Abstract:
A housing structure includes a first plurality of wall panels which form a lower course and a second plurality of wall panels which form an upper course. Each of the wall portions is generally rectangular and includes integrally formed interlocking portions which facilitate attachment of adjacent lateral edges of the wall portions of the first plurality to each other. Integrally formed interlocking portions facilitate attachment of the panels in the lower course to the panels in the upper course. In addition, rectangular roof panels are provided to enclose the housing structure. The interlocking portions enable the panels to slide into an interlocked engagement configuration thereby forming a rigid structure without the need for tools.

Description:
RELATED APPLICATIONS 
   This application claims priority from Provisional Application No. 60/501,694, filed Sep. 9, 2003, and Provisional Application No. 60/500,089, filed Sep. 4, 2003. 

   FIELD OF THE INVENTION 
   The present invention relates generally to the field of housing structures and more particularly to a prefabricated housing structure having a plurality of interlocking panels. 
   BACKGROUND OF THE INVENTION 
   The prior art related to housing structures includes numerous examples of prefabricated structures. These structures are typically composed of a plurality of prefabricated flat panels which are assembled at the location of use to form a structure. The assembly of conventional prefabricated operation generally involves the use of various fasteners which require various hand or power tools. The fasteners are used to join the edges of the panels to form rigid structure. In an effort to overcome the disadvantages associated with the need to assemble the relatively large number of fasteners in a conventional prefabricated structure, designers often resort to the use of relatively large panels thereby reducing the total number of joints for a given size structure. However, the use of relatively large panels results in additional shipping cost and relatively heavy panels which results in the need for two or more workers to accomplish the erection process. Despite the developments of the prior art, there remains a need for a prefabricated housing structure which can be easily erected and disassembled. 
   OBJECTS AND SUMMARY OF THE INVENTION 
   It is an object of the present invention to provide a prefabricated housing structure which can be easily assembled and disassembled. 
   Another object of the present invention is to provide a prefabricated housing structure which can be easily stored when not in use. 
   Another object of the present invention is to provide a prefabricated housing structure which includes a plurality of relatively small rigid panels. 
   Another object of the present invention is to provide a prefabricated housing structure which includes a plurality of panels which interlock to form a rigid structure. 
   Another object of the present invention is to provide a prefabricated housing structure which includes a plurality of relatively light weight panels which can be assembled without the use of tools. 
   Yet another object of the present structure is to provide a prefabricated housing structure which is composed of a number of components which can be easily manufactured, in volume, resulting in a relatively low overall cost. 
   Additional objects and advantages of the present invention will be provided hereinafter. 
   In accordance with the present invention, there is provided a prefabricated housing structure which includes a first plurality of wall panels which form a lower course and a second plurality of wall panels which form an upper course. Each of the wall portions is generally rectangular and includes integrally formed interlocking portions which facilitate the attachment of adjacent lateral edges of the wall portions of the first plurality to each other. Integrally formed interlocking portions on the panels facilitate attachment of the panels in the lower course to the panels in the upper course. In addition, rectangular roof panels are provided to enclose the housing structure. 
