Reinforced Roof Structure of a Prefab Modular Shed

This application claims the priority of Chinese Application No. 202420880153.9, entitled “Roof Structure of a Modular Shed,” filed Apr. 26, 2024, which is incorporated herein by reference for all purposes.

The present subject matter is in the field of plastic assembly. More particularly, embodiments of the present subject matter relate to a roof structure of a storage shed comprising modular molded plastic panels.

Molded plastic has a wide variety of benefits as a furniture material and component. For example, it is highly resistant to impact, moisture, and chemicals, which makes it more durable compared to other materials like wood or glass; it is also lighter than many other materials, rendering it advantageous for transportation cost. Furthermore, molded plastics can be shaped into virtually any form, allowing for a great deal of design flexibility. This allows for more creative and complex designs than other materials. An example of such a design is a prefab modular shed that is economical to manufacture, easy to transport and install while providing many novel and beneficial design features.

The roof is an important component of a modular shed because its stability has a significant impact on the overall structural stability of the shed. For traditional wooden modular sheds, the roof beams and panels are made of wood, with the roof panels fixed to the beam support structure by screws. Although this structure is relatively secure, the assembly and disassembly processes are time-consuming. For metal sheds, while the overall structure is stable, the cost is higher. The roof, beam supports, and wall panels are assembled using many screws or bolts, which also makes assembly and disassembly time-consuming and labor-intensive.

Existing plastic modular sheds often suffer from insufficient structural strength, despite having the advantages of being lightweight and easy to install. For example, the conventional roof is only attached to the beam support without sufficient support. With strong winds, the roof may be lifted, leading to water damage to the interior of the shed. Additionally, the conventional roofs typically use flat panels, and when multiple panels are joined together, water can seep into the shed through the seams during rainy weather. In summary, there is a need for further improvement in the roof structures of plastic modular sheds.

The present subject matter is directed to improved roof designs for a modular storage shed that optimizes the structural stability while rendering ease of assembly and disassembly. Embodiments of the present subject matter are discussed below with reference to.

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present subject matter. It will be apparent, however, to one skilled in the art that the present subject matter may be practiced without some of these specific details. In addition, the following description provides examples, and the accompanying drawings show various examples for the purposes of illustration. Moreover, these examples should not be construed in a limiting sense as they are merely intended to provide examples of embodiments of the subject matter rather than to provide an exhaustive list of all possible implementations. In other instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the details of the disclosed features of various described embodiments.

The present subject matter is directed to a novel roof designs of a blow-molded storage shed that enhances structural stability while ensuring ease of assembly and disassembly. The roof assembly features a beam support frame with multiple interconnected beam columns and crossbars, providing robust support for the roof structure. A central roof panel, equipped with an embedded seamless folding groove, folds to create a roof peak during installation. Additionally, side roof panels are connected to the central roof panel, forming a cohesive and durable roof assembly. This design optimizes both strength and ease of construction.

According to some embodiments, the roof assembly can include a beam support frame for supporting the roof. The shed can further comprise triangular door lintels on two sides beneath the roof. The beam support frame can include a central beam column and horizontal crossbars. The central beam column can be positioned parallel to the triangular door lintel, and the horizontal crossbars can be spaced along the central beam column. The roof can cover the beam support frame and be fixed to both the central beam column and the crossbars. Additionally, there is a limiting structure between the roof and the lintels to ensure secure positioning.

According to some embodiments, to fix the central beam column to the wall panels, the ends of the central beam column can be secured to the shed's wall panels via a connecting component.

According to some embodiments, to control the central beam column under the packaging length, the central beam column can be collapsed in the middle, allowing it to be folded when disassembled. Similarly, other supporting columns or crossbars can be folded before installation. This collapsible feature can ensure that the folded part of the beam column helps distribute the load when the roof bears pressure.

According to some embodiments, to prevent the roof from sliding down along the door lintels, a limiting protrusion can be at the top of the lintel, and a corresponding limiting groove can be positioned at the bottom of the roof. The limiting protrusion can fit into the corresponding groove, forming the limiting structure.

According to some embodiments, to enhance the connection between the roof and the lintels, an open downward slot can be formed at the bottom of the roof corresponding to the upper edge of the triangular gable. The upper edge of the lintel can fit into this slot, forming a coupling structure.

According to some embodiments, the roof can have a central roof panel and two or more side roof panels. The side roof panels can be positioned on both sides of the central roof panel. Both the central and side roof panels can be securely connected to the door lintel and/or fixed to the beam support frame.

According to some embodiments, the beam support frame can have various structures to enhance its strength and durability. According to some embodiments, it can include a central beam column, central crossbars, and side crossbars. The central beam column can be arranged parallel to the triangular door lintel, with the central crossbars and side crossbars spaced along the central beam column. The ends of the central crossbars can be fixed to the triangular door lintel, while the side crossbars can be fixed to the roof. As such, this structure can provide a more stable overall framework.

