OUTDOOR ENCLOSURE AND A WALL PANEL FOR AN OUTDOOR ENCLOSURE

Technical Field

The present invention relates to the field of outdoor enclosures. The invention particularly relates to an outdoor storage enclosure such as a shed. The invention has been developed in particular for use as a backyard shed or shelter, or garden shed. However, it will be appreciated that the invention is not necessarily limited to this application and might also be used in other types of outdoor enclosure, structure or building.

Background of Invention

The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any aspect of the discussion was part of the common general knowledge as at the priority date of the application.

Backyard sheds (also known as garden sheds) are used in domestic or residential settings for storage and protection of various items against the elements. Existing backyard sheds are commonly assembled using corrugated steel sheets fixed to a frame structure. The frame structure typically includes top and bottom horizontal rails joined at corners with brackets and with the wall sheets fitted into the horizontal rails. Fasteners are used to connect the wall sheets to the rails of the frame structure which are exteriorly visible. A gable-style roof configuration is commonly used which requires tapered barge caps and a ridge cap sealing the roof apex.

A drawback of conventional outdoor shed designs is the relatively high number of different parts required which contribute to manufacturing cost and assembly complexity.

A further drawback of existing backyard sheds is the relatively ubiquitous visual appearance associated with corrugated wall sheets. To achieve requisite structural stiffness and strength, the sheet corrugations are orientated perpendicularly to the top and bottom rails. In this manner, the horizontal rails resist bending of the wall sheets about a vertical axis whilst the vertical corrugations resist bending of the wall sheets about a horizontal axis. However, a consequence of this configuration is that the shed wall aesthetic is one of relatively high-density vertically oriented lines which some consumers consider banal.

Certain alternative backyard shed designs include cladding affixed to an internal frame structure. Whilst more aesthetically desirable than conventional corrugated sheets, these designs are costly and require an undesirably large number of different components adding to assembly complexity.

Some alternative backyard sheds are of a ‘frameless’ design in which corrugated wall sheets are either connected to one another at corners or are provided with a bended corner portion. These designs are typically suitable for only relatively small sheds where loads are sufficiently small so as not to require an internal frame. Furthermore, existing frameless shed designs can be aesthetically undesirable due to the use of corrugated sheets.

Summary of the Invention

According to a broad aspect of the present invention, there is provided a wall panel for an outdoor enclosure. The wall panel includes an at least generally planar wall surface portion extending between a first end and an oppositely disposed second end. The wall surface portion has a first edge region and an oppositely disposed second edge region. The first and second edge regions are at least substantially parallel and extend at least substantially between the first and second ends. The wall panel further includes a first connector portion extending at least part way along the first edge region, and a second connector portion extending at least part way along the second edge region. Each of the first and second connector portions are generally offset from a plane of the at least generally planar wall surface portion. The first connector portion is configured for abutting contact with a second connector portion of a first adjacent component of the outdoor enclosure. The second connector portion is configured for abutting contact with a first connector portion of a second adjacent component of the outdoor enclosure. At least one first fastener is receivable through both the first connector portion of the panel and the second connector portion of the first adjacent component to secure the panel to the first adjacent wall panel. At least one second fastener is receivable through both the second connector portion of the panel and the first connector portion of the second adjacent wall panel to secure the panel to the second adjacent wall panel.

It is envisaged that the wall panel is configured for abutting contact with the first adjacent component. The first adjacent component may be in the form of a roof structure, gutter portion or a second connector portion of a first adjacent panel of the outdoor enclosure.

It is further envisaged that the wall panel is configured for abutting contact with a second adjacent component in the form of a base structure, a wall lower edge locating structure, or a first connector portion of a second adjacent panel of the outdoor enclosure.

In a preferred form, the planar wall surface portion, first connector portion and second connector portion of the wall panel are integrally formed from sheet metal.