   The interlocking portions enable the various panels to slide into an interlocked engagement configuration thereby forming a rigid structure without the need for tools. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other important objects and advantages of the invention will be apparent from the following description of the invention taken in connection with the accompanying drawings in which: 
       FIG. 1  is an overall perspective view of a prefabricated housing structure made according to the present invention; 
       FIG. 2  is a perspective view of the first step and the second step in the erection of the prefabricated housing structure of  FIG. 1 ; 
       FIG. 3  is a perspective view of the third step in the erection of the prefabricated housing structure of  FIG. 1 ; 
       FIG. 4  is a fragmentary exploded perspective view of the fourth step in the erection of the prefabricated housing structure of  FIG. 4 ; 
       FIG. 5  is a fragmentary perspective view of the fifth step in the erection of the prefabricated housing structure of  FIG. 1  showing the installation of the door; 
       FIG. 6  is an elevation view of the corner panel of the prefabricated housing structure of  FIG. 1 ; 
       FIG. 7  is a fragmentary cross-sectional view taken along the line  6 — 6  of  FIG. 5 ; 
       FIG. 8  is a fragmentary cross-sectional view taken along the line  7 — 7  of  FIG. 5 ; 
       FIG. 9  is a fragmentary perspective view of a typical panel showing the interdigiting projections; 
       FIG. 10  is a fragmentary elevation view of the panel of  FIG. 8  taken along the line  9 — 9  of  FIG. 8 ; 
       FIG. 11  is a fragmentary elevation view taken along the line  10 — 10  of  FIG. 8 ; 
       FIG. 12  is a fragmentary elevation view showing the first step in the assembly of an upper panel and a lower panel; 
       FIG. 13  is a fragmentary elevation view similar to  FIG. 11  showing the upper and lower panels of  FIG. 11  in an assembled state and showing a second lower panel; 
       FIG. 14  is a top view taken along the line  13 — 13  of  FIG. 9 ; 
       FIG. 15  is a fragmentary cross-sectional view taken along the line  14 — 14  of  FIG. 9 ; 
       FIG. 16  is a fragmentary perspective view of the lower portion of a typical panel; 
       FIG. 17  is a fragmentary exploded cross-sectional view of the lower portion of a typical panel and a base channel; 
       FIG. 18  is a perspective view showing the assembly of typical panels; 
       FIG. 19  is a perspective view drawn to an enlarged scale showing the interlocking of typical panels; 
       FIG. 20  is an exploded view showing the assembly of lower panels and upper panels; 
       FIG. 21  is an exploded perspective view similar to  FIG. 20  showing the assembly of an additional panel; 
       FIG. 22  is a perspective view showing the completion of the assembly of the panels of  FIG. 21 ; 
       FIG. 23  is an elevation view of a typical window panel; 
       FIG. 24  is a cross-sectional view taken along the line  24 — 24  of  FIG. 23 ; and 
       FIG. 25  is a fragmentary portion of  FIG. 24  drawn to an enlarged scale. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to the drawings, there is shown in  FIG. 1  a prefabricated housing structure  10  made in accordance with the present invention. 
     FIG. 2  shows the first two steps in the erection of the prefabricated housing structure  10  showing the placement of the base channels  12 ,  14 ,  16 ,  18 . The first step comprises the placement of the base channels  12 ,  14 ,  16 ,  18  to form a rectangle which defines the perimeter of the structure. 
   The second step includes the placement of the lower panels  20 ,  22 ,  26 ,  28 ,  30 ,  32 . The lower panels  20 ,  22 ,  26 ,  28 ,  30 ,  32  are shown with their bottom portions  34  inserted into the base channels  12 ,  14 ,  16 ,  18 .  FIG. 2  also shows the corner panel  24  and the method of interlocking the individual lower panels to form the first course  54  of walls  36 ,  38 . 
     FIG. 3  shows the third step which includes the placement of the upper panels  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52  to form the second course  56  of the walls  36 ,  38 . As shown in  FIG. 3 , the lower edges  58  of the upper panels  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52  engage the upper edges  60  of the lower panels  20 ,  22 ,  26 ,  28 ,  30 ,  32  of the first course  54 . 
     FIG. 4  shows the completion of the second course  54  of upper panels and the erection of the roof  62 . The roof  62  includes top channels  64 ,  66 ,  68 ,  70  which are mounted on the upper edges of the upper panels and a plurality of roof panels which are illustrated typically by the roof panel  64 . The roof also includes roof channels  72 ,  74  which engage the roof panels  62 . 
     FIGS. 5 ,  6  and  7  show the installation of the sliding door. The sliding door  88  includes six panels  76 ,  78 ,  80 ,  82 ,  84 ,  86 . The operation of the sliding door  88  will be described presently. 