According to some embodiments, the roof panel can include a central roof panel and side roof panels. The central roof panel can be bent in the middle to form a roof peak coupled with the triangular door lintel and can be fixed to the beam support frame. The two or more side roof panels can be positioned on either side of the central roof panel, and they can be connected and secured to the side crossbars adjacent to the central crossbars of the beam support frame. The top surfaces of the central and side roof panels can form a stepped structure that can gradually descend from the center to the sides.

According to some embodiments, the central roof panel can be a flat blow-molded panel when unfolded or prior to the assembly. During installation, the central roof panel can bend at an embedded folding groove and form a roof peak matching the triangular lintel. The embedded folding groove can be molded with flexible, thinner plastic material, allowing easy folding during installation. This seamless embedded groove also can prevent water to enter the shed during raining weather.

According to some embodiments, to prevent rainwater from entering the shed through the roof, the top surfaces of the central and side roof panels can form a stepped structure that slopes downward from the center to the sides when installed.

According to some embodiments, to secure the side roof panels to the wall panels, the lower edge of the side roof panels can be equipped with positioning slots at intervals along the length. Fixed connectors can be installed within the positioning slots, securing the side roof panels to the wall panels through these connection pieces.

Compared to conventional designs and structures, the present roof assembly can provide optimized features because the inter-connected beam columns and crossbars can increase the strength and durability of the roof. Furthermore, the foldable central roof panel is more compact and easier to install. Additionally, each main component, e.g., the roof, the beam support frame, the door lintels are all detachable and can engage with each other via fixation elements, rendering convenient assembly and disassembly of the modular shed. Furthermore, the foldable central roof panel creates a seamless roof peak that prevent water to enter the shed.

According to some embodiments, the present subject matter is directed to a roof assembly of a blow-molded modular shed that comprises a beam support frame configured to support the roof, wherein the beam support frame comprises at least one central beam column and a central crossbar positioned in the middle of the at least one central beam column, and a plurality of roof panels coupled with the beam support frame, wherein the plurality of roof panels comprise a central roof panel that is foldable via an embedded folding groove to form a roof peak, and one or more side roof panels connected to the central roof panel. The embedded folding groove has thinner plastic material than rest of the central roof panel.

According to some other embodiments, the present subject matter is directed to a roof assembly of a blow-molded modular shed that comprises a beam support frame configured to support the roof, a plurality of roof panels coupled with the beam support frame, wherein the plurality of roof panels comprise a central roof panel that is foldable via an embedded folding groove to form a roof peak, and one or more side roof panels connected to the central roof panel, and at least one door lintel installed under the plurality of roof panels.

According to some other embodiments, the present subject matter is directed to a modular shed structure made of molded plastic panels that comprises a floor comprising a plurality of floor panels, a plurality of wall panels coupled with the plurality of floor panels, a plurality of door panels, and a roof that comprises: a beam support frame configured to support the roof, wherein the beam support frame comprises at least one central beam column and a central crossbar positioned in the middle of the at least one central beam column, and a plurality of roof panels coupled with the beam support frame, wherein the plurality of roof panels comprise a central roof panel that is foldable via an embedded folding groove to form a roof peak, and one or more side roof panels connected to the central roof panel.

According to some other embodiments, the beam support frame further comprises a plurality of side crossbars in parallel to the central crossbar, and wherein the central crossbar and the plurality of side crossbars are distributed on the central beam column at intervals. The central crossbar is affixed to at least one door lintel and the plurality of side crossbars are affixed to the plurality of roof panels.

According to some other embodiments, at least one door lintel is installed under the plurality of roof panels. Furthermore, a plurality of downward slots are embedded at the bottom edge of the central roof panel and the one or more side roof panels.

According to some other embodiments, the top edge of the at least one triangular door lintel is inserted into the plurality of downward slots embedded at the bottom edge of the central roof panel and the one or more side roof panels.

According to some other embodiments, the top edge of the door lintel further comprises limiting protrusions, and the plurality of downward slots further provide limiting grooves into which the limiting protrusions are engaged with.

According to some other embodiments, top surfaces of the central roof panel and the one or more side roof panels form a stepped structure that gradually descends from the center to the sides. According to some other embodiments, at least one of the central beam column and the central crossbar is collapsible before installation.

Other aspects and advantages of the present subject matter will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the present subject matter.

It is to be understood that even though numerous characteristics and advantages of various embodiments of the present subject matter have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the subject matter, this disclosure is illustrative only. In some cases, certain subassemblies are only described in detail with one such embodiment. Nevertheless, it is recognized and intended that such subassemblies may be used in other embodiments of the subject matter. Practitioners skilled in the art will recognize many modifications and variations. Changes may be made in detail, especially matters of structure and management of parts within the principles of the embodiments of the present subject matter to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Having disclosed exemplary embodiments and the best mode, modifications and variations may be made to the disclosed embodiments while remaining within the scope of the embodiments of the subject matter as defined by the following claims.