The first connector portion of the wall panel may be configured to secure to a second connector portion of a first adjacent wall panel, the first adjacent wall panel also having an at least generally planar wall surface portion. In such an arrangement, the planar wall surface portion of the first adjacent wall panel may be at least generally provided in the plane of the wall surface portion of the wall panel.

Similarly, the second connector portion of the wall panel may be configured to secure to a first connector portion of a second adjacent wall panel, the second adjacent wall panel having an at least generally planar wall surface portion. In this way the planar wall surface portion of the second adjacent wall panel may be at least generally provided in the plane of the wall surface portion of the wall panel.

This arrangement of the wall panel being secured to each of the first and second wall panels with the at least generally planer wall surfaces of each panel being at least generally provided in the same plane is desirable, as it provides an aesthetically pleasing flat surface to the overall wall structure. Such a flat wall surface is not achievable with enclosures having conventional corrugated sheet metal wall surfaces, or conventional overlapping board/weatherboard wall surfaces. A plurality of first fasteners is preferably receivable through both the first connector portion of the wall panel and the second connector portion of the first adjacent wall panel to secure the wall panel to the first adjacent wall panel. The fasteners are preferably spaced along the panels.

Similarly, a plurality of second fasteners is preferably receivable through both the second connector portion of the wall panel and the first connector portion of the second adjacent panel to secure the wall panel to the second adjacent wall panel.

In a preferred form, each of the first and second fasteners is substantially identical, thereby simplifying the enclosure assembly process. In one form, each of the first and second fasteners is a sheet-metal fastener, although other fastener types may be used if desired.

Preferably, the second connector portion of the wall panel includes a channel extending along the second end region, with a stiffening and/or strengthening brace receivable in the channel. Such an arrangement is desirable because it provides an optional arrangement for stiffening/strengthening the overall enclosure. In this regard, it is to be appreciated that in some applications it may be desirable to stiffen and/or strengthen the enclosure, such as in areas prone to relatively high winds, since the enclosure doesn’t include a frame of the type found in conventional enclosures.

So far, the invention has been generally described in the context of a wall panel for an outdoor enclosure. However, the invention also pertains to an outdoor enclosure incorporating a plurality of the afore mentioned wall panels. Thus, according to another broad aspect of the present invention, there is provided an outdoor enclosure. The outdoor enclosure includes a plurality of walls, an access aperture and a roof structure, with each wall assembled from a plurality of wall panels of the type previously described.

The outdoor enclosure has been developed specifically, but not exclusively, as a garden shed or shelter and will hereinafter be generally described as a shed. The shed may be four-sided and may include one or more open sides. One advantage of the outdoor enclosure according to the present invention is that it is relatively easily assembled without the need to first construct or erect a frame. The enclosure is also relatively easy to disassemble should it be required to do so. Thus, it is to be appreciated that the enclosure may be in the form of a permanent, semipermanent or temporary enclosure.

The outdoor enclosure may further include a door for closing the access aperture; with the plurality of walls, door (when closed), roof structure and underlying ground or base structure defining a storage space within the outdoor enclosure. The outdoor enclosure may also include one or more windows, shelves, mounting boards and peg boards.

Brief Description of the Drawings

The present invention will now be described with reference to the accompanying drawings, which illustrate a particular preferred embodiment of the present invention, wherein:

Figure 1 is perspective view showing bottom channels of an outdoor enclosure in the form of a shed according to a first embodiment of the present invention.

Figure 2 is a perspective view showing bottom channels of the shed of Figure 1 in an assembled configuration, with a wall panel in position relative to the bottom channels. Figure 3 is a perspective view showing a first bottom layer of shed wall panels in position relative to the bottom channels.

Figure 4 is a perspective view similar to Figure 3, but with a door and door frame/jamb in position.

Figure 5 is another perspective view of the arrangement shown in Figure 4.

Figure 6 shows an additional wall panel being secured in position to a wall panel of the first bottom layer of wall panels.