   A key feature of the present invention is related to the configuration of the interface between the various panels. This interface enables the various panels to interlock in a manner which enables the assembled panels to withstand the application of forces in various directions and thus form a rigid structure without the need for fasteners of any kind. 
   The construction of the interlocking interface between the various panels is best shown in  FIGS. 8–12 .  FIG. 8  shows a fragmentary perspective view of the top portion  90  of a typical lower panel  92 .  FIG. 9  shows an elevation view of the top portion of the panel  92  as viewed along the lines  9 — 9  of  FIG. 8  and shows a profile view of the upper portion  94  of the panel  92 , the left edge  96  of the panel  92 , and the right edge  98  of the panel  92 . 
   The interlocking features of the left and right edges  96 ,  98  of the panel enable the panel  92  to interlock with and become attached to adjacent similar panels in a manner which will be described presently. 
   The upper portion  94  of the panel  92  includes a plurality of projecting portions and step portions which cooperate with complementary portions formed on the lower edge of adjacent upper panels in a manner which will be presently described. 
   As viewed in  FIG. 9 , the upper portion  94  of the panel  92  includes a first step  100 , a second step  102 , a third step  104 , a fourth step  106 , a fifth step  108 , a sixth step  110 , a seventh step  112 , and eighth step  114 , a ninth step  116 , and a tenth step  118 . The various steps will be described with reference to an imaginary reference line which is shown as the broken line  120  in  FIG. 9 . 
   The first step  100  is defined by the vertical surface  122 , the horizontal surface  124 , and the vertical surface  126 . The second step  102  is defined by the vertical surface  126 , the horizontal surface  128 , and the vertical surface  130 . The second step  102  is further described by the surface  132  which is below the plane of the surface  134  of the panel  92 . 
   The third step  104  is defined by the vertical surface  130 . The horizontal surface  136  and the vertical surface  138 . 
   The vertical surface  138  is disposed to the right of the vertical surface  130 . 
   The fourth step  106  is defined by the vertical surface  138 , the horizontal surface  140  and the vertical surface  142 . The fourth step  106  is further defined by the surface  144 . The surface  144  is disposed below the surface  134  of the panel  92 . 
   The fifth step  108  is defined by the vertical surface  144 , the vertical surface  138 , the vertical surface  142 , and the horizontal surface  146 . 
   The sixth step  110  is defined by the vertical surface  142 , the vertical surface  148  and the horizontal surface  150 . 
   The seventh step  112  is defined by the vertical surface  148 , the vertical surface  152 , and the horizontal surface  154 . 
   The eighth step  114  is defined by the vertical surface  152 , the vertical surface  156 , and the horizontal surface  158 . The eighth step  114  is further defined by the surface  160 . The surface  160  is disposed below the surface  134  of the panel  92 . 
   The ninth step  116  is defined by the vertical surface  152 , the vertical surface  162  and the horizontal surface  164 . 
   The tenth step  118  is defined by the vertical surface  162 , the vertical surface  164 , and the horizontal surface  166 . 
   As is best shown in  FIG. 8 , the surfaces  132 ,  144 ,  160  lie in a common plane. 
   As is best shown in  FIGS. 8–12 , the panel  92  which has been previously described, forms part of the first row, first course or lower course  54  of the structure  10 . The second row or second course or upper course  56  of the panels has a plurality of step portions and surfaces which complement the step portions and surfaces on the panel which have been previously described. 
     FIG. 11  shows the first step in the assembly of the typical upper  168  and lower panels  92 . As is shown in  FIGS. 11 and 12 , the projecting portions of the upper  168  and lower panels  92  are brought into mutual engagement by moving the upper panel  168  in the direction shown by arrow  170 .  FIG. 12  shows the upper and lower panels  168 ,  92  in fully interlocked or interdigiting engagement. The various projecting portions, surfaces, and step portions formed on the upper and lower panels enable the interlocked upper and lower panels  168 ,  92  to resist forces which may be applied in the directions shown by the arrows  170 ,  172 ,  174 ,  176 ,  178  in  FIG. 1 . The panels can also withstand any combination of the forces shown. 
