FIG. 1 ;
  • FIG. 4 is a perspective exploded view of the wall panels utilized in the instant invention.
  • FIG. 5 is a bottom view of one embodiment of the top panel utilized in the instant invention.
  • FIG. 6 is a perspective view illustrating assembly of the top panel
  • FIG. 7 is front plan view of the instant invention.
  • FIG. 8 is a section view taken along line 1 - 1 of the cupola embodiment shown in FIG. 7 illustrating the cooperative engagement between the side panels and cover panel;
  • FIG. 9 is a side plan view of the instant invention.
  • FIG. 10 is a section view taken along line 2 - 2 of the cupola embodiment shown in FIG. 9 illustrating the cooperative engagement between the side panels and cover panel;
  • FIG. 11 is a perspective view illustrating the instant invention in a shipping configuration.
  • FIGS. 1-10 which are now referenced illustrate perspective, exploded and sectioned views of the cupola assembly and kit therefor, generally referenced as 100 , according to a preferred embodiment of the present invention.
  • the cupola assembly is made up of substantially like-constructed left wall panel and right side panel 200 , substantially like constructed rear side panel and front side panel 300 and cover panel 400 .
  • the panels comprising the assembly are formed of but not limited to a suitable plastic such as polystyrene, polypropylene, polyvinyl chloride, polyethylene or the like, through the process of injection molding.
  • a suitable plastic such as polystyrene, polypropylene, polyvinyl chloride, polyethylene or the like
  • Strengthening ribs 202 and gussets 204 are formed within the inner surfaces of the side panels 200 , 300 and cover panel 400 in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in FIG. 1 .
  • the front and rear side panels 300 are each configured having a first end 308 and a second end 312 . Both ends 308 , 312 include an integrally formed first attachment means illustrated as at least one outwardly extending attachment post 310 .
  • the attachment posts 310 are generally constructed and arranged to cooperate with inwardly extending sockets 208 provided in either end of the left and right panels 200 .
  • the top surface 314 includes a second attachment means illustrated herein as one side of an upwardly extending boss 316 . When all four side panels are assembled the boss 316 is constructed and arranged to cooperate with a socket 408 ( FIG. 5 ) that extends around the perimeter of the lower surface of the cover panel 400 .
  • the left and right side panels 200 are shown.
  • the left and right side panels include a top surface 205 , bottom surface 206 , first end 210 and second end 212 .
  • Adjacent to each of the first and second edges 210 , 212 is a means of attaching the left and right side panels 200 to the front and rear side panels 300 illustrated herein as a plurality of integrally formed sockets 216 extending downwardly from about the top surface 205 to about the bottom surface 206 .
  • the formed sockets 216 are constructed and arranged to cooperate with locking posts 310 extending outwardly along the first and second edges 308 , 312 of the front and rear side panels 300 .
  • the locking posts 310 and sockets 216 are constructed and arranged so that the locking posts 310 enter and mateably engage the sockets 216 securing the panels together in an inter-fitting engagement with their respective outer surfaces in a perpendicular arrangement.
  • the bottom surface of the cover panel 400 is illustrated.
  • the bottom surface of the cover panel 400 is constructed with a socket 408 extending around the perimeter of the bottom surface 402 .
  • the socket 408 is constructed and arranged to cooperate with the boss 316 ( FIG. 4 ) extending upwardly from the top surfaces of the front, back, and side panels.
  • the boss 316 and socket 408 arrangement increases the structural integrity of the cupola assembly 100 by preventing the panels 200 , 300 from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the cupola 100 .
  • the outer surface of the side panels 200 , 300 are constructed generally smooth having a plurality of inwardly bowed grooves 218 for added strength and aesthetic appearance.
  • a portion of each groove includes an elongated aperture (not shown).
  • the apertures are constructed and arranged to allow air to flow through the cupola for ventilation of the structure to which it is attached as is well known in the art.
  • the inside surface of the side panels 200 , 300 are constructed with a plurality of integrally formed strengthening ribs 202 extending across the panels with a portion of the ribs 202 being provided with a plurality of gussets 204 to further strengthen the panels.
  • the ribs 202 and gussets 204 increase the structural integrity of the cupola 100 by preventing the side panels 200 , 300 from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the cupola 100 .
  • the integrally formed ribs 202 and gussets 204 are facilitated by injection molding. Injection molding offers significant strength and stability advantages over cupola constructions utilized in the prior art. In this manner the cupola assembly of the instant invention is capable of handling a significant amount of snow and wind loads.
  • the left and right side panels 200 are attached to the front and rear panels 300 by inserting the locking posts 310 into sockets 216 until the spring tabs 318 integrally formed onto the locking posts 310 engage the apertures 220 integrally formed into the sockets 216 of the left and right side panels 200 .
  • the purpose of the locking posts 310 are to align two panels in a perpendicular relationship and to facilitate their mechanical connection.
  • the perpendicular panels are brought into an overlapping relationship wherein the contoured locking posts 310 enter the corresponding socket 216 in the left and right panels 200 .
  • the result is a mechanically secure connection between the two panels.
  • the overlapping edges between the panels as described above provides a secure connection and offers several advantages.
  • the design allows the panels to be connected without the need for separate connectors.
  • the design creates a positive lock that prevents separation of the panels.
  • the design maintains alignment of the panels and prevents bowing or bending of either panel relative to one another.
  • the resultant cupola assembly created by the combination of the interlocking panels benefits from high structural integrity and reliable operation.
  • the side panels 200 , 300 are attached to the cover panel 400 by sliding the boss 316 formed along the top edges 205 , 314 of the assembled side panels into the corresponding socket 408 integrally formed into the bottom surface of the cover panel.
  • the socket 408 in the cover panel 400 corresponds in shape and size to that of the boss 316 .
  • spring tabs 318 integrally formed onto the boss 316 align with apertures 220 in the socket 408 to engage the cover panel to the side panels 200 and 300 .
  • self threading fasteners are inserted through apertures 220 for engagement a side surface 410 of the cover socket. The result of either embodiment is a positive mechanical connection between the side panels 200 , 300 , and the cover panel 400 .
  • the kit for assembling a cupola is illustrated in a knocked-down configuration.
  • the cupola may be packaged, shipped and stored more economically than prior art cupolas.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Rigid Containers With Two Or More Constituent Elements (AREA)
US11/264,574 2005-10-31 2005-10-31 Modular cupola assembly Abandoned US20070107326A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/264,574 US20070107326A1 (en) 2005-10-31 2005-10-31 Modular cupola assembly
CA002565428A CA2565428A1 (fr) 2005-10-31 2006-10-25 Coupole modulaire

