Interlocking panel structure

Abstract

The panel frame structures and methods for making and using the same are disclosed herein. The panel frame structures can include a plurality of interlocking panels. Each of those interlocking panels can include a protrusion having a plurality of interlocking teeth. The interlocking teeth between each of the interlocking panels can be positioned between one another such that the interlock creating a rigid connection between the interlocking panels. Thus, the panel frame structure can incorporate interlocking panels having a number of protrusions in a variety of shapes to create numerous structures.

What is claimed is: 
     
         1 . An interlocking panel for use in building a panel frame structure, the interlocking panel comprising:
 a panel body to form a portion of a panel frame structure and comprising a rigid material, the panel body having:
 a first supporting surface; 
 a second supporting surface positioned opposite the first supporting surface; and 
 a panel edge bounding the first supporting surface and the second supporting surface of the panel body, the panel edge having a plurality of central side walls; 
   one or more protrusions extending from at least one of the plurality of central side walls, each of the protrusions comprising:
 a first protrusion surface; 
 a second protrusion surface opposite the first protrusion surface; 
 a protrusion edge having at least a first protrusion side wall and a second protrusion side wall; and 
 a plurality of interlocking teeth extending from the protrusion edge, the plurality of interlocking teeth each comprising:
 a first connection surface; and 
 a second connection surface opposite the first connection surface; and 
 
   one or more fastener ports to receive a fastener, wherein each fastener port is formed through at least one of the protrusion and the central region.   
     
     
         2 . The interlocking panel of  claim 1 , wherein the plurality of interlocking teeth further comprises at least one first interlocking tooth extending from the first protrusion sidewall and at least one second interlocking tooth extending from the second protrusion sidewall. 
     
     
         3 . The interlocking panel of  claim 2 , wherein the first interlocking tooth is substantially perpendicular to the first protrusion sidewall. 
     
     
         4 . The interlocking panel of  claim 3 , wherein the second interlocking tooth is substantially perpendicular to the second protrusion sidewall, and wherein the first interlocking tooth is positioned opposite of the second interlocking tooth. 
     
     
         5 . The interlocking panel of  claim 1 , wherein the first connection surface of the first interlocking tooth is configured to receive and connect with a first connection surface or a second connection surface of a selected interlocking tooth of the plurality of interlocking teeth. 
     
     
         6 . The interlocking panel of  claim 1 , wherein the first connection surface and the second connection surface are substantially perpendicular to one another. 
     
     
         7 . The interlocking panel of  claim 1 , wherein the plurality of interlocking teeth include a set of at least two (2) interlocking teeth positioned substantially opposite one another, wherein the surfaces of the interlocking teeth in the set are substantially coplanar. 
     
     
         8 . The interlocking panel of  claim 1 , wherein the protrusion further comprises the rigid material. 
     
     
         9 . The interlocking panel of  claim 8 , wherein at least one of the plurality of interlocking teeth further comprises a flexible material. 
     
     
         10 . The interlocking panel of  claim 1 , wherein the plurality of central side walls comprises a rounded side wall, the rounded side wall to form a flexible joint between adjoining interlocking panels. 
     
     
         11 . An interlocking modular subunit for use in building a panel frame structure, the interlocking modular subunit comprising:
 a plurality of interlocking panels, each interlocking panel comprising:
 a panel body to form a portion of a panel frame structure and comprising a rigid material, the panel body having:
 a first supporting surface; 
 a second supporting surface positioned opposite the first supporting surface; and 
 a panel edge bounding the first supporting surface and the second supporting surface of the panel body, the panel edge having a plurality of central side walls; 
 
 one or more protrusions extending from at least one of the plurality of central side walls, each of the protrusions comprising:
 a first protrusion surface; 
 a second protrusion surface opposite the first protrusion surface; and 
 a protrusion edge having at least a first protrusion side wall and a second protrusion side wall; 
 a plurality of interlocking teeth extending from the protrusion edge, the plurality of interlocking teeth each comprising:
 a first connection surface; and 
 a second connection surface opposite the first connection surface; and 
 
 
 one or more fastener ports to receive a fastener, wherein each fastener port is formed through at least one of the protrusion and the central region. 
   wherein two (2) selected interlocking panels of the plurality of interlocking panels are positioned substantially perpendicular to one another, the protrusions of the selected interlocking panels being interconnected with an opposing interlocking panel of the plurality of interlocking panels, wherein at least one of the interlocking teeth of the protrusion of each of the selected interlocking panels connects to and overlaps with at least one of the interlocking teeth of the protrusion of the opposing interlocking panel; and   a fastener to connect two (2) of the plurality of interlocking panels, wherein the fastener passes through the fastener port of each of the two (2) interlocking panels in a substantially perpendicular fashion.   
     
     
         12 . The interlocking modular subunit of  claim 11 , wherein the protrusion of each of the selected interlocking panels and the protrusion of the opposing interlocking panel connect to form a substantially continuous surface. 
     
     
         13 . The interlocking modular subunit of  claim 11 , further comprising one or more interlocking surface panels to create a surface. 
     
     
         14 . The interlocking modular subunit of  claim 11 , wherein the selected interlocking panels and the opposing interlocking panel connect to form an outer surface of the interlocking modular subunit, and wherein the outer surface is a substantially flat surface. 
     
     
         15 . The interlocking modular subunit of  claim 11 , wherein the first connection surface and the second connection surface are configured to increase friction with an adjoining connection surface. 
     
     
         16 . A panel frame structure, comprising:
 a plurality of interlocking panels, each interlocking panel comprising a panel body having one or more protrusions extending therefrom, the interlocking panels being connected with one another at the one or more protrusions, at least one of the plurality of support panels having one or more fastener ports, wherein the plurality of interlocking panels includes one or more pairs of interlocking panels being connected with a fastener through the fastener ports.   
     
     
         17 . The panel frame structure of  claim 16 , wherein each of the plurality of interlocking panels further comprise:
 a panel body to form a portion of a panel frame structure and comprising a rigid material, the panel body having:
 a first supporting surface; 
 a second supporting surface positioned opposite the first supporting surface; and 
 a panel edge bounding the first supporting surface and the second supporting surface of the panel body, the panel edge having a plurality of central side walls; 
   one or more protrusions extending from at least one of the plurality of central side walls, each of the protrusions comprising:
 a first protrusion surface; 
 a second protrusion surface opposite the first protrusion surface; and 
 a protrusion edge having at least a first protrusion side wall and a second protrusion side wall; 
 a plurality of interlocking teeth extending from the protrusion edge, the plurality of interlocking teeth each comprising:
 a first connection surface; and 
 a second connection surface opposite the first connection surface; and 
 
 one or more fastener ports to receive a fastener, wherein each fastener port is formed through at least one of the protrusion and the central region. 
   
     
     
         18 . The panel frame structure of  claim 16 , further comprising one or more interlocking surface panels to create a surface.