   The key interlocking feature as described above enables the various panels to be assembled without the need for tools, fasteners, or clamps or auxiliary equipment of any kind. 
   The upper portions  180  of the upper panels and the lower portions of the lower panels  182  are generally flat and without any projections. This configuration facilitates mounting the upper channels  64 ,  66 ,  68 ,  70  which are generally formed as “U” shaped channels on the upper panels and facilitate insertion of the lower portions  182  of the lower panels in the base channels which are also generally “U” shaped channels. 
   In addition to the various projecting portions which facilitate the interlocking engagement of the upper and lower panels as described above, the longitudinal edges typically designated by the reference numerals  96 ,  98  in  FIG. 8  and include a plurality of projecting lips  200 ,  202 ,  204  which facilitate the interlocking engagement of adjacent panels. 
   The interlocking features of the longitudinal edges  96 ,  98  will be described with reference to  FIGS. 8 and 9  which shows a typical panel  92 . As is shown in  FIG. 9 , the left edge portion  96  includes grooves  206  which extend in a downward direction from the surface  208 . The lower portion of the grooves  206  end at an intermediate portion  212  of the panel  92 . The grooves  206  are further defined by the surfaces  214  and the lips  200 . 
   The right hand portion  98  of the panel  92  includes the upper lip  204  and the lower lip  202 . 
   The lips  200 ,  202 ,  204  are similar in construction and facilitate the interlocking engagement of adjacent panel  92 ,  208 . 
   As is best shown in  FIGS. 5 ,  6  and  7 , the structure  10  includes a sliding door  88  which includes panels  76 ,  78 ,  80 ,  82 ,  84 ,  86 . The panels  76 ,  78 ,  80 ,  82 ,  84 ,  86  interlock in the manner previously described to form a single rigid panel  88 . 
   As is best shown in  FIG. 6 , an upper door channel  220  is mounted on the upper portion  222  of the door  88 . The upper door channel  220  includes a pair of leg portions  224 ,  226  having inwardly directed end portions  228 ,  230  which engage grooves  232 ,  234  formed in the surfaces  236 ,  238  of the door panel  88 . The upper door channel  220  also includes a downwardly directed slider leg  240 . 
   The slider leg  240  slides between a pair of upwardly projecting guide legs  242 ,  244  which are part of the upper wall channel  66 . The upper wall channel  66  includes a pair of leg portions  246 ,  248  and inwardly directed end portion  250 ,  252  which grasp grooves  254 ,  256  formed in the surfaces  258 ,  260  of the wall panels  262  in the manner previously described. 
   The leg portion  246  includes a projecting leg  254  which projects from an intermediate portion  256  on the leg portion  246 . The projecting leg  254  projects in a generally horizontal direction when viewed as in  FIG. 6 . The projecting leg  254  includes an upwardly projecting flange  258 . The end portions of the slider leg  240  and the guide leg  242  have rounded projecting portions  260 ,  262  which mutually interlock as shown in  FIG. 6 . The end portion of the flange  258  has a rounded projecting portion  264 . 
   As is best shown in  FIG. 6 , a roof support channel  266  includes a vertical leg  268  and a horizontal leg  270 . The upper end of the vertical leg  268  includes a horizontal portion  272 , a downwardly projecting leg  274  and a rounded projecting portion  276 . The horizontal portion  272  and the downwardly projecting leg  274  engage and are supported by the upwardly projecting flange  258 . The first edge  278  of the horizontal leg  270  engages a groove  280  formed in the surface  282  of the panel  284 . The second edge  286  of the horizontal leg  270  has an upwardly projecting flange  288 . The horizontal leg  270  and the upwardly projecting flange  288  support the roof beam  290 . The roof beam  290  in turn supports the roof  292  which may be formed by solid panels  62  as shown in  FIG. 1  or by lengths of any suitable roofing material such as wood or bamboo. 