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/264,574 US20070107326A1 (en) 2005-10-31 2005-10-31 Modular cupola assembly

Publications (1)

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US20070107326A1 true US20070107326A1 (en) 2007-05-17

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US11/264,574 Abandoned US20070107326A1 (en) 2005-10-31 2005-10-31 Modular cupola assembly

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CA (1) CA2565428A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10889986B1 (en) * 2019-09-03 2021-01-12 Plyco Corporation CUPOLA body fabricated from extrusions

Citations (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1220219A (en) * 1915-03-27 1917-03-27 Barney Goldman Sectional skylight.
US1648604A (en) * 1925-10-05 1927-11-08 Roy S Knaggs Building card structure and blank for producing the same
US1890269A (en) * 1930-04-10 1932-12-06 Carl E Swanson Toy construction unit
US2566156A (en) * 1948-04-06 1951-08-28 Joseph A Apolonio Skylight
US2737876A (en) * 1952-12-17 1956-03-13 Lester L Smith Ventilator structure
US3209669A (en) * 1963-07-19 1965-10-05 Donald E Bayne Cupola
US3216161A (en) * 1962-07-06 1965-11-09 Helger L Forsman Adjustable cupola
US3410441A (en) * 1966-06-29 1968-11-12 Jeff S. Rhyne Container
US3522686A (en) * 1969-05-19 1970-08-04 E Don Corp Method of fabricating plastic structures
US3779623A (en) * 1971-06-23 1973-12-18 Sekisui Chemical Co Ltd Sectional rack
US4173287A (en) * 1976-05-25 1979-11-06 Shozo Kumakawa Method of making boards and packing cases made therefrom
US4782972A (en) * 1986-06-30 1988-11-08 Traex Corporation Collapsible file box
US4888923A (en) * 1987-12-10 1989-12-26 Post Jr Russell H Cupola Mount
US5402613A (en) * 1993-12-07 1995-04-04 Giumenta; Frederic F. Chimney cap
US5487690A (en) * 1994-01-24 1996-01-30 Stoffle; Thomas N. Clamps for making corrugated panel free standing play structures
US5687514A (en) * 1996-01-03 1997-11-18 Gillispie; John Joseph Adjustable curb with flashing
US5829595A (en) * 1997-03-03 1998-11-03 Trienda Corporation Thin sheet thermoformed pallet sleeve
US5996298A (en) * 1997-12-08 1999-12-07 Shutters, Inc. Modular shutter
US6093098A (en) * 1998-10-30 2000-07-25 South Carolina Research Authority Satellite disk housing and roof ventilation device
US6170206B1 (en) * 1999-09-11 2001-01-09 Plyco Corporation Cupola roof panels with snap-fit edges
US6422936B1 (en) * 2001-04-17 2002-07-23 Behlen Engineered Plastics Building-attached ornament or ventilator
US20030203703A1 (en) * 2002-02-28 2003-10-30 Desalvo John Anthony Play structure and structural building elements for building a play structure
US20040026296A1 (en) * 2000-06-16 2004-02-12 Nesting Erik Markvard Grubbe Container with collapsible sides
US20040200832A1 (en) * 2003-04-08 2004-10-14 Brian Moon Deck storage box
US6811048B2 (en) * 2002-02-12 2004-11-02 David M. K. Lau Fold-up storage container
US6892497B2 (en) * 2003-03-31 2005-05-17 Suncast Corporation Plastic panel enclosure system
US20050144859A1 (en) * 2001-10-25 2005-07-07 Keter Plastic Ltd. Construction kit
US20050204664A1 (en) * 2004-02-18 2005-09-22 Snyder Darryl L Register grille and connector frame with releasable connection
US6966449B2 (en) * 2003-01-02 2005-11-22 The Little Tikes Company Bulk box
US20070044391A1 (en) * 2005-08-30 2007-03-01 Richardson Jed C Plastic expandable utility shed
US20070175108A1 (en) * 2005-12-29 2007-08-02 Stein Robert J Plastic utility shed wall system

