Outdoor Structure Construction Kits, Such as Pavilion Construction Kits

Abstract

Outdoor structure kits according to various embodiments are adapted to construct one or more outdoor structures, such as a pavilion. The outdoor structure kits may include a plurality of modular truss sub-assemblies that are adapted to be assembled into trusses. In particular embodiments, the kits are adapted to allow users to install pre-assembled roof panels on the assembled trusses by fitting tabs that extend from the bottoms of the roof panels into recesses defined in the respective top surfaces of the trusses. In particular embodiments, the kits may include a plurality of posts and a plurality of reinforced truss members (which may be made of a reinforced plastic material) that may be assembled to create the structure's floor and/or ceiling frames. In certain embodiments, the kits may include a plurality of roof sub-panels that may be assembled to form a larger roof panel with shingles that overlap the edges of the subpanels.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/727,140 entitled “Joist Assemblies and Assembly Kits”, which was filed on Mar. 18, 2010 and which is a continuation-in-part of U.S. patent application Ser. No. 12/725,618 entitled “Reinforced Boards and Other Building Materials”, which was filed on Mar. 17, 2010; this application is also a continuation-in-part of U.S. patent application Ser. No. 12/698,126 entitled “Awning and Portico Kits”, which was filed on Feb. 1, 2010. All of the above-referenced patent applications are hereby incorporated herein by reference in their entirety.

BACKGROUND

Currently, most outdoor deck structures, such as decks and pavilions, are made of wood. However, there are several disadvantages associated with using wood to build decks and other outdoor structures. For example, although wood has proven to be a suitable, relatively inexpensive decking material, wooden deck structures tend to fade and splinter over time. Also, out of concern for a decreasing supply of natural resources, many consumers prefer to avoid using wood as a building material. Wood boards can also be relatively heavy and expensive.

Although alternative decking products are currently used, in some cases, for the surfaces of decks and other outdoor structures, the structural portions of such structures (e.g., the structure's posts, beams, and joists) are still typically made of wood. This is due to challenges in producing a low maintenance product that has the structural integrity to support the alternative deck structure surfacing products that are available on the market today.

Accordingly, there is a need for new building materials, such as decking materials (e.g., floor, ceiling, and band joists), that are durable, lightweight, inexpensive, and environmentally friendly. There is also a need for improved outdoor structures, and related roofing structures, that are made of such new materials and/or other materials.

SUMMARY

A building structure kit for use in building a particular building structure, according to various embodiments of the invention, comprises a first roof panel and a second roof panel. The first roof panel comprises a first base portion and a first plurality of shingles that have been pre-installed adjacent an upper surface of the first roof panel. The second roof panel comprises a second base portion and a second plurality of shingles that have been pre-installed adjacent an upper surface of the second roof panel. The first roof panel also comprises a first protruding shingle that extends over a side edge of the first base portion, and the second plurality of shingles are adapted to receive a particular portion of the first protruding shingle between a first shingle of the second plurality of shingles and a second shingle of the second plurality of shingles.

A building structure kit for use in building a particular building structure, according to particular embodiments of the invention, comprises a base portion assembly kit for building a base portion of the building structure and a roof assembly. The base portion assembly kit comprises: (1) a plurality of posts, each of the posts defining at least one lower recess; (2) a plurality of band members; and (3) a plurality of joists, each of the joists having a first tenon adjacent a first end of the joist, and a second tenon adjacent a second end of the joist. The plurality of posts, plurality of band members, and plurality of joist members are collectively adapted to be assembled to create a base portion of the building structure. The roof assembly is adapted to be assembled to form a roof of the building structure.

In various embodiments, a particular one of the plurality of joist members comprises: (1) a first elongated casing that is substantially in the form of a rectangular prism; (2) a tenon that is disposed adjacent an end portion of the first elongated casing; and (3) a first metal reinforcing member. The first metal reinforcing member extends longitudinally within an interior of the first elongated casing and extends longitudinally within an interior of the tenon. A particular portion of the first metal reinforcing member extends out of the interior of the tenon adjacent a particular end surface of the tenon. A particular one of the band members comprises a second elongated casing that is substantially in the form of a rectangular prism, and a second metal reinforcing member that extends longitudinally within an interior of the second elongated casing. The second elongated casing defines at least one mortise. The tenon of the particular joist is adapted and dimensioned so that when the tenon is inserted into the particular band member's mortise, the particular joist's tenon matingly engages the particular band member about a perimeter of the mortise, and the particular joist and the particular band member are adapted and dimensioned so that a particular portion of the first metal reinforcing member engages a particular portion of the second metal reinforcing member when the tenon is inserted into the particular band member's mortise.

A building structure kit for use in building a particular building structure, according to further embodiments of the invention, comprises: (1) a base portion assembly kit for building a base portion of the building structure; and (2) a roof assembly. The base portion assembly kit comprises: (1) a plurality of elongated posts having a first end and a second end, each of the posts defining a groove adjacent the first end; (2) a plurality of band members; and (3) a plurality of joists, each of the joists having a first tenon adjacent a first end of the joist, and a second tenon adjacent a second end of the joist. The plurality of posts, plurality of band members, and plurality of joist members are collectively adapted to be assembled to create a base portion of the building structure. The plurality of band members and the plurality of joist members are collectively adapted to be assembled to create a ceiling frame of the building structure, and the roof assembly is adapted to be assembled to form a roof of the building structure. A particular one of the plurality of joist members comprises: (1) a first elongated casing that is substantially in the form of a rectangular prism; (2) a tenon that is disposed adjacent an end portion of the first elongated casing; and (3) a first metal reinforcing member that: (a) extends longitudinally within an interior of the first elongated casing, and (b) extends longitudinally within an interior of the tenon.

In particular embodiments, a particular portion of the first metal reinforcing member extends out of the interior of the tenon adjacent a particular end surface of the tenon. A particular one of the band members comprises a second elongated casing that is substantially in the form of a rectangular prism, and a second metal reinforcing member that extends longitudinally within an interior of the second elongated casing. The second elongated casing defines at least one mortise. The tenon of the particular joist is adapted and dimensioned so that when the tenon is inserted into the particular band member's mortise, the particular joist's tenon matingly engages the particular band member about a perimeter of the mortise. The particular joist and the particular band member are adapted and dimensioned so that a particular portion of the first metal reinforcing member engages a particular portion of the second metal reinforcing member when the tenon is inserted into the particular band member's mortise. The particular tenon of the particular joist and the particular band member are adapted to be attached together to form at least part of the ceiling frame, and the ceiling frame is adapted to be supported adjacent respective top surfaces of the plurality of posts and held in place, at least in part, by respective portions of the ceiling frame extending into respective grooves that are defined within respective end surfaces of the posts.

A building structure kit for use in building a particular building structure, according to additional embodiments of the invention comprises: (1) a base portion assembly kit that comprises a plurality of base portion components, the base portion components being adapted to be assembled to create a base portion of the building structure; (2) a truss assembly kit; and (3) a pre-assembled roof assembly. The truss assembly kit comprises: (1) a first truss portion; (2) a second truss portion, the first and second truss portions being adapted to be attached together to form at least a portion of a first truss; (3) a third truss portion; and (4) a fourth truss portion. The third and fourth truss portions are adapted to be attached together to form at least a portion of a second truss. The pre-assembled roof assembly comprises: (1) a roof base structure; (2) a plurality of shingles that have been preinstalled on the roof base structure; and (3) a plurality of elongated tabs that extend downwardly from a bottom surface of the roof base structure. The first and second truss portions are adapted so that, when they are attached together to form the portion of the first truss, the first and second truss portions cooperate to form a first roof support structure that defines a first plurality of recesses. The third and fourth truss portions are adapted so that, when they are attached together to form the portion of the second truss, the third and fourth truss portions cooperate to form a second roof support structure that defines a second plurality of recesses. The truss assembly kit and the pre-assembled roof assembly are adapted to be installed adjacent the base portion of the building structure to create at least a portion of a roof of the building structure by: (1) installing the first truss adjacent the base portion of the building structure; (2) installing the second truss adjacent the base portion of the building structure; and (3) moving the roof assembly into a particular position adjacent respective top surfaces of the first and second trusses. When the roof assembly is in the particular position, each of the elongated tabs extends downwardly into at least a respective one of the first or second plurality of recesses.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described various embodiments of the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1A is a side elevation view of a floor joist according to a particular embodiment of the invention.

