Patent Abstract:
According to the invention, a structure is disclosed. The structure may include a dual channel joint member and a plurality of panels. The dual channel joint member may define two channels, each channel possibly being configured to receive an edge of a panel thereby coupling two panels. The plurality of panels may include a first panel, a second panel, and a third panel. The first panel or the second panel may define a cavity. The other of the first panel or the second panel may include a hooked tab. The hooked tab may engage the cavity and couples the first panel with the second panel. The dual channel joint member may couple the second panel with the third panel.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to Provisional U.S. Patent Application No. 60/894,159 filed Mar. 9, 2007, entitled “Building With Interlocking Panels,” the entire disclosure of which is hereby incorporated by reference, for all purposes, as if fully set forth herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to building construction methods. More particularly the invention relates to methods of constructing buildings using interlocking wall panels, possibly using Structurally Insulated Panels (“SIPs”). 
         [0003]    Traditional methods of assembling buildings usually involve a trade-off of benefits. Quick and inexpensive methods produce buildings which are not robust enough to handle repeated use and/or the environment. More sturdy construction methods are available, but take more time and costly materials. 
         [0004]    The present invention provides for speedier construction by using novel techniques to produce a durable building in less time, and with less costly materials than conventional methods. The present invention may also provide other advantages such as allowing one with minimal skill in the art to construct a building with only written instructions and a reduced number of standard tools. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    In one embodiment, a structure is provided. The structure may include a dual channel joint member and a plurality of panels. The dual channel joint member may define two channels, each channel possibly being configured to receive an edge of a panel thereby coupling two panels. The plurality of panels may include a first panel, a second panel, and a third panel. The first panel or the second panel may define a cavity. The other of the first panel or the second panel may include a hooked tab. The hooked tab may engage the cavity and couples the first panel with the second panel. The dual channel joint member may couple the second panel with the third panel. 
         [0006]    In another embodiment, a structure is provided. The structure may include a plurality of dual channel joint members and a plurality of panels. The plurality of dual channel joint members may include a first dual channel joint member and a second dual channel member. Each dual channel joint member may define two channels, with each channel possibly configured to receive an edge of a panel thereby coupling two panels. The plurality of panels may include a first panel, a second panel, and a third panel. The first dual channel joint member may couple the first panel with the second panel. The second dual channel joint member may couple the second panel with the third panel. 
         [0007]    In another embodiment, a structure is provided. The structure may include a plurality of panels. The plurality of panels may include a first panel, a second panel, and a third panel. The first panel may be coupled with the second panel, where the first panel may have a cavity or a hooked tab, and the second panel may have the other of the cavity or the hooked tab. The hooked tab may engage the cavity to couple the first panel with the second panel. The second panel may be coupled with the third panel, where the second panel may have a cavity or a hooked tab, and the third panel may have the other of the cavity or the hooked tab. The hooked tab may engage the cavity to couple the second panel with the third panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The present invention is described in conjunction with the appended figures: 
           [0009]      FIGS. 1A-1C  are axonometric views of a building in one embodiment of the invention constructed using a method embodiment of the invention; 
           [0010]      FIGS. 2A-2E  include multiple views of a floor panel of the building from  FIGS. 1A-1C ; 
           [0011]      FIGS. 3A-3E  include multiple views of a base joint piece of the building from  FIGS. 1A-1C ; 
           [0012]      FIGS. 4A-4O  include multiple views of side panels of the building from  FIGS. 1A-1C ; 
           [0013]      FIGS. 5A-5M  include multiple views of back panels of the building from  FIGS. 1A-1C ; 
           [0014]      FIGS. 6A and 6B  show the joining of the corners of the building from  FIGS. 1A-1C ; 
           [0015]      FIGS. 7A and 7B  show the addition of a cover piece to cover and secure the joints shown in  FIGS. 6A and 6B ; 
           [0016]      FIGS. 7C and 7D  show dual channel members which provide another means of coupling two side panels at a corner of the building from  FIGS. 1A-1C ; 
           [0017]      FIGS. 8A-8C  show an H-shaped joint piece which may join the back panels of the building from  FIGS. 1A-1C ; 
           [0018]      FIGS. 9A-9C  show an H-shaped joint piece which may join the side panels of the building from  FIGS. 1A-1C ; 
           [0019]      FIGS. 10A-10M  and  FIGS. 11A-11E  include multiple views of front panels of the building from  FIGS. 1A-1C ; 
           [0020]      FIGS. 12A-12D  show H-shaped joint pieces which may join the front panels of the building from  FIGS. 1A-1C ; 
           [0021]      FIGS. 13A-13D  show a door panel for the building from  FIGS. 1A-1C ; 
           [0022]      FIGS. 14A-14J  show U-shaped members which may at least partially form the door frame of the building from  FIGS. 1A-1C ; 
           [0023]      FIGS. 15A-15H  show two U-shaped members which may form a hinge to rotatably couple the door from  FIGS. 13A-13D  with the building from  FIGS. 1A-1C ; 
           [0024]      FIGS. 16A-16E  show a wall-and-base joint piece hold down; 
           [0025]      FIGS. 17A-17F  show a roof panel of the building from  FIGS. 1A-1C ; 
           [0026]      FIG. 17G  shows a roof tab reinforcement being applied to a top edge of a front or back panel of the building from  FIGS. 1A-1C ; 
           [0027]      FIGS. 18A and 18B  show a roof joint piece of the building from  FIGS. 1A-1C ; 
           [0028]      FIG. 19  shows a cross section of the roof edging of the building from  FIGS. 1A ,  1 B,  1 C; 
           [0029]      FIG. 20  shows an anchor-pin; and 
           [0030]      FIGS. 21-23  show alternative fastening elements to the anchor-pin shown in  FIG. 20 . 
