Method and system for a modular building structure

Abstract

A method and system for construction of building structures from a variety of standard size panels having integral dovetail tenons on all four edges and a variety of connectors with corresponding mortises for interlocking the panels. The panels may be horizontally disposed to form floors, ceilings or roofs or may be vertically disposed to form walls. The panels are produced from blow-molded plastic. Panels are interlocked in columns and rows of a planar array to form walls, floors, roofs, etc. Panels can also be interlocked edge to edge in a non-planar orthogonal manner, allowing the panels to be interconnected in virtually unlimited ways. Plastic frame members with trussing interconnect to the panels to provide rigidity and strength to the assembled building structure. The panels may be formed of opaque material for ordinary sheds or of transparent or translucent material for greenhouses.

1 . A method of constructing a building structure comprising the steps of:
 forming a polymer into a plurality of generally planar panels each characterized by four edges, each of said four edges having an integral tenon of a dovetail shape;   forming a polymer into a plurality of connector members each characterized by an extrusion profile defining four orthogonally disposed mortises, each of said four orthogonally disposed mortises dimensioned to slidingly receive a tenon of said dovetail-shape in interlocking engagement therein;   assembling a two-dimensional planar array of said plurality of panels into a first building surface by connecting the adjacent edges of each of two adjacent panels in said array together by one of said plurality of connector members, said tenons of said adjacent edges being slidingly received and interlocked in two oppositely disposed mortises of said one of said plurality of connector members; and   connecting said first building surface with a plurality of other building surfaces to form said building structure.   
   
   
       2 . The method of  claim 1  further comprising the steps of:
 forming said plurality of panels from a clear polymer; and   assembling said plurality of panels of said clear polymer into said building structure.   
   
   
       3 . The method of  claim 1  further comprising the step of:
 forming said plurality of panels by a blow-molding process.   
   
   
       4 . The method of  claim 1  further comprising the steps of:
 forming a polymer into a plurality of generally planar rectangular wall panels each characterized by edge dimensions of x by y, each of the four edges of each of said rectangular wall panels having an integral tenon of said dovetail shape;   forming a polymer into a plurality of generally planar rectangular short panels each characterized by edge dimensions of x by z, where z equals the quotient of x/tangent θ, where θ defines the pitch angle of a roof of said building structure to a horizontal reference, each of said four edges of each of said short panels having an integral tenon of said dovetail shape;   forming a polymer into a plurality of generally planar trapezoidal panels each characterized by a base dimension of x and first and second parallel edge dimensions of z and 2z, respectively, each of the four edges of each of said trapezoidal panels having an integral tenon of said dovetail shape;   assembling a first number of said plurality of wall panels, a second number of said plurality of short panels, and a third number of said connector members into first and second opposite side walls of said building structure; and   assembling a fourth number of said plurality of wall panels, a fifth number of said plurality of short panels, a sixth number of said plurality of trapezoidal panels, and a seventh number of said connector members into front and back walls of said building structure connected to said first and second opposite side walls.   
   
   
       5 . The method of  claim 4  further comprising the steps of:
 forming a polymer into a plurality of generally planar rectangular roof panels each characterized by edge dimensions of x by w, where w equals the quotient of x/cosine θ, each of the four edges of each of said wall panels having an integral tenon of said dovetail shape;   forming a polymer into a plurality of roof connector members each characterized by an extrusion profile defining first, second and third mortises with 180−2θ degrees between said first and second mortises and 90+θ degrees between said second and third mortises, said first, second and third mortises of said roof connector each dimensioned to receive a tenon of said dovetail shape; and   assembling an eighth number of said plurality of roof panels, a ninth number of said connector members and a tenth number of said roof connector members into a roof connected to said first and second side walls and said front and back walls.   
   
   
       6 . The method of  claim 4  further comprising the steps of:
 forming a polymer into a plurality of generally planar floor panels each characterized by edge dimensions of x by x, each of the four edges of each of said floor panels having an integral tenon of said dovetail shape; and   assembling an eighth number of said plurality of floor panels and a ninth number of said connector members into a floor connected to said first and second side walls and said front and back walls.   
   
   
       7 . The method of  claim 1  further comprising the steps of:
 forming a polymer into a plurality of frame members each characterized by having first and second tenons disposed along first and second transverse edges, a third tenon of said dovetail shape disposed along a first longitudinal edge, and interior trussing that defines a number of triangular regions;   forming a polymer into a plurality of frame couplings each characterized by having four orthogonally disposed mortises each dimensioned to slidingly receive in interlocking engagement said first and second tenons of one of said plurality of frame members;   assembling said plurality of said frame members and said plurality of said frame couplings into a frame structure;   connecting said frame structure to said building structure by slidingly interlocking said third tenon of one of said plurality of frame members into one of said four orthogonally-disposed mortises of said one of said plurality of connector members; and   supporting said building structure by said frame structure.   
   
   
       8 . The method of  claim 7  further comprising the steps of:
 forming a polymer into a bracket arranged and designed to fit in one of said triangular regions;   securing said bracket to said one of said triangular regions; and   supporting a shelf on said bracket.   
   