FIG. 1B is an end view of the floor joist of FIG. 1A.

FIG. 1C is a cross-sectional view of the body portion of the floor joist of FIG. 1A taken about Section 1C-1C.

FIG. 2A is a side elevation view of an end band joist according to a particular embodiment of the invention.

FIG. 2B is a cross-sectional view of the end band joist of FIG. 2A taken about section 2B-2B. This cross section is also a representation of various embodiments of the cross section of the side band joist 15¹ discussed in detail below.

FIG. 3 is an end view of a ceiling joist according to a particular embodiment.

FIG. 4A is a top perspective exploded view of an exemplary decking structure that incorporates the joists of FIGS. 1A-1C and FIGS. 2A-2B.

FIG. 4B is a top perspective view of an assembled version of the decking structure shown in FIG. 4A.

FIG. 5A is a side elevation view of a ceiling joist according to a particular embodiment of the invention.

FIG. 5B is an end view of the ceiling joist of FIG. 5A.

FIG. 5C is a cross-sectional view of the ceiling joist of FIG. 5A taken about cross-section 5C-5C.

FIG. 5D is a perspective end view of the ceiling joist of FIG. 5A.

FIG. 5E is a perspective view of the reinforcing member of the ceiling joist of FIG. 5A.

FIG. 6 is a partial cross-sectional view of a portion of the decking structure of FIGS. 4A and 4B taken about Section 6-6.

FIG. 7A is an exploded front elevation view of a post assembly according to a particular embodiment.

FIG. 7B is a perspective view of the post of the post assembly of FIG. 7A.

FIG. 8A is an exploded front elevation view of a post assembly according to a particular embodiment.

FIG. 8B is a perspective view of the post assembly of FIG. 8A.

FIG. 8C is a perspective view of a roof support shown in FIG. 8A.

FIG. 9A is an elevation view of a truss according to a particular embodiment.

FIG. 9B is an elevation view of two portions of the truss of FIG. 9A.

FIG. 10 is a perspective view of a ceiling decking structure according to a particular embodiment.

FIG. 11 is a perspective view of a partially assembled pavilion kit according to a particular embodiment of the invention. The kit's roof panels have not yet been installed.

FIG. 12A is a perspective top view of a roof panel according to a particular embodiment.

FIG. 12B is a bottom view of the roof panel of FIG. 12A.

FIG. 13A is a side elevation view of an assembled pavilion kit according to one embodiment of the invention.

FIG. 13B is a front elevation view of the assembled pavilion kit of FIG. 13A.

FIG. 13C is a perspective view of the assembled pavilion kit of FIG. 13A.

FIG. 14A is a top plan view of a first roof panel and a second roof panel of a building structure kit according to a particular embodiment of the invention.

FIG. 14B is a bottom plan view of the first roof panel and the second roof panel of the building structure kit of FIG. 14A.

FIGS. 15-18 are perspective views showing an assembly process of an interlocking roof structure according to a particular embodiment of the invention.

FIG. 19 is a perspective view of the assembled building structure kit of FIGS. 15-18.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Various embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments of the invention are shown. The inventions may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

Exemplary Building Structures

FIGS. 11 and 13A-13C show building structure kits (in an at least partially assembled form) according to various embodiments. These kits include the parts necessary to build: (1) one or more post assemblies; (2) a floor frame; (3) a ceiling frame; (4) one or more truss assemblies; and (5) a roof assembly. Each of these components is discussed in greater detail below.

Post Assemblies

A corner post assembly 400 according to a particular embodiment is shown in FIGS. 7A and 7B. As may be understood from these figures, the corner post assembly 400 includes an elongated post 405 that is substantially in the form of a rectangular prism. In particular embodiments, the post 405 includes two lower mortises 407 that are disposed at about the same height above the bottom end of the post 405 on adjoining sides of the post 405. Similarly, the post 405 includes two upper mortises 411, 413 that are disposed at about the same height above the bottom end of the post 405 on adjoining sides of the post 405. The post 405 further includes two grooves 415, 417 in the top end of the post 405 on adjoining sides of the post 405. These two grooves 415, 417 cooperate to form an L-shaped channel in the post's top surface.

As may be understood from FIG. 7A, in particular embodiments, the corner post assembly includes two roof supports 520, which include an elongated base portion 521 and a tenon 522, 524 adjacent each end of the base portion 521. FIG. 8C shows a perspective view of the roof support 520 of FIG. 7A. In particular embodiments, each of the post's upper mortises 411, 413 is adapted to matingly receive a corresponding one of the lower tenons 524 of the roof supports 520.

FIGS. 8A and 8B show a middle post assembly 500 according to a particular embodiment of the invention. As may be understood from these figures, the middle post assembly 500 is similar in structure to the corner post assembly 400 described above, except that the corner post assembly's post 505 includes three lower mortises 507-509 that are adjacent adjoining sides of the post 505 as shown in FIGS. 8A and 8B. Similarly, the post's upper mortises 511, 513 are on opposite sides of the post 505 as shown in FIGS. 8A and 8B. In addition, the top of the post includes a single, straight groove 510 rather than an L-shaped groove.

Floor and Ceiling Frames

In particular embodiments, the building structure kits' floor and ceiling frames comprise reinforced boards that are used as the floor and ceiling frames' joists. These reinforced boards are discussed in greater detail below.

First Exemplary Reinforced Board

A reinforced board (e.g., a reinforced joist 10, such as a floor joist) according to a particular embodiment is shown in FIGS. 1A-1C. As may be understood from these figures, the joist 10 comprises: (1) a body portion 111; and (2) two tenons 125, each of which extends from a respective end of the joist 10. In particular embodiments, the joist's body portion 111 has a substantially uniform cross section (e.g., an entirely uniform cross section) along the entire length of the joist's body portion 111.

As may be understood from FIG. 1C, which shows the cross section of the joist's body portion, the joist 10 comprises an elongated reinforcing member 100 that has a substantially Z-shaped (e.g., Z-shaped) cross section. In particular embodiments, the reinforcing member 100 is metal (e.g., steel, aluminum, or other suitable metal) although, in alternative embodiments, the reinforcing member 100 may be made of other suitable materials.

In the embodiment shown in FIG. 1C, the reinforcing member 100 comprises a substantially planar base portion 101 that is substantially parallel to (e.g., parallel to) the joist's exterior side surfaces, and that is substantially perpendicular to (e.g., perpendicular to) the joist's exterior top and bottom surfaces.

The reinforcing member 100 further includes a first extension portion 102 that, in various embodiments, is substantially planar (e.g., planar). In particular embodiments, such as the embodiment shown in FIG. 1C, the first extension portion 102: (1) extends outwardly from the top end of the reinforcing member's base portion 101; and (2) is substantially perpendicular to (e.g., perpendicular to) the reinforcing member's base portion 101. As shown in FIG. 1C, the top portion of the reinforcing member's base portion 101 and the first extension portion 102 cooperate to form a right angle that defines a recess between the sides of the right angle.