Figure 7 is a perspective view similar to Figure 6 but showing a further additional wall panel being secured in position to a wall panel of the first bottom layer of wall panels. Figure 8 is a perspective view showing roof flashing being fitted to a top layer of wall panels.

Figure 9 is a perspective view showing corrugated roof sheets being fitted into slots provided in the roof flashing. Figure 10 is a perspective view showing the corrugated roof sheets being secured to the roof flashing.

Figure 11 is a perspective internal view of the shed showing fitment of a corner shelf. Figure 12 is a perspective view of the shed (with a wall missing for clarity) showing fitment of floor beams prior to fitment of flooring panels on top of the floor beams. Figure 13 is a perspective internal view of the shed showing fitment of a shelf along an end wall.

Figure 14 is a perspective internal view of the shed showing fitment of a mounting board or peg board to an internal wall surface of the shed.

Figure 15 shows as a preferred embodiment, a magnified side view of two connected shed panels, with a first panel shown mounted to and above a second panel.

Detailed Description of the Drawings

Referring to the drawings there is illustrated an outdoor enclosure in the form of a garden shed 10 (as most clearly illustrated in Figures 8 and 12).

The illustrated shed 10 is a four-sided structure, although it may include one or more partially or fully open sides if desired. The illustrated shed 10 has a rectangular footprint of approximately 1250mm x 2150mm, although it may be provided in any other practical dimensions if desired. Another proposed shed according to the present invention has a square footprint of approximately 2150mm x 2150mm. The shed 10 may be provided in any desired, practical height.

It is to be appreciated that the shed 10 is specifically designed to be delivered to site as a kit of components, which can then be relatively easily assembled by the purchaser or handyman.

As most clearly shown in Figures 8, 10 and 12, the shed 10 includes four walls 12, 14, 16, 18 (see Figure 8), an access aperture 20 (see Figure 5) and a door 22 for closing the access aperture 20. The shed 10 also includes a roof structure 24 (see Figures 9 and 10). The shed 10 is supported on a base in the form of a concrete slab (not shown), although it may also be suitably supported on pavers, directly on the ground, on screenings or on any other suitable base. As shown in Figure 12, the shed 10 may include floor beams 86 for receiving flooring panels (not shown) thereon. The walls 12, 14, 16, 18, door 22 (when closed), roof structure 24 and base 26 collectively define a storage space 1 1 (se Figure 8) within the shed 10.

The shed 10 may optionally include one or more windows (not shown), corner shelf 27 (see Figure 1 1 ), side shelf 30 (see Figure 13) and mounting board and/or peg board 32 (see Figure 14).

Each of the walls 12, 14, 16, 18 is assembled from a plurality of stacked wall panels 28. The length of the wall panels 28 differ. However, the features of each panel 28 are otherwise substantially identical. In this respect, each wall panel 28 includes a generally planar wall surface portion 30 extending between a first end 32 and an oppositely disposed second end 34.

The wall surface portion 30 of each wall panel 28 has a first edge region 36 and an oppositely disposed second edge region 38. The first and second edge regions 36, 38 are at least substantially parallel and extend at least substantially between the first and second ends 32, 34.

Each wall panel 28 further includes a first connector portion 40 extending along the first edge region 36, and a channel-shaped second connector portion 42 extending along the second edge region 38. Each of the first and second connector portions 40, 42 is generally offset from a plane aligned with the surface 44 of the wall surface portion 30. This is desirable, because the surface 44 is the outer, visible surface of the wall panel 28. That is, the surface 44 is the portion of each wall panel 28 that is visible when looking at the exterior of the shed 10. With the first and second connector portions 40, 42 off-set from the surface 44, the first and second connector portions 40, 42 are hidden from view inside the assembled shed 10. This contributes to an overall a clean, sleek and aesthetically pleasing shed exterior, with only a series of horizontal lines 43 visible on the walls 12, 14, 16, 18.