   
       9 . The method of  claim 1  further comprising the steps of:
 forming said plurality of connection members by an extrusion process; and   co-extruding a resilient weather-stripping bead on to one of said plurality of connection members.   
   
   
       10 . A building structure comprising:
 first, second, third and fourth generally planar panels each disposed vertically and characterized by top, bottom, left and right edges having dovetail tenons; and   first, second, third and fourth connector members each characterized by first and second mortises extending longitudinally on opposite sides along said connector member and dimensioned to slidingly interlock with one of said dovetail tenons, said right tenon of said first panel slidingly interlocked in said first mortise of said first connector member, said left tenon of said second panel slidingly interlocked in said second mortise of said first connector member, said bottom tenon of said second panel slidingly interlocked in said first mortise of said second connector member, said top tenon of said third panel slidingly interlocked in said second mortise of said second connector member, said left tenon of said third panel slidingly interlocked in said first mortise of said third connector member, said right tenon of said fourth panel slidingly interlocked in said second mortise of said third connector member, said top tenon of said fourth panel slidingly interlocked in said first mortise of said fourth connector member, and said bottom tenon of said first panel slidingly interlocked in said second mortise of said fourth connector member;   whereby said first, second, third and fourth panels and said first, second, third and fourth connector members form a wall surface of said building structure.   
   
   
       11 . The building structure of  claim 10  further comprising:
 a fifth generally planar panel vertically disposed and characterized by top, bottom, left and right edges having dovetail tenons; and   a fifth connector member characterized by first and second mortises extending longitudinally on orthogonal sides along said fifth connector member and dimensioned to slidingly interlock with one of said dovetail tenons, said left tenon of said first panel slidingly interlocked is said first mortise of said fifth connector member, said right tenon of said fifth panel slidingly interlocked in said second mortise of said fifth connector;   whereby said first panel, said fifth panel and said fifth connector member form a corner of said building structure.   
   
   
       12 . The building structure of  claim 10  further comprising:
 a fifth generally planar panel disposed horizontally and characterized by first, second, third and fourth edges having dovetail tenons; and   a fifth connector member characterized by first and second mortises extending longitudinally on orthogonal sides along said fifth connector member and dimensioned to slidingly interlock with one of said dovetail tenons, said bottom tenon of said fourth panel slidingly interlocked in said first mortise of said fifth connector member, said first tenon of said fifth panel slidingly interlocked in said second mortise of said fifth connector;   whereby said fifth panel forms a floor surface of said building structure.   
   
   
       13 . The building structure of  claim 10  further comprising:
 a fifth generally planar panel disposed at an angle of θ from a horizontal reference and characterized by first, second, third and fourth edges having dovetail tenons; and   a fifth connector member characterized by first and second mortises with an angle if 90+θ degrees therebetween extending longitudinally along said fifth connector member, said top tenon of said first panel slidingly interlocked in said first mortise of said fifth connector member, said first tenon of said fifth panel slidingly interlocked in said second mortise of said fifth connector member;   whereby said fifth panel forms a roof surface of said building structure.   
   
   
       14 . The building structure of  claim 10  wherein:
 said first panel has a trapezoidal shape characterized by said left edge being parallel to said right edge and said top edge disposed at an angle of θ degrees from an imaginary line parallel to said bottom edge; and   the building structure further comprises,   a fifth generally planar panel disposed at said angle of θ degrees from a horizontal reference and characterized by first, second, third and fourth edges having dovetail tenons, and   a fifth connector member characterized by first and second mortises extending longitudinally on orthogonal sides along said fifth connector member and dimensioned to slidingly interlock with one of said dovetail tenons, said top tenon of said first panel slidingly interlocked in said first mortise of said fifth connector member, said first tenon of said fifth panel slidingly interlocked in said second mortise of said fifth connector member;   whereby said fifth panel forms a roof surface and said first panel forms a portion of a gable of said building structure.   
   
   
       15 . The building structure of  claim 10  further comprising:
 a plastic frame member characterized by first and second dovetail tenons disposed along first and second transverse edges, a third dovetail tenon disposed along a longitudinal edge, and an interior trussing that defines a number of triangular regions; and   a third mortise extending longitudinally along said first connector member orthogonally to said first and second mortises of said first connector member, said third mortise of said first connector member dimensioned to slidingly interlock with one of said dovetail tenons, said third tenon of said frame member slidingly interlocked in said third mortise of said first connector member;   whereby said building structure id at least partially supported by said frame member.   
   
   
       16 . The building structure of  claim 15  further comprising:
 a bracket arranged and designed to fit in one of said triangular regions; and   a shelf disposed on said bracket and supported thereby.   
   
   
       17 . The building structure of  claim 10  wherein:
 said first panel is made of a generally transparent polymer material.   
   
   
       18 . The building structure of  claim 10  wherein:
 said first panel is made of a polymer material; and   said top, bottom, left and right edges of said first panel have dovetail tenons integrally formed with said first panel.