As may be understood from FIG. 1C, in particular embodiments, the reinforcing member 100 further includes a second extension portion 103 that, in various embodiments, is substantially planar (e.g., planar). In particular embodiments, such as the embodiment shown in FIG. 1C, the second extension portion 103: (1) extends outwardly from the bottom end of the reinforcing member's base portion 101; and (2) is at least substantially perpendicular to the reinforcing member's base portion 101. As shown in FIG. 1C, the bottom portion of the reinforcing member's base portion 101 and the second extension portion 103 cooperate to form a right angle that defines a recess between the sides of the right angle. In particular embodiments, the first and second extension portions 102, 103 are on opposite side of the reinforcing member's base portion 101.

In the embodiment shown in FIG. 1C, the joist 10 further comprises a first length of material 110 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 1C, the cross section of the first length of material 110 is about half as wide as the joist's body portion and is about the same height as the reinforcing member's base portion 101. Also, in particular embodiments, the first length of material 110 extends substantially the full length of (e.g., the entire length of) the joist's body portion 111.

As may be understood from FIG. 1C, the first length of material 110 is adapted to substantially mate with the structure formed by the reinforcing member 100 and the first extension portion 102. In this embodiment, an interior corner side of the first length of material is disposed within the recess defined by the reinforcing member 100 and the first extension portion 102.

In the embodiment shown in FIG. 1C, the joist 10 also comprises a second length of material 120 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 1C, the cross section of the second length of material 120 is about half as wide as the joist's body portion and is about the same height as the reinforcing member's base portion 101. Also, in particular embodiments, the second length of material 120 extends substantially the full length of (e.g., the entire length of) the joist's body portion 111.

As may be understood from FIG. 1C, the second length of material 120 is adapted to substantially mate with the structure formed by the reinforcing member 100 and the second extension portion 103. In this embodiment, an interior corner side of the second length of material 120 is disposed within the recess defined by the reinforcing member 100 and the second extension portion 103.

Turning further to FIG. 1C, in this embodiment, the joist 10 further comprises a third length of material 130 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 1C, the cross section of the third length of material 130 is about as wide (e.g., exactly as wide) as the joist's body portion. Also, in particular embodiments, the third length of material 130 extends substantially the full length of (e.g., the entire length of) the joist's body portion 111.

This third length of material 130 is mounted below: (1) the first and second lengths of material 110, 120; and (2) the second extension portion 103 of the reinforcing member 100. In particular embodiments, such as the embodiment shown in FIG. 1C, a first side edge of the third length of material 130 is substantially coplanar with (e.g., coplanar with) the outer side of the first length of material 110. Similarly, the second side edge of the third length of material 130 is substantially coplanar with the outer side of the second length of material 120. As a result, the first, second, and third lengths of material 110, 120, 130, and the reinforcing member 100 cooperate to form a structure having a substantially rectangular cross section (See FIG. 1C).

Turning again to FIG. 1C, in this embodiment, the joist 10 further comprises a fourth length of material 140 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 1C, the cross section of the fourth length of material 140 is about as wide (e.g., exactly as wide) as the joist's body portion 111. Also, in particular embodiments, the fourth length of material 140 extends substantially the full length of (e.g., the entire length of) the joist's body portion 111.

This fourth length of material 140 is mounted above: (1) the first and second lengths of material 110, 120; and (2) the first extension portion 102 of the reinforcing member 100. In particular embodiments, such as the embodiment shown in FIG. 1C, a first side edge of the fourth length of material 140 is substantially coplanar with (e.g., coplanar with) the outer side of the first length of material 110. Similarly, the second side edge of the fourth length of material 140 is substantially coplanar with the outer side of the second length of material 120. As a result, the first, second, and fourth lengths of material 110, 120, 140, and the reinforcing member 100 cooperate to form a structure having a substantially rectangular cross section. As may be understood from FIG. 1C, the first, second, third and fourth lengths of material 110, 120, 130, 140, and the reinforcing member 100 also cooperate to form a structure having a substantially rectangular cross section.

In various embodiments, the first, second, third and fourth lengths of material 110, 120, 130, 140, and the reinforcing member 100 are attached together in the arrangement shown in FIG. 1C. For example, in particular embodiments, these various components are glued together with a suitable adhesive, such as PVC glue or another suitable glue. In other embodiments, these components may be attached together using a suitable fastener, such as suitable fastening hardware. In such an arrangement, the first, second, third and fourth lengths of material 110, 120, 130, 140 can be understood to form a casing around the reinforcing member 100.

As noted above, and as shown in FIGS. 1A-1C and FIG. 3, in various embodiments, the joist 10 comprises two tenons 125, each of which is disposed adjacent a respective end of the joist's body portion 111. In particular embodiments, such as the embodiment shown in FIGS. 1A-1C, these tenons 125 are substantially in the form of a rectangular prism and comprise: (1) an end portion of the first and second lengths of material 110, 120; and (2) an end portion of the structural support 100.

As shown in FIG. 1B, the end 150 of the base portion 101 of the structural support 100 is folded over the end of the first length of material 110, and is attached (e.g., glued) to the end of the first length of material 110 so that: (1) the end of the structural support's base portion 101 is at least substantially perpendicular to (e.g., perpendicular to) the rest of the structural support's base portion 101; and (2) the end of the structural support's base portion 101 overlaps at least a portion of the end of the first length of material 110. As described in greater detail below, in particular embodiments, this end portion of the structural support's base portion 101 (which, in various embodiments, is made of a hard metal, such as steel) may help to securely attach the joist 10 to a corresponding band joist 15.

Second Exemplary Reinforced Board

A second exemplary reinforced board (e.g., a reinforced joist, such as a band joist 15, 15¹) according to a particular embodiment is shown in FIGS. 2A-2B. A cross-section of this band joist 15, 15¹ is shown in FIG. 2B. In particular embodiments, and as shown in FIG. 3, certain embodiments of the band joist 15 (e.g., in which the joist is used as a side band joist 15) may include a plurality of mortises 40 that are dimensioned to matingly receive a tenon 125 of a respective floor joist 10. In particular embodiments, the mortises 40 are spaced evenly (e.g., every 300 mm—or other predetermined distance—on centre) along the length of the side band joist 15.

In other embodiments, such as when the band joist is used as an end band joist 15¹, the end band joist 15¹includes no mortises 40.

In particular embodiments, the band joist's body portion 211 has a substantially uniform cross section along the length of the body portion 211, except where a portion of the cross section (e.g., the second length of material 220 referenced below) has been removed to create a recess (e.g., a mortise 40) in the band joist 15 (See FIG. 3). Also, in particular embodiments, the ends of the band joist's reinforcing member 200 (which is discussed below) may extend just short of the respective ends of the band joist 15, 15¹. This allows a user to cut the ends of the band joist 15, 15¹ to a desired angle (e.g., 45 degrees), as shown in FIG. 3, without having to cut through the reinforcing member 200.

As may be understood from FIG. 2B, which shows the cross section of the band joist's body portion 211, the band joist 15, 15¹ comprises an elongated reinforcing member 200 that has a substantially U-shaped (e.g., U-shaped) cross section. In particular embodiments, the reinforcing member 200 is metal (e.g., steel, aluminum, or other suitable metal) although, in alternative embodiments, the reinforcing member 200 may be made of other suitable materials.

In the embodiment shown in FIG. 2B, the reinforcing member 200 comprises a substantially planar base portion 201 that is substantially parallel to (e.g., parallel to) the joist's exterior side surfaces, and that is substantially perpendicular to (e.g., perpendicular to) the band joist's exterior top and bottom surfaces. The reinforcing member 200 further includes a first extension portion 202 that, in various embodiments, is substantially planar (e.g., planar). In particular embodiments, such as the embodiment shown in FIG. 2B, the first extension portion 202: (1) extends outwardly from the top end of the reinforcing member's base portion 201; and is (2) substantially perpendicular to (e.g., perpendicular to) the reinforcing member's base portion 201. As shown in FIG. 2B, the top portion of the reinforcing member's base portion 201 and the first extension portion 202 cooperate to form a right angle that defines a recess between the sides of the right angle. In particular embodiments, the first and second extension portions 202, 203 are on the same side of the reinforcing member's base portion 201.