According to some embodiments, as shown in, the roof assembly of the modular shed includes a roof () and a beam support frame () for supporting the roof (). Two triangular door lintels () can be placed between the two opposing sides of the shed beneath the roof (). The roof panels can include a central roof panel () and two or more side roof panels () positioned on both sides of the central roof panel. The central roof panel () and side roof panels () can be coupled to the triangular door lintels () via limiting structures. Furthermore, these roof panels can be affixed to the beam support frame () via various connectors.

According to some embodiments, the connection structure between the roof panels and the door lintel () can comprise: a downward slot () at the bottom edge of the roof () corresponding with the top edge of the triangular door lintel (). The top edge of the triangular door lintel can be inserted into the downward slot () so that the roof's edge can encase the top edge of the triangular door lintel (). The top of the triangular door lintel can be provided with a limiting protrusion (). The downward slot () can further provide a limiting groove () into which the limiting protrusion () can be engaged, creating a fixation structure. According to some embodiments, the limiting protrusion () can include spaced, strip-shaped protrusions that fit into the limiting groove () to prevent the roof () from sliding down.

According to some embodiments, the roof beam support frame () can include a central beam column (), central crossbars (), and side crossbars (). The central beam column () can be arranged parallel to the door lintel (), while the central crossbars () and side crossbars () can be arranged on the central beam column (). According to some embodiments, the ends of the central crossbars () can be fixed to the triangular door lintel, whereas the side crossbars () can be fixed to the roof ().

According to some embodiments, the terminals of the central crossbars () can have protruding connection plates (), which can secure the central crossbars () to the door lintel (). The ends of the side crossbars () can either be fixed to the side roof panel (), or be fixed to the door lintel ().

According to some embodiments, the side crossbars () can serve to connect the central roof panel () with the side roof panels (). According to some embodiments, the side crossbars () can connect the side roof panel () with the door lintel () on either side of the central beam column (), enhancing the roof's load-bearing capacity.

According to some embodiments, the ends of the central beam column () can be fixed to the wall panels () through connectors (). For example, the connectors () can be injection-molded parts. The rectangular openings of these parts can be inserted into the square openings of the central beam column (), which can be secured to the wall panels () with screws to enhance support.

According to some embodiments, the central beam column () can be foldable at the center, allowing its length to reduce to half when disassembled. This way, this foldable column can be stored within a reasonably-sized packaging box. Furthermore, under external pressure or weight, the foldable, sloped column can share and distribute the weight on the roof ().

According to some embodiments, the roof () can cover the beam support frame () and can be fixed to the central beam column () and side crossbars (). According to some embodiments, before installation, the central roof panel () can be a flat blow-molded panel in its unfolded state. When it is installed, the central roof panel () can bend, via an embedded and integrated folding groove, at a certain angle to form a roof peak matching the door lintel (). The embedded folding groove can be manufactured by injecting less or thinner plastic material than the rest of the panel, thus rendering a soft area that is flexible and pivotable. The middle of the central roof panel () can be fixed to the central beam column (), while its sides can be connected and fixed to the roof side panels () through the adjacent side crossbars ().

According to some embodiments, the top surfaces of the central roof panel () and side roof panels () can form a stepped structure () that gradually descends from the middle towards both sides. This layered design can prevent rainwater from entering the interior of the shed structure.

According to some embodiments, the lower edge of the side roof panels () can be equipped with positioning slots () at intervals along its length. A number of connectors () can be installed within these slots. The connectors () can be made of metal or plastic. The side roof panels () can be secured via the matching grooves of the wall panels () using these connectors (), enhancing the stability of the wall panels and preventing the side roof panels () from sliding or being dislocated.

According to some embodiments, the storage shed structure of the present subject matter can be an indoor shed. Furthermore, some or all features of the present subject matter can be incorporated into other types of molded plastic assembly.

The above are only the preferred embodiments of the present subject matter. It should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present subject matter, various modifications or improvements can be made to the present subject matter, such as in other applications. For example, the disclosed features can be incorporated into other molded plastic furniture assemblies, or these features, when applicable, can be incorporated into non-molded plastic furniture assembly, and these are all considered to be within the protection scope of the present subject matter.

It is to be understood that even though numerous characteristics and advantages of various embodiments of the present subject matter have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the subject matter, this disclosure is illustrative only. In some cases, certain subassemblies are only described in detail with one such embodiment. Nevertheless, it is recognized and intended that such subassemblies may be used in other embodiments of the subject matter. Practitioners skilled in the art will recognize many modifications and variations. Changes may be made in detail, especially matters of structure and management of parts within the principles of the embodiments of the present subject matter to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Having disclosed exemplary embodiments and the best mode, modifications and variations may be made to the disclosed embodiments while remaining within the scope of the embodiments of the subject matter as defined by the following claims.