The planar wall surface portion 30, the first connector portion 40 and the second connector portion 42 of each wall panel 28 are integrally formed from sheet metal, such that each panel 28 is one-piece. The first connector portion 40 of each wall panel 28 is configured for receiving in, and abutting contact with, a channel-shaped second connector portion 42 of a first adjacent component of the shed 10 located immediately above the panel 28. Such an arrangement can be seen in cross-section is Figure 6. The first adjacent component may be any one of a roof gutter portion 46, roof structure 48 or second connector portion 42 of a first adjacent wall panel 28, depending on the precise location of a given panel 28 in a given wall 12, 14, 16, 18.

The second connector portion 42 of each wall panel 28 is configured for abutting contact with a first connector portion 40 of a second adjacent component of the shed 10 located immediately below the panel 28 (see Figure 2). Indeed, the first connector portion 40 is receivable in and abuts the channel-shaped second connector portion 42. The second adjacent component 42 may be any one of a bottom channel 60 (as shown in Figure 2), other base structure or first connector portion 40 of a second adjacent wall panel 28 (as shown in Figure 6), depending on the precise location of the panel 28 in the given wall 12, 14, 16, 18.

As shown in, for example in Figures 2, 3, 6, 7, 11 , 13 and 14, fasteners in the form of sheet metal screws 52 are receivable through both of the first connector portion 40 of each wall panel 28 and second connector portion 42 of the respective first adjacent shed component 40. The provision of screws 52 secure the panel 28 to the first adjacent component (such as an adjacent wall panel 28). Each screw 52 is receivable through respective aligned receiving apertures provided in each of the first connector portion 40 of the panel and the second connector portion 42 of the first adjacent component.

Further, a plurality of fasteners in the form of sheet metal screws (also designated 52) is receivable through both the second connector portion 42 of each panel 28 and the first connector portion 40 of the respective second adjacent component (such as an adjacent wall panel 28) to secure the panel 28 to the second adjacent component (as shown in Figure 6). Each screw 52 is receivable through respective aligned receiving apertures provided in each of the second connector portion 42 and the first connector portion 40 of the second adjacent component. Each of the screws 52 is substantially identical, thereby simplifying the shed assembly process, and contributing to a relatively simple shed assembly process.

It is to be appreciated that the shed 10 does not incorporate a frame as of the type found in conventional sheds. Instead, the shed 10 achieves sufficient rigidity by connecting each panel 28 above and below (and at its ends 32, 34) to adjacent panels and/or bottom channel 60 and/or roof gutter 25 and/or door jamb 72. This provides a point of differentiation with existing sheds on the market and simplifies assembly since fewer parts require assembly. It also reduces the overall number of separate components to be transported to site.

It is to be appreciated from the accompanying drawings that some panels 28 are secured to and between two adjacent wall panels. However, it is also to be appreciated that the lowermost panel on each side of the shed 10 is secured between an upper panel and a bottom channel portion 60a, 60b, 60c, 60d (as shown in Figures 2 and 3). Further, the uppermost panel on each side of the shed is secured between a lower panel and a respective gutter portion 62a, 62b, 62c, 62d of the shed (as shown in Figure 8).

As shown in Figure 6, the channel 64 integrally formed in the second connector portion 42 of each panel 28 can optionally receive a stiffening and/or strengthening brace 66 (shown in dashed line format). Each brace 66 extends longitudinally along the respective channel 64. Such an arrangement is desirable, because in some applications it may be desirable to stiffen and/or strengthen the shed 10, such as in areas prone to relatively high winds or other loads. In such situations, the channel 64 of each panel 28 may be provided with a respective brace 66.

The roof structure 24 is a substantially flat roof constructed from corrugated sheet metal 68. The roof structure 24 does have a slight pitch to assist with rainfall runoff. The roof structure 24 may be of any other practical design if desired.

One advantage of the shed 10 is that it is relatively easily assembled without the need to first construct or erect a frame. The shed 10, being frameless, also requires fewer components. It is also relatively easy to disassemble should the need be required to do so. Thus, it is to be appreciated that the shed 10 may be in the form of a permanent, semi-permanent or temporary structure.