   A lower door channel  300  is mounted on the lower portion  302  of the door  88 . The lower door channel  300  has a pair of upwardly projecting leg portions  304 ,  306  and inwardly directed end portions  308 ,  310  engage the grooves  312 ,  314  and which grasp the surfaces  316 ,  318  of the door panel  88  in the manner previously described. The lower door channel  300  has a downwardly directed slider leg  318 . 
   The slider leg  318  slides between an upwardly projecting side leg  320  and the leg portion  322  which are part of the lower wall channel  324 . The lower wall channel  324  also has a leg portion  326  and inwardly directed end portions  328 ,  330  which engage grooves  332 ,  334  and grasp the surfaces  336 ,  338  of the wall panel  66  in the manner previously described. The lower door channel  300  is generally similar to the channel  220 . 
     FIGS. 16 and 17  show the details of construction of the lower portion  340  of a typical panel  66 . The lower portion  340  engages a lower-rail channel  342 . The construction shown in  FIGS. 16 and 17  is typical of the upper and lower portions of the various panels such as panels  28 ,  48 . 
   As is best shown in  FIGS. 16 and 17 , the portion  340  of the panel  66  is tapered. The angle of taper is denoted by the letter “A.” The tapered portion is defined by wall portions  341 ,  343 . A preferred value for the angle of taper is in the order of 20 degrees. The channel  342  has a base portion  344  and a pair of leg portions  304 ,  306 . The upper portion of each of the leg portions  304 ,  306  has been inwardly directed projecting portion  308 ,  310 . The projecting portions  308 ,  310  include a rounded end portion  346 ,  348 , a ramp portion  350 ,  352 , and a wall portion  354 ,  356  which is generally perpendicular to the leg portions  308 ,  310 . 
   As shown in  FIG. 17 , the surfaces  358 ,  360  of the panel  66  includes a groove  312 ,  314  which is formed by a first wall portion  362  which is generally perpendicular to the surfaces  358 ,  360  of the panel  66 , a second wall  364  portion which is generally parallel to the surfaces  358 ,  360  of the panel  66 , and a third curved wall portion  366 . The curved wall portion  366  allows the projecting portions  308 ,  310  to snap into the grooves  312 ,  314 . 
     FIGS. 18–22  show the assembly of typical panels  26 ,  28 ,  30 ,  46 ,  48 ,  50  which were previously described in connection with  FIGS. 1–3 . As shown in  FIGS. 18–22 , the panels  28  and  30  and the panels  48  and  50  are formed as single units. 
     FIGS. 23–25  show a typical window panel  400 . The window panel includes transparent or translucent panes  402 ,  404 , which may be made of glass or plastic, and which is supported by a frame  406  as is shown in  FIGS. 24 and 25 .  FIG. 25  shows a portion of  FIG. 24  which is encircled by the arrow which is designated by the letter “B.” The frame  406  includes flanges  408 ,  410 ,  412  which support the panes  402 ,  404 . The frame  406  also includes flanges  414 ,  416  which fit within an aperture  420  which is formed in the panel  400 . The frame  400  is held in place by a screw  420  which forces the frame  400  to bear against the step portion  422  of the panel  400 . 
   Each of the panels is preferably formed as a hollow, plastic integrally molded member. The panels may preferably each have a plurality of indentations indicated typically by the reference numerals  506 ,  508 ,  510 ,  512  in  FIG. 2  which form individual panels  514 . The indentations add stiffness to the panels and provide a degree of aesthetic appeal. 
   The foregoing specific embodiment of the present invention as set forth in the specification herein is for illustrative purposes only. Various deviations and modifications may be made within the spirit and scope of this invention without departing from the main theme thereof.