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.

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.