As may be understood from FIG. 2B, in particular embodiments, the reinforcing member 200 further includes a second extension portion 203 that, in various embodiments, is substantially planar (e.g., planar). In particular embodiments, such as the embodiment shown in FIG. 2B, the second extension portion 203: (1) extends outwardly from the bottom end of the reinforcing member's base portion 201; and is (2) substantially perpendicular (e.g., perpendicular) to the reinforcing member's base portion 201. As shown in FIG. 2B, the bottom portion of the reinforcing member's base portion 201 and the second extension portion 203 cooperate to form a right angle that defines a recess between the sides of the right angle.

In the embodiment shown in FIG. 2B, the band joist 15, 15¹ further comprises a first length of material 210 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 2B, the cross section of the first length of material 210 is about half as wide as the joist's body portion and is about the same height as the reinforcing member's base portion 201. Also, in particular embodiments, the first length of material 210 extends substantially the full length of (e.g., the entire length of) the joist's body portion 211.

As may be understood from FIG. 2B, the first length of material 210 is adapted to substantially mate with the structure formed by the reinforcing member 200 and the first extension portion 202. In this embodiment, a first interior corner side of the first length of material 210 is disposed within the recess defined by the base portion 201 of the reinforcing member 200 and the first extension portion 202. Similarly, a second interior corner side of the first length of material 210 is disposed within the recess defined by the base portion 201 of the reinforcing member 200 and the second extension portion 203.

In the embodiment shown in FIG. 2B, the band joist 15, 15¹ also comprises a second length of material 220 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 2B, the cross section of the second length of material 220 is about half as wide as the joist's body portion and is about the same height as the reinforcing member's base portion. Also, in particular embodiments, the second length of material 220 extends substantially the full length of (e.g., the entire length of) the joist's body portion. In other embodiments, the second length of material 220 extends the full length of the joist's body portion in the form of a plurality of sections that are separated by gaps, which are used as the joist's mortises 40 (See FIG. 3).

Turning further to FIG. 2B, in this embodiment, the band joist 15, 15¹ further comprises a third length of material 230 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 2B, the cross section of the third length of material 230 is about as wide (e.g., exactly as wide) as the joist's body portion 211. Also, in particular embodiments, the third length of material 230 extends substantially the full length of (e.g., the entire length of) the joist's body portion 211.

This third length of material 230 is mounted below: (1) the first and second lengths of material 210; and (2) the second extension portion 203 of the reinforcing member 200. In particular embodiments, such as the embodiment shown in FIG. 2B, a first side edge of the third length of material 230 is substantially coplanar with (e.g., coplanar with) the outer side of the first length of material 210. Similarly, the second side edge of the third length of material 230 is substantially coplanar with the outer side of the second length of material 220. As a result, the first, second, and third lengths of material 210, 220, 230, and the reinforcing member 200 cooperate to form a structure having a substantially rectangular cross section.

Turning again to FIG. 2B, in this embodiment, the band joist 15, 15¹ further comprises a fourth length of material 240 (e.g., a plastic material such as polystyrene or polypropylene) that, in various embodiments, is in the form of a substantially rectangular prism. In particular embodiments, such as the embodiment of FIG. 2B, the cross section of the fourth length of material 240 is about as wide (e.g., exactly as wide) as the joist's body portion 211. Also, in particular embodiments, the fourth length of material 240 extends substantially the full length of (e.g., the entire length of) the joist's body portion 211.

This fourth length of material 240 is mounted above: (1) the first and second lengths of material 210, 220; and (2) the first extension portion 202 of the reinforcing member 200. In particular embodiments, such as the embodiment shown in FIG. 2B, a first side edge of the fourth length of material 230 is substantially coplanar with (e.g., coplanar with) the outer side of the first length of material 210. Similarly, the second side edge of the fourth length of material 240 is substantially coplanar with the outer side surface of the second length of material 220. As a result, the first, second, and fourth lengths of material 210, 220, 240, and the reinforcing member cooperate to form a structure having a substantially rectangular cross section, as shown in FIG. 2B. The first, second, third and fourth lengths of material 210, 220, 230, 240, and the reinforcing member 200 also cooperate to form a structure having a substantially rectangular cross section.

In various embodiments, the first, second, third and fourth lengths of material 210, 220, 230, 240, and the reinforcing member 200 are attached together in the arrangement shown in FIG. 2B. For example, in particular embodiments, these various components are glued together with a suitable adhesive, such as PVC glue. In other embodiments, these components may be attached together using one or more suitable fasteners, such as suitable fastening hardware. In such an arrangement, the first, second, third and fourth lengths of material 210, 220, 230, 240 can be understood to form a casing around the reinforcing member 200.

FIGS. 5A-5C show a slightly modified version of the floor joists 10 described above. In this embodiment, the joist 35 (which is particularly suitable for use as a ceiling joist) comprises: (1) a body portion 311; and (2) two tenons 325, each of which extends from a respective end of the ceiling joist 35. In particular embodiments, the ceiling joist's body portion 311 has a substantially uniform cross section (e.g., an entirely uniform cross section) along the entire length of the ceiling joist's body portion 311. Aside from various dimensional differences, the full cross section of the ceiling joist 35 is generally the same as the full cross section of the floor joist 10 described above (See FIGS. 1A-1C and FIGS. 5A-5C). For example, like the floor joist 10 of FIGS. 1A-1C, the ceiling joist 35 of FIGS. 5A-5C comprises a reinforcing member 300, and first, second, third, and fourth lengths of material 310, 320, 330, 340 that are dimensioned, assembled and attached together generally as described above in regard to the floor joists 10 of FIGS. 1A-1C.

Alternative Board Structures

It should be understood that the structure of the various reinforced board structures described above may vary in other embodiments of the invention. For example, the relative sizes of the various components of the board may be different than those described above. For example, the joist 35 of FIG. 5C (which is discussed above) is a relatively shorter and wider version of the joist 10 shown in FIG. 1C.

It should also be understood that the shape, position, and relative size of the reinforcing member may vary among different embodiments of the invention. For example, the reinforcing member may be substantially in the form of an I, an L, or an O.

Similarly, although various embodiments of the reinforced boards are described above as having plastic first, second, third, and fourth lengths of material, it should be understood that, in other embodiments, these components may be made of any other suitable material, such as wood or fiberglass. Also, although the first, second, third, and fourth lengths of material are described above as being in the form of at least substantially rectangular prisms, these components can be of any other suitable shape.

In addition, it should be understood, in light of this disclosure, that the board structures described herein may be used in the context of a variety of different building materials, such as posts, beams, and other types of joists.

Exemplary Deck Frame including Exemplary Reinforced Boards

FIGS. 4A and 4B show an exemplary deck frame 7 that includes the exemplary floor and band joists 10, 15, 15¹ described above. As may be understood from this figure, the deck frame 7 includes a deck band and a plurality of (e.g., two) floor joists 10. The deck band includes a plurality of side band joists 15, and two end band joists 15¹. The side band joists 15 are structured as described above, and each defines a plurality of substantially vertically oriented mortises 40 on its interior surface. These mortises 40 are spaced evenly (e.g., every 300 mm on center) along the length of the side band joists 15.

As noted above, each floor joist 10 comprises two tenons 125, each of which extends from a respective end of the joist 10. These tenons 125 are substantially in the form of a rectangular prism, and the body portion 101 of the joist's reinforcing member 100 (which, in various embodiments, is made of steel) folds over (or otherwise extends adjacent) and is attached to the end of the tenons 125.