Patent Citations (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1220219A (en) * 1915-03-27 1917-03-27 Barney Goldman Sectional skylight.
US1648604A (en) * 1925-10-05 1927-11-08 Roy S Knaggs Building card structure and blank for producing the same
US1890269A (en) * 1930-04-10 1932-12-06 Carl E Swanson Toy construction unit
US2566156A (en) * 1948-04-06 1951-08-28 Joseph A Apolonio Skylight
US2737876A (en) * 1952-12-17 1956-03-13 Lester L Smith Ventilator structure
US3216161A (en) * 1962-07-06 1965-11-09 Helger L Forsman Adjustable cupola
US3209669A (en) * 1963-07-19 1965-10-05 Donald E Bayne Cupola
US3410441A (en) * 1966-06-29 1968-11-12 Jeff S. Rhyne Container
US3522686A (en) * 1969-05-19 1970-08-04 E Don Corp Method of fabricating plastic structures
US3779623A (en) * 1971-06-23 1973-12-18 Sekisui Chemical Co Ltd Sectional rack
US4173287A (en) * 1976-05-25 1979-11-06 Shozo Kumakawa Method of making boards and packing cases made therefrom
US4782972A (en) * 1986-06-30 1988-11-08 Traex Corporation Collapsible file box
US4888923A (en) * 1987-12-10 1989-12-26 Post Jr Russell H Cupola Mount
US5402613A (en) * 1993-12-07 1995-04-04 Giumenta; Frederic F. Chimney cap
US5487690A (en) * 1994-01-24 1996-01-30 Stoffle; Thomas N. Clamps for making corrugated panel free standing play structures
US5687514A (en) * 1996-01-03 1997-11-18 Gillispie; John Joseph Adjustable curb with flashing
US5829595A (en) * 1997-03-03 1998-11-03 Trienda Corporation Thin sheet thermoformed pallet sleeve
US5996298A (en) * 1997-12-08 1999-12-07 Shutters, Inc. Modular shutter
US6093098A (en) * 1998-10-30 2000-07-25 South Carolina Research Authority Satellite disk housing and roof ventilation device
US6170206B1 (en) * 1999-09-11 2001-01-09 Plyco Corporation Cupola roof panels with snap-fit edges
US20040026296A1 (en) * 2000-06-16 2004-02-12 Nesting Erik Markvard Grubbe Container with collapsible sides
US6422936B1 (en) * 2001-04-17 2002-07-23 Behlen Engineered Plastics Building-attached ornament or ventilator
US20050144859A1 (en) * 2001-10-25 2005-07-07 Keter Plastic Ltd. Construction kit
US6811048B2 (en) * 2002-02-12 2004-11-02 David M. K. Lau Fold-up storage container
US20030203703A1 (en) * 2002-02-28 2003-10-30 Desalvo John Anthony Play structure and structural building elements for building a play structure
US6923705B2 (en) * 2002-02-28 2005-08-02 Kidzbuilt, Llc Play structure and structural building elements for building a play structure
US6966449B2 (en) * 2003-01-02 2005-11-22 The Little Tikes Company Bulk box
US6892497B2 (en) * 2003-03-31 2005-05-17 Suncast Corporation Plastic panel enclosure system
US20040200832A1 (en) * 2003-04-08 2004-10-14 Brian Moon Deck storage box
US20050204664A1 (en) * 2004-02-18 2005-09-22 Snyder Darryl L Register grille and connector frame with releasable connection
US20070044391A1 (en) * 2005-08-30 2007-03-01 Richardson Jed C Plastic expandable utility shed
US20070175108A1 (en) * 2005-12-29 2007-08-02 Stein Robert J Plastic utility shed wall system

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10889986B1 (en) * 2019-09-03 2021-01-12 Plyco Corporation CUPOLA body fabricated from extrusions

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AS Assignment

Owner name: SUNCAST CORPORATION,ILLINOIS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:UFFNER, MICHAEL;RICHARDSON, JED;ANDERSON, TORRENCE;SIGNING DATES FROM 20051013 TO 20051020;REEL/FRAME:017187/0135

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION