REINFORCED ROOF STRUCTURE OF A PREFAB MODULAR SHED

Abstract

The present subject matter discloses 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.

Claims

1. A roof assembly of a blow-molded modular shed, comprising: a beam support frame configured to support the roof assembly, 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 comprises 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.

2. The roof assembly of claim 1, wherein 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.

3. The roof assembly of claim 2, wherein 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.

4. The roof assembly of claim 1, wherein a plurality of downward slots are embedded at the bottom edge of the central roof panel and the one or more side roof panels.

5. The roof assembly of claim 1, further comprising: at least one door lintel installed under the plurality of roof panels.

6. The roof assembly of claim 5, wherein 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.

7. The roof assembly of claim 6, wherein 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.

8. The roof assembly of claim 1, wherein the embedded folding groove has thinner plastic material than rest of the central roof panel.

9. The roof assembly of claim 1, wherein 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.

10. The roof assembly of claim 1, wherein at least one of the central beam column and the central crossbar is collapsible before installation.

11. The roof assembly of claim 1, wherein 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.

12. The roof assembly of claim 11, wherein the one or more side roof panels are connected with one or more wall panels via positioning slots and connectors.

13. A roof assembly of a blow-molded modular shed, comprising: a beam support frame configured to support the roof assembly; 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.

14. The roof assembly of claim 13, wherein the embedded folding groove has thinner plastic material than rest of the central roof panel.

15. The roof assembly of claim 13, 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.

16. The roof assembly of claim 15, wherein 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.

17. The roof assembly of claim 16, wherein the central crossbar is affixed to the at least one door lintel and the plurality of side crossbars are affixed to the plurality of roof panels.

18. A modular shed structure made of molded plastic panels, comprising: 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.

19. The modular shed structure of claim 18, wherein 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.

20. The modular shed structure of claim 18, wherein the embedded folding groove has thinner plastic material than rest of the central roof panel.

Description

DESCRIPTION OF DRAWINGS

[0030] The present subject matter will be further described in detail below with reference to the embodiments of the accompanying drawings.

[0031] FIG. 1 is a schematic diagram of the structure of the prefab modular shed, according to one embodiment of the present subject matter;

[0032] FIG. 2 is another schematic diagram of the prefab modular shed shown in FIG. 1 from another angle;

[0033] FIG. 3 is a schematic diagram of the prefab modular shed shown in FIG. 1 with part of the roof removed;

[0034] FIG. 4 is a schematic diagram of the roof's beam support frame, according to one embodiment of the present subject matter;

[0035] FIG. 5 is a schematic diagram of the central roof panel, according to one embodiment of the present subject matter; and

[0036] FIG. 6 is a schematic diagram of the side roof panel, according to one embodiment of the present subject matter.

DETAILED DESCRIPTION

[0037] 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.

[0038] 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.

[0039] According to some embodiments, as shown in FIGS. 1 to 6, the roof assembly of the modular shed includes a roof (1) and a beam support frame (2) for supporting the roof (1). Two triangular door lintels (3) can be placed between the two opposing sides of the shed beneath the roof (1). The roof panels can include a central roof panel (11) and two or more side roof panels (12) positioned on both sides of the central roof panel. The central roof panel (11) and side roof panels (12) can be coupled to the triangular door lintels (3) via limiting structures. Furthermore, these roof panels can be affixed to the beam support frame (2) via various connectors.

[0040] According to some embodiments, the connection structure between the roof panels and the door lintel (4) can comprise: a downward slot (14) at the bottom edge of the roof (1) corresponding with the top edge of the triangular door lintel (3). The top edge of the triangular door lintel can be inserted into the downward slot (14) so that the roof's edge can encase the top edge of the triangular door lintel (3). The top of the triangular door lintel can be provided with a limiting protrusion (31). The downward slot (14) can further provide a limiting groove (13) into which the limiting protrusion (31) can be engaged, creating a fixation structure. According to some embodiments, the limiting protrusion (31) can include spaced, strip-shaped protrusions that fit into the limiting groove (64) to prevent the roof (6) from sliding down.

[0041] According to some embodiments, the roof beam support frame (2) can include a central beam column (21), central crossbars (22), and side crossbars (23). The central beam column (21) can be arranged parallel to the door lintel (3), while the central crossbars (22) and side crossbars (23) can be arranged on the central beam column (21). According to some embodiments, the ends of the central crossbars (22) can be fixed to the triangular door lintel, whereas the side crossbars (23) can be fixed to the roof (1).

[0042] According to some embodiments, the terminals of the central crossbars (22) can have protruding connection plates (221), which can secure the central crossbars (22) to the door lintel (3). The ends of the side crossbars (23) can either be fixed to the side roof panel (12), or be fixed to the door lintel (3).

[0043] According to some embodiments, the side crossbars (23) can serve to connect the central roof panel (11) with the side roof panels (12). According to some embodiments, the side crossbars (23) can connect the side roof panel (12) with the door lintel (3) on either side of the central beam column (21), enhancing the roof's load-bearing capacity.

[0044] According to some embodiments, the ends of the central beam column (21) can be fixed to the wall panels (16) through connectors (5). For example, the connectors (5) can be injection-molded parts. The rectangular openings of these parts can be inserted into the square openings of the central beam column (21), which can be secured to the wall panels (16) with screws to enhance support.

[0045] According to some embodiments, the central beam column (21) 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 (1).

[0046] According to some embodiments, the roof (1) can cover the beam support frame (2) and can be fixed to the central beam column (21) and side crossbars (23). According to some embodiments, before installation, the central roof panel (11) can be a flat blow-molded panel in its unfolded state. When it is installed, the central roof panel (11) can bend, via an embedded and integrated folding groove, at a certain angle to form a roof peak matching the door lintel (3). 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 (11) can be fixed to the central beam column (21), while its sides can be connected and fixed to the roof side panels (12) through the adjacent side crossbars (23).

[0047] According to some embodiments, the top surfaces of the central roof panel (11) and side roof panels (12) can form a stepped structure (15) that gradually descends from the middle towards both sides. This layered design can prevent rainwater from entering the interior of the shed structure.

[0048] According to some embodiments, the lower edge of the side roof panels (12) can be equipped with positioning slots (16) at intervals along its length. A number of connectors (5) can be installed within these slots. The connectors (5) can be made of metal or plastic. The side roof panels (12) can be secured via the matching grooves of the wall panels (16) using these connectors (5), enhancing the stability of the wall panels and preventing the side roof panels (12) from sliding or being dislocated.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.