To assemble the deck frame 7, an individual first attaches a first side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 15¹ to one of the deck frame's side band joists 15 (or to one co-linear set of side band joists 15 if multiple side band joists are used to define one side of the deck band). As noted above, in the embodiment shown in FIG. 3, the outer ends of the various band joists are cut to form 45 degree angles. To attach the deck frame's end band joists 15¹ to one of the deck frame's side band joists 15, a user simply: (1) aligns respective end surfaces of the band joists 15, 15¹ (e.g., so that the respective perimeters of the end surfaces align with each other); and (2) attaches the aligned ends of the band joists 15, 15¹ together using suitable hardware and/or adhesives.

To attach one of the deck frame's floor joists 10 to one of the deck frame's side band joists 15, the user inserts the floor band joist's tenon 125 into a respective mortise 40 within the side band joist 15, and affixes the tenon 125 in place within the mortise 40 (e.g., by using suitable hardware and/or adhesives).

For example, to attach a first side of one of the deck frame's floor joists 10 to one of the deck frame's side band joists 15, the user first coats the floor joist's tenon 125 with PVC glue and inserts the tenon 125 into a mortise 40 defined by the first side band joist 15 as shown in FIG. 6. The user then drives a self-tapping screw 452 (or other suitable fastener) through: (1) the outer surface of the first side band; (2) the base portion 201 of the first side band joist's reinforcing member 200; and (3) the end portion 150 of the floor joist's reinforcing member (which, as shown in FIG. 1B, covers at least a portion of the end of the floor joist's first length of material 110). The user then continues to drive the self-tapping screw 452 into the interior of the floor joist's first length of material 110). Once this process is complete, the floor joist 10, side band joist 15, and screws 452 are situated as shown in FIG. 6. The user may then repeat this process with another fastener (e.g., another self-tapping screw 452) to further secure the floor joist 10 to the side band joist 15.

After the individual attaches a first side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 15¹ to one or more of the deck frame's side band joists 15 as described above, the individual attaches, in the manner described above, a second side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 15¹ to another one of the deck frame's side band joists 15 (or to one co-linear set of side band joists 15 if multiple side band joists are used to define one side of the deck band). This step typically completes the deck frame assembly process.

In light of the discussion above, it should be understood that, in various embodiments, when the deck frame 7 is entirely assembled, the reinforcing members 100, 200 of the various joists 10, 15, 15¹ are at least substantially encased (e.g., entirely encased) in other components of the joists 10, 15, 15¹ (e.g., in the joists' respective first, second, third, and fourth lengths of material which may, for example, be polystyrene). This may, in particular embodiments, serve to at least substantially insulate the reinforcing members 100, 200 from the atmosphere. This may reduce the possibility that the reinforcing members 100, 200 will rust or otherwise degrade over time.

Exemplary Floor and Ceiling Frames

It should be understood that the type of deck frame described above may be used as the floor or ceiling frame of a building structure, such as the floor frame 710 or ceiling frame 720 of the pavilions shown in FIGS. 11 and 13A-13C. Turning to the embodiments of FIGS. 11 and 13A-13C, in particular embodiments, each of the pavilions' floor band joists (which, in various embodiments, may be the type of band joist described herein) includes a tenon adjacent each of its respective ends (e.g., in a configuration similar to that of the joist shown in FIGS. 1A-1C). These tenons are adapted to at least substantially mate with corresponding mortises 407, 409, 507, 509 in the pavilion's posts 405, 505 (which are described above). The tenons are then secured in position within the posts' respective mortises 407, 409, 507, 509 with suitable hardware or other fasteners (e.g., screws and/or a suitable adhesive).

FIGS. 10 and 11 show a ceiling frame 720 that includes ceiling joists 35 and band joists 45 such as those described above. In this embodiment, the ceiling joists 35 are mounted to a rectangular base frame 50 that includes four elongated sides 52, 54, 56, 58 that generally correspond in length to the respective sides of the ceiling frame. In various embodiments, the base frame 50 defines a cutout adjacent each of its corners, so that each of its corners defines a corner attachment portion 64 that is adapted to mate with a corresponding L-shaped groove in a top surface of the pavilion's corner posts 405 (See FIG. 7B). In particular embodiments, this L-shaped groove is formed by the grooves 415, 417 discussed above.

Similarly, in various embodiments, the base frame 50 defines one or more cutouts in non-corner portions of the base frame 50, so that each of the cutouts defines a mid-frame attachment portion 60 that is adapted to mate with a corresponding groove 515 in a top surface of the pavilion's middle post assembly posts 505 (See FIG. 8B).

Also, in particular embodiments, the base frame 50 defines a plurality of mortises (not shown) adjacent its bottom surface that are each adapted to at least substantially matingly receive a corresponding tenon 522 of a roof support 520.

Exemplary Roof Assembly

In particular embodiments, the building structure kit comprises a roof assembly that includes one or more roof support assemblies 600 and one or more roof panels 800. These components are described in greater detail below.

Roof Support Assemblies

An exemplary roof support assembly 600 is shown in FIG. 9A. As may be understood from this figure, in this example, the roof support assembly 600 is a roof truss that defines a plurality of recesses 602 adjacent its upper surface. These recesses 602 are dimensioned to receive (and, in various embodiments, substantially mate with) corresponding tabs that extend from the lower surface of the kit's roof panels 800.

In the embodiment shown in FIG. 9A, the roof support assembly 600 comprises four truss subsections 610, 620, 630, 640 that are adapted to be selectively attached together to form the roof support assembly 600. These truss subsections include two end truss subsections 610, 640 that may be substantially triangular and that each include: (1) a substantially horizontal base member 611, 641; (2) a substantially vertical support 617, 647 that extends upwardly from a first end of the base member 611, 641; (3) an angled roof panel support member 615, 645 that extends at least between the upper end of the substantially vertical support 617, 647 and the distal end of the base member 611, 641; and (4) a plurality of internal supports 613, 614, 643, 644 that are adapted to extend between the base member 611, 641, the substantially vertical support 617, 647 and/or the roof panel support 615, 645 to provide additional structural support to the truss subsection 610, 640.

The truss subsections further include two interior truss subsections 620, 630 that each include: (1) a substantially horizontal base member 621, 631; (2) a first substantially vertical support 627, 637 that extends upwardly from a first end of the base member 621, 631; (3) a second substantially vertical support 629, 639 that extends upwardly from a first end of the base member 621, 631; (3) an angled roof panel support member 625, 635 that extends between the upper end of the first substantially vertical support 627, 637 and the upper end of the second substantially vertical support 629, 639; and (4) a plurality of internal supports 623, 624, 633, 634 that are adapted to extend between the base member 621, 631, the first and second vertical supports 627, 629, 637, 639 and/or the roof panel support 625, 635 to provide additional structural support to the truss subsection 620, 630.

In the embodiment shown in FIG. 9A, each lateral side of the roof truss 600 (which may be substantially planar) is comprised of an end truss subsection 610, 640 and an interior truss subsection 620, 630, and the truss' respective roof panel support members 615, 625, 635, 645 cooperate to form a continuous angled support surface for a roof panel 800. As may be understood from FIGS. 9A and 9B, this angled support surface may define a plurality of recesses 602 that are dimensioned to receive (and, in various embodiments, substantially mate with) corresponding tabs 810 that extend from the lower surface of the kit's roof panels 800. This allows the roof panels 800 to be mounted adjacent, and attached to, a plurality of the trusses in the manner generally discussed in U.S. patent application Ser. No. 12/698,126, which, as noted above, is incorporated herein by reference in its entirety. In particular embodiments, the recesses 602 are defined between an array of blocks 601 that comprise part of the roof panel support member 615, 625, 635, 645.

Exemplary Roof Panel

A roof panel 800 according to various embodiments of the invention is shown in FIGS. 12A and 12B, and has the same general structure as the roof assembly described in U.S. patent application Ser. No. 12/698,126, which was referenced above. As may be understood from FIGS. 12A and 12B, in particular embodiments, the roof panel 800 is substantially planar and defines a top surface and a bottom surface. In various embodiments, the roof panel 800 defines a layer of shingles 805 that are preinstalled on (e.g., are attached to) the top surface of the roof panel 800.