Assembly of the shed 10 follows a generally stepwise procedure, as shown in the accompanying Figures 1 to 14.

An initial step in assembling the shed 10 is shown in Figure 1 , whereby the bottom channel portions 60a, 60b, 60c, 60d are arranged on a suitable (preferably at least generally flat) underlying surface. The ends of each channel portion 60a, 60b, 60c, 60d have screw receiving apertures. The ends of adjacent channel portions 60a, 60b, 60c, 60d are overlapped such that respective apertures are aligned, and then screws are inserted through the apertures to retain the channel portions in a rectangular configuration generally defining the footprint of the shed 10.

As shown in Figure 2, a first lowermost layer of wall panels 28 is then secured by way of screws to the bottom channel 60. Figure 2 shows the first panel 28 being secured to the bottom channel 60. The panel 28 is secured by way of a series of screws receivable through aligned apertures provided in each of the second connector portion 42 of the panel 28, and the first connector portion 40 of the channel portion 60a.

Figure 3 shows the completed first, bottom layer of wall panels 28 in position and secured (or being secured) to the bottom channel 60 by screws. The ends of each wall panel 42 are secured to adjacent panels (in the same layer of panels) by way of end screws 70, as shown in Figure 5.

Figure 4 shows fitment of the door 22 and door jamb 72. The door jamb 72 is moved/slid in a downwardly direction to engage with the adjacent wall panels. Thereafter, the jamb 72 is fastened into position to the adjacent wall panels and bottom channel 60 by way of screws receivable through aligned apertures.

Once the bottom layer of wall panels 28 is secured in position, the second lowermost layer of wall panels can be secured in position. This as shown in Figure 6, where a second layer panel 28 is secured in position on top of a first (bottom) layer panel 28. The second layer panel 28 is secured by way of screws 52 receivable through aligned apertures provided in each of the second connector portion 42 of the second layer panel 28, and the first connector portion 40 of first layer panel 28. The second layer panel 28 (as with the first layer panel 28) is also secured to the door jamb 72 with screws inserted through appropriately aligned apertures.

As shown in Figure 7, additional screws 74 extend through the first and second layers of wall panels 28 to further secure and provide additional rigidity of the overall structure.

Each layer of wall panels 28 is progressively added to the structure and secured in position to adjacent components, until the top layer of panels 28 has been added, as shown in Figure 8. With all the wall panels now secured in place, the roof flashing 76 is then mounted in position (with screws) to the first connector portion of the top layer of wall panels 28.

Figure 8 begins to reveal the unique appearance of the shed 10, with the wall panels 28 combining to provide an aesthetically pleasing exterior wall surface having a series of parallel horizontal lines extending across each wall 12, 14, 16, 18.

Figures 8 and 9 illustrate fitment of the roof (in the form of corrugated sheet metal 68) into a groove 78 provided by the roof flashing 76. Following fitment, the sheet metal 68 is secured in position with screws 78 - see Figure 10.

Internal fitments may be added to the interior of the shed 10, several of which are shown in Figures 1 1 to 14.

Figure 11 shows a corner shelf 27 being secured into position with screws 80.

Figure 12 shows floor beams 86 being fitted into position, following which flooring panels (not shown) may be fitted on top of the floor beams 86 and secured in position.

Figure 13 shows a side shelf 30 being secured into position with screws 82. Figure 14 shows a mounting board 32/peg board 34 being secured in position with screws 84.

Figure 15 shows two substantially identical wall panels 28a and 28b lapped together. This lapping of the two panels provides a void 88 between the first connector portion 40a of panel 28a and the second connector portion 42b of panel 28b. The presence of void 88 is desirable, as it prevents capillary action of water.

Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

Where any or all of the terms "include", "includes", "included" or "including" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components.

Where the terms “comprise”, “comprises” and “comprising” are used in the specification (including the claims) they are to be interpreted as specifying the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components, or group thereof.