As shown in FIGS. 12A and 12B, in particular embodiments, the roof panel 800 includes a plurality of tabs 810 that extend downwardly from, and substantially perpendicular to, the bottom surface of the roof panel 800. As may be understood from FIG. 12B, these tabs 810 are elongated, substantially planar tabs that form a substantially parallel array adjacent the roof panel's bottom surface. In particular embodiments, each substantially planar tab 810 is adapted to be substantially matingly positioned into at least one recess 602 defined by a first one of the roof assembly's roof support assemblies 600 (e.g., roof trusses), and also, simultaneously into at least one recess defined by a second one of the roof assembly's roof support assemblies (e.g., roof trusses).

In particular embodiments, such as the embodiment shown in FIGS. 14A-19 a particular roof panel 900, 1000 may include one or more shingles 910, 1010 that are adapted to extend across the upper surface of multiple roof panels when the multiple roof panels 900, 1000 are installed in place adjacent to each other. In various embodiments, these shingles 910, 1010 are adapted to be nested between two or more shingles on the adjacent roof panel 900, 1000 to create a unified, continuous arrangement of shingles (e.g., as shown in FIGS. 15-19).

The roof panels 900, 1000 shown in FIGS. 14A-19 will now be described in somewhat greater detail. As may be understood from FIG. 14A, the first roof panel 900 shown in this figure comprises a substantially rectangular support structure and a plurality of horizontal courses of shingles 902-908 (in this case, four horizontal courses of shingles) that define a substantially rectangular top surface of the first roof panel 900. These courses of shingles are preinstalled on the roof panel 900 so that the courses at least partially overlap each other as shown in FIG. 14A. In the embodiment of FIG. 14A, the roof panel's various shingles are flexible shingles (although, in other embodiments, the shingles may be of a less flexible or inflexible variety). In particular embodiments, such as the embodiment shown in FIG. 14A, the various shingles within a course of shingles are substantially evenly spaced apart. However, in other embodiments, the shingles within a particular course of shingles may be irregularly spaced apart.

The rightmost end shingle 910 in the first roof panel's second course of shingles 902 extends over a first side edge 935 of the first roof panel 900 so that the central axis of this shingle 910 is substantially perpendicular to this first side edge 935. In the embodiment shown in FIG. 14A, about half of the length of the shingle 910 extends over the roof panel's first side edge 935. In other embodiments, the shingle 910 may extend over the roof panel's side edge 935 by more or less than half of a shingle length (e.g., by at least about 30%, at least about 40%, at least about 50%, or at least about 60% of the shingle's length). In a particular embodiment, the end shingle 915 in the first roof panel's third course of shingles 906 is adapted so that its distal end may be flexed upwardly away from the roof panel's upper surface. As described in greater detail below, this allows a protruding shingle 1010 from an adjacent roof panel 1000 to be placed into a nested arrangement between the end shingle 915 in the first roof panel's third course of shingles 906 and the end shingle 921 of the first roof panel's fourth course of shingles 908 as shown in FIG. 19.

As may be understood from FIG. 14A, the second roof panel 1000 shown in this figure also comprises a substantially rectangular support structure and a plurality of horizontal courses of shingles 1002-1008 (in this case, four horizontal courses of shingles) that define a substantially rectangular top surface of the second roof panel 1000. These courses of shingles are preinstalled on the roof panel 1000 so that the courses at least partially overlap each other as shown in FIG. 14A. In the embodiment of FIG. 14A, the roof panel's various shingles are flexible shingles (although, in other embodiments, the shingles may be of a less flexible or inflexible variety).

The left end shingle 1010 in the second roof panel's fourth course of shingles 1008 extends over a first side edge 1035 of the second roof panel 1000 so that the central axis of this shingle 1010 is substantially perpendicular to this first side edge 1035. In the embodiment shown in FIG. 14A, about half of the length of the shingle 1010 extends over the second roof panel's first side edge 1035. In other embodiments, the shingle 1010 may extend over the roof panel's first side edge 1035 by more or less than half of a shingle length. In a particular embodiment, the end shingle 915 of the first roof panel's first course of shingles 1002 is adapted so that its distal end may be flexed upwardly away from the roof panel's upper surface. As described in greater detail below, this allows a protruding shingle 910 from an adjacent roof panel 900 to be placed into a nested arrangement between the end shingle 1015 in the first roof panel's first course of shingles 902 and the end shingle 1021 of the first roof panel's second course of shingles 902 as shown in FIG. 19.

As may be understood from FIGS. 14A-19, and as described in greater detail below, the complimentary shingle arrangements of the first and second panels 900, 1000 allow these panels to be assembled immediately adjacent each other so that a plurality of the panels' respective shingles interlock, and produce a single, continuous assembly of shingles that extends over the panels' respective side edges. For example, when the first and second panels 900, 1000 are properly installed adjacent each other, at least one particular course of the first roof panel's shingles aligns with a corresponding course of the second roof panel's shingles to form an at least substantially continuous (e.g., continuous) course of shingles that extends across abutting portions of said first and second roof panels 900, 1000. In particular embodiments, this is the case for all (or at least most) of the roof panels' respective corresponding courses of shingles.

Hardware

In particular embodiments, the kit includes appropriate hardware for assembling the kit into a building structure. As will be understood by one skilled in the relevant field in light of this disclosure, such hardware may include, for example, screws, bolts, washers, nuts, nails, and the like.

Assembly of Exemplary Building Assembly Kit

To assemble the building assembly kit shown (partially assembled, with roof panels omitted) in FIG. 11, a user first assembles the floor deck frame 710 as described generally above, while using the building assembly's post assemblies 400, 500 to connect the kit's floor band trusses 15, 15¹ as shown generally in FIG. 11. In particular embodiments, the floor band trusses 15, 15¹ include tenons that fit into, and mate within, corresponding mortises within the posts 400, 500.) Suitable hardware is used to attach the floor frame's various components together as described, for example, elsewhere herein.

Once the floor frame 710 is assembled and the kit's posts are in the vertical orientation, the user assembles the kit's ceiling frame 720 as generally described above. The user then attaches the ceiling frame 720 to the top of the kit's posts 405, 505 by: (1) fitting the ceiling frame's corner attachment portions 64 into the L-shaped grooves defined within the tops of the building structure's corner posts 405; (2) fitting the ceiling frame's mid-frame attachment portions 60 into the grooves 510 defined within the tops of the posts 505 of the building structure's middle post assemblies 500; and (3) attaching the kit's roof supports 520 so that they extend between a respective post 400, 500 and an adjacent bottom surface of the ceiling frame 720 as shown in FIG. 11. As noted above, in particular embodiments, each ceiling support member 520 is installed so that: (1) a tenon 524 adjacent its first end extends into a mortise defined within an upper end of one of the posts 405, 505; and (2) a tenon 522 adjacent its second end extends into a mortise defined by the bottom surface of the ceiling frame 720. During the assembly process, suitable hardware is used to attach the ceiling frame's various components in place.

Once the floor frame 710, posts 405, 505, and ceiling frame 710 are in place, the kit's roof trusses 600 are assembled, and then positioned and installed in an array on top of, and along the length of, the ceiling frame 720. In particular embodiments, the trusses 600 are spaced evenly apart along the length of the building structure and are each positioned at least substantially parallel to the end band joists 15¹ of the structure's floor frame 710.

After the building structure's trusses 600 are installed, each of the kit's roof panels 800 is installed on the trusses 600 as generally described in U.S. patent application Ser. No. 12/698,126, which, as mentioned above, is incorporated herein by reference. For example, one of the kit's roof panels 800 may be lowered onto the respective roof panel support members 615, 625, 635, 645 of at least two of the trusses 600 (e.g., at least two adjacent trusses). During this process, each of the roof panel's tabs 810 is positioned so that a respective portion of it is disposed within: (1) a recess 602 defined by the first of the trusses 600; and (2) a recess 602 defined by a second of the trusses 600. (These recesses may be, for example, at least substantially co-linear.) In various embodiments, the tabs 810 are dimensioned to matingly engage the respective first and second trusses 600 when the tabs 810 are disposed within these recesses 602.

After the roof panel's tabs are disposed in place within the trusses' recesses, the roof panel 800 may be repositioned laterally, as needed. The user may then use appropriate hardware to secure the roof panel 300 in place on the trusses. (FIGS. 13A-13C show a pavilion with roof panels 800 installed on trusses 600A in this manner). Finally, the user may install a deck surface on the Pavilion's floor deck frame 710, 810.

To assemble roof panels, such as those shown in FIGS. 14A-19, in which the roof panels' shingles overlap, a user installs the first roof panel 900 adjacent a suitable truss (or other suitable roof support structure) as described above. The user then position the second roof panel 1000 next to the first roof panel 900 and then moves the second roof panel laterally toward the first roof panel 900. FIGS. 14A-19 are a sequence of figures that depict this lateral movement.

As the respective first edges 935, 1035 of the first and second panels 900, 1000 approach each other, a user: (1) flexes the distal end of the end shingle 915 in the first roof panel's third course of shingles 906 from the roof panel's upper surface; (2) positions the second roof panel's protruding shingle 1010 in a nested arrangement between (a) the end shingle 915 in the first roof panel's third course of shingles 906 and (b) the end shingle 921 of the first roof panel's fourth course of shingles 908; (3) flexes the distal end of the end shingle 1015 in the second roof panel's first course of shingles 1002 from the roof panel's upper surface; and (4) positions the first roof panel's protruding shingle 910 in a nested arrangement between (a) the end shingle 1015 in the second roof panel's first course of shingles 1002 and (b) the end shingle 1021 of the second roof panel's second course of shingles 1004. The user then continues to laterally move the second roof panel 1000 toward the first roof panel 900 until: (1) the first, second, third, and fourth courses 902, 904, 906, 908 of the first roof panel 900 align respectively with the first, second, third, and fourth courses 1002, 1004, 1006, 1008 of the second roof panel 1000; and (2) the courses of shingles on the first and second roof panels 900, 1000 cooperate to form a plurality of substantially horizontal courses of shingles in which the shingles within each of these courses of shingles are substantially uniformly spaced apart as shown in FIG. 19. In other embodiments, the shingles within the various courses of shingles may not be uniformly spaced apart.

It should be understood that, although the interlocking shingle concept described above is described herein in regard to two adjacent roof panels, it should be understood that the concept may also be used in a larger continuous series of roof panels (e.g., a continuous series of 3, 4, or 5 roof panels). In such embodiments, a particular roof panel may, for example have one or more protruding shingles on each of its lateral sides.

Packaging of Pavilion Kit

In particular embodiments, the pavilion kit may be adapted to fit into one or more boxes (such as a standard rectangular box) for easy shipping. To aid in packaging the kit, some or all of the kit's components and/or the kit's roof panel 800 may be substantially planar. This allows the components to fit (for example, in a substantially stacked arrangement) within a cardboard box that is substantially in the form of a rectangular cuboid.

Alternative Embodiments

It should be understood that while the roof structure kit's various components are shown as having particular shapes and relative dimensions in the enclosed figures, the kit's components may be in the form of a variety of different, suitable structures. Similarly, while the kits described above as being adapted to form a pavilion, the kits may be adapted to form other types of building structures. Also, it should be understood that, while the kit's various components are described above as comprising various particular types of materials, in other embodiments, other suitable materials may be used to form the components.

Conclusion

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, as will be understood by one skilled in the relevant field in light of this disclosure, the invention may take form in a variety of different mechanical and operational configurations. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation.

Claims

1. A building structure kit for use in building a particular building structure, said building structure kit comprising:

(A) a first roof panel comprising a first base portion and a first plurality of shingles that have been pre-installed adjacent an upper surface of said first roof panel;

(B) a second roof panel comprising a second base portion and a second plurality of shingles that have been pre-installed adjacent an upper surface of said second roof panel, wherein: said first roof panel comprises a first protruding shingle that extends over a side edge of said first base portion; said second plurality of shingles are adapted to receive a particular portion of said first protruding shingle between: (1) a first shingle of said second plurality of shingles; and (2) a second shingle of said second plurality of shingles.

2. The building structure of claim 1, wherein:

said first and second pluralities of shingles are flexible shingles; and

said first shingle of said second plurality of shingles is adapted to allow a user to bend said first shingle of said second plurality of shingles away from said upper surface of said second roof panel to facilitate positioning said particular portion of said first protruding shingle between: (1) said first shingle of said second plurality of shingles; and (2) said second shingle of said second plurality of shingles.

3. The building structure of claim 1, wherein said first and second roof panels are adapted so that, when said portion of said first protruding shingle is disposed between said first and second shingles of said second plurality of shingles, said first protruding shingle and said first and second shingles of said second plurality of shingles cooperate to form a nested array of shingles.

4. The building structure of claim 3, wherein said first and second roof panels are adapted so that, when said first and second roof panels are properly installed adjacent each other, at least 40% of a width of said first protruding shingle is disposed adjacent said upper surface of said second roof panel.

5. The building structure of claim 3, wherein said first and second roof panels are adapted so that, when said first and second roof panels are properly installed adjacent each other, a particular course of said first plurality of shingles aligns with a particular course of said second plurality of shingles to form an at least substantially continuous course of shingles that extends across abutting portions of said first and second roof panels.

6. The building structure of claim 5, wherein said at least substantially continuous course of shingles is a continuous course of substantially evenly spaced shingles.

7. The building structure of claim 1, wherein said second roof panel comprises a second protruding shingle that extends over a side edge of said second base portion;

said first plurality of shingles are adapted to receive a particular portion of said second protruding shingle between: (1) a first of said first plurality of shingles; and (2) a second of said first plurality of shingles.

8. The building structure of claim 1, wherein:

said first and second pluralities of shingles are flexible shingles; and

said first shingle of said second plurality of shingles is adapted to allow a user to bend said first shingle of said second plurality of shingles away from said upper surface of said second roof panel to facilitate positioning said particular portion of said first protruding shingle between: (1) said first shingle of said second plurality of shingles; and (2) said second shingle of said second plurality of shingles.

said first shingle of said first plurality of shingles is adapted to allow a user to bend said first shingle of said first plurality of shingles away from said upper surface of said first roof panel to facilitate positioning said particular portion of said second protruding shingle between: (1) said first shingle of said first plurality of shingles; and (2) said second shingle of said first plurality of shingles.

9. The building structure of claim 7, wherein said first and second roof panels are adapted so that:

when said portion of said first protruding shingle is disposed between said first and second shingles of said second plurality of shingles, said first protruding shingle and said first and second shingles of said second plurality of shingles cooperate to form a first nested array of shingles, and

when said portion of said second protruding shingle is disposed between said first and second shingles of said first plurality of shingles, said second protruding shingle and said first and second shingles of said first plurality of shingles cooperate to form a second nested array of shingles.

10. The building structure of claim 9, wherein said first and second roof panels are adapted so that:

when said first and second roof panels are properly installed adjacent each other, at least 40% of a width of said first protruding shingle is disposed adjacent said upper surface of said second roof panel; and

said first and second roof panels are adapted so that, when said first and second roof panels are properly installed adjacent each other, at least 40% of a width of said second protruding shingle is disposed adjacent said upper surface of said first roof panel.

11. The building structure of claim 9, wherein said first and second roof panels are adapted so that, when said first and second roof panels are properly installed adjacent each other:

a particular course of said first plurality of shingles aligns with a particular course of said second plurality of shingles to form an at least substantially continuous course of shingles that extends across abutting portions of said first and second roof panels.

12. The building structure of claim 11, wherein said at least substantially continuous course of shingles is a continuous course of substantially evenly spaced shingles.

13. A building structure kit for use in building a particular building structure, said building structure kit comprising:

(A) a base portion assembly kit for building a base portion of said building structure, said base portion assembly kit comprising: a plurality of posts, each of said posts defining at least one lower recess; a plurality of band members; a plurality of joists, each of said joists having a first tenon adjacent a first end of said joist, and a second tenon adjacent a second end of said joist; and

(B) a roof assembly, wherein: said plurality of posts, plurality of band members, and plurality of joist members are collectively adapted to be assembled to create a base portion of said building structure; said roof assembly is adapted to be assembled to form a roof of said building structure; a particular one of said plurality of joist members comprises: a first elongated casing that is substantially in the form of a rectangular prism; a tenon that is disposed adjacent an end portion of said first elongated casing; and a first metal reinforcing member that: (1) extends longitudinally within an interior of said first elongated casing; and (2) extends longitudinally within an interior of said tenon, a particular portion of said first metal reinforcing member extends out of said interior of said tenon adjacent a particular end surface of said tenon; and a particular one of said band members comprises: a second elongated casing that is substantially in the form of a rectangular prism; and a second metal reinforcing member that extends longitudinally within an interior of said second elongated casing, said second elongated casing defines at least one mortise; said tenon of said particular joist is adapted and dimensioned so that when said tenon is inserted into said particular band member's mortise, said particular joist's tenon matingly engages said particular band member about a perimeter of said mortise; and said particular joist and said particular band member are adapted and dimensioned so that a particular portion of said first metal reinforcing member engages a particular portion of said second metal reinforcing member when said tenon is inserted into said particular band member's mortise.

14. The building structure kit of claim 13, wherein said joist assembly kit further comprises at least one fastener that is adapted to fasten said first and second joists together by extending through both:

a) said particular portion of said first metal reinforcing member; and

b) said particular portion of said second metal reinforcing member.

15. The building structure kit of claim 14, wherein said first metal reinforcing member has a substantially Z-shaped cross-section.

16. The building structure kit of claim 15, wherein said second metal reinforcing member has a substantially U-shaped cross-section.

17. The building structure kit of claim 16, wherein:

said first elongated casing comprises a plurality of elongated structures that are disposed circumferentially about said first metal reinforcing member; and

said second elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said second metal reinforcing member.

18. The building structure kit of claim 17, wherein:

said first and second joists are configured so that, when said tenon is inserted into said second joist's mortise said first and second plastic casings at least substantially insulate both said particular metal surface of said second joist and said particular portion of said first metal reinforcing member from the atmosphere.

19. A building structure kit for use in building a particular building structure, said building structure kit comprising:

(A) a base portion assembly kit for building a base portion of said building structure, said base portion assembly kit comprising: a plurality of elongated posts having a first end and a second end, each of said posts defining a groove adjacent said first end; a plurality of band members; a plurality of joists, each of said joists having a first tenon adjacent a first end of said joist, and a second tenon adjacent a second end of said joist; and

(B) a roof assembly, wherein: said plurality of posts, plurality of band members, and plurality of joist members are collectively adapted to be assembled to create a base portion of said building structure; said plurality of band members and said plurality of joist members are collectively adapted to be assembled to create a ceiling frame of said building structure; said roof assembly is adapted to be assembled to form a roof of said building structure; a particular one of said plurality of joist members comprises: a first elongated casing that is substantially in the form of a rectangular prism; a tenon that is disposed adjacent an end portion of said first elongated casing; and a first metal reinforcing member that: (1) extends longitudinally within an interior of said first elongated casing; and (2) extends longitudinally within an interior of said tenon, a particular portion of said first metal reinforcing member extends out of said interior of said tenon adjacent a particular end surface of said tenon; and a particular one of said band members comprises: a second elongated casing that is substantially in the form of a rectangular prism; and a second metal reinforcing member that extends longitudinally within an interior of said second elongated casing, said second elongated casing defines at least one mortise; said tenon of said particular joist is adapted and dimensioned so that when said tenon is inserted into said particular band member's mortise, said particular joist's tenon matingly engages said particular band member about a perimeter of said mortise; said particular joist and said particular band member are adapted and dimensioned so that a particular portion of said first metal reinforcing member engages a particular portion of said second metal reinforcing member when said tenon is inserted into said particular band member's mortise; said particular tenon of said particular joist and said particular band member are adapted to be attached together to form at least part of said ceiling frame; and said ceiling frame is adapted to be supported adjacent respective top surfaces of said plurality of posts, and held in place, at least in part, by respective portions of said ceiling frame extending into respective grooves that are defined within respective end surfaces of said posts.

20. The building structure kit of claim 19, wherein said joist assembly kit further comprises at least one fastener that is adapted to fasten said first and second joists together by extending through both:

a) said particular portion of said first metal reinforcing member; and

b) said particular portion of said second metal reinforcing member.

21. The building structure kit of claim 20, wherein said first metal reinforcing member has a substantially Z-shaped cross-section.

22. The building structure kit of claim 21, wherein said second metal reinforcing member has a substantially U-shaped cross-section.

23. The building structure kit of claim 22, wherein:

said first elongated casing comprises a plurality of elongated structures that are disposed circumferentially about said first metal reinforcing member; and

said second elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said second metal reinforcing member.

24. The building structure kit of claim 23, wherein:

said first and second joists are configured so that, when said tenon is inserted into said second joist's mortise said first and second plastic casings at least substantially insulate both said particular metal surface of said second joist and said particular portion of said first metal reinforcing member from the atmosphere.

25. A building structure kit for use in building a particular building structure, said building structure kit comprising:

(A) a base portion assembly kit comprising a plurality of base portion components, said base portion components being adapted to be assembled to create a base portion of said building structure;

(B) a truss assembly kit comprising:

a first truss portion,

a second truss portion, said first and second truss portions being adapted to be attached together to form at least a portion of a first truss,

a third truss portion, and

a fourth truss portion, said third and fourth truss portions being adapted to be attached together to form at least a portion of a second truss;

(C) a pre-assembled roof assembly comprising: (1) a roof base structure; (2) a plurality of shingles that have been preinstalled on said roof base structure; and (3) a plurality of elongated tabs that extend downwardly from a bottom surface of said roof base structure, wherein: said first and second truss portions are adapted so that, when they are attached together to form said portion of said first truss, said first and second truss portions cooperate to form a first roof support structure that defines a first plurality of recesses; said third and fourth truss portions are adapted so that, when they are attached together to form said portion of said second truss, said third and fourth truss portions cooperate to form a second roof support structure that defines a second plurality of recesses; said truss assembly kit and said pre-assembled roof assembly are adapted to be installed adjacent said base portion of said building structure to create at least a portion of a roof for said building structure by: (a) installing said first truss adjacent said base portion of said building structure; (b) installing said second truss adjacent said base portion of said building structure; and (c) moving said roof assembly into a particular position adjacent respective top surfaces of said first and second trusses, wherein when said roof assembly is in said particular position, each of said elongated tabs extends downwardly into at least a respective one of said first or second plurality of recesses.

26. The building structure kit of claim 25, wherein:

said base portion assembly kit comprises one or more support columns; and

said building structure is a pavilion.

27. The building structure kit of claim 26, wherein said base portion assembly kit comprises a plurality of joists that are adapted to form at least a portion of a framing assembly for said building structure, wherein each of said joists has an exterior surface and an interior portion, and each of said joists comprises:

(A) an elongated structural support that extends longitudinally within said interior portion of said joist; and

(B) a plurality of lengths of material that each have a substantially rectangular cross section and that each extend longitudinally along a particular length of said joist; and wherein: said plurality of lengths of material are at least substantially matingly attached together in at least a substantially circumferential manner about said elongated structural support to form said joist.