       
    
    
       [0031]    In the appended figures, similar components and/or features may have the same numerical reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the letter suffix. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing one or more exemplary embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims. 
         [0033]    Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, processes, steps, methods may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known components in the art may be shown without unnecessary detail in order to avoid obscuring the embodiments. 
         [0034]    Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, etc. 
         [0035]    Turning now to  FIGS. 1A-1C , one embodiment of the invention is shown. In this embodiment, a building  100  is provided. Building  100  may be constructed, at least in part, with panels  110  and joint pieces  120 . In an exemplary embodiment, panels  110  may be SIPs and joint pieces  120  may be extruded aluminum joint pieces which may couple multiple SIPs with each other. SIPs may include, for example, polystyrene foam, polypropylene foam, polyurethane foam, and/or other insulatory/structural materials between two pieces of high density fiberboard, tempered hardboard (“THB”), oriented strand board (“OSB”), cement board, and/or other similar materials. In some embodiments, the SIPs may instead incorporate metal (i.e. sheet metal such as steel or aluminum), plastic, polymer and/or composites such as fiber reinforced plastics (rigid or felixbile) in place of one or more of the THB layers. Some embodiments may have metal, plastic or polymers in addition to the THB layers. 
         [0036]    In some embodiments, sides of the SIPs which will be in the interior of building  100  may have a smoother finish than sides of the SIPs which will be on the exterior of building  100 . The finish of the exterior side of a SIP may be patterned or textured in such a manner to make it appear to an observer that the building  100  is constructed of more conventional materials such as lumber. Other materials may also be used for panels  110 , including, but not limited to, oriented strand board, particle board, fibreboard, plywood, wood, cement board, composites, plastics, polymers and/or metals. 
         [0037]    In some embodiments, panels  110  may have added reinforcement, either on their exterior (either side) or in their interior, possibly within the interior foam or on either side of the interior foam. The added reinforcement may include, merely by way of example, high density fiberboard, tempered hardboard (“THB”), oriented strand board (“OSB”), cement board, metal, plastic, polymer, composites such as fiber reinforced plastics, and/or other materials. These reinforcement materials may be located on panels  110  such that they increase the strength and/or rigidity of panels, for example, at the edge of panels  110 , or in the interior portions of panels  110 . Such reinforcement, especially when at the edge of panels  110  may assist in strengthening coupling of adjacent panels by the methods discussed herein. When reinforcement is added in the interior portions of panels  110 , it may also allow items to be coupled with panels  110  (either on the outside or inside of building  100 ). 
         [0038]    In some embodiments, the interior and/or exterior layers of panels  110  may be prepared smaller than their final desired dimensions. Changes in moisture and temperature exposure experienced by the panels during actual use in building  100  may thereafter cause the interior and/or exterior layers of panels  110  to expand to their final dimensions. In some embodiments, the center of panels  110  may not be as affected by such changes in moisture and temperature, and therefore eventually conform to the sizes of the changed interior and exterior layers. 
         [0039]    Different materials and/or methods of manufacture may be used to create joint pieces  120 . Merely by way of example, steel, aluminum alloys, steel alloys, polymers, plastics, composites and/or other materials known in the art may be used to create joint pieces  120 . Likewise, manufacturing methods other than extrusion may also be employed, including, but not limited to forming and fabrication. 
         [0040]    In some embodiments, one or more panels  110  may form the floor, front, sides, back and roof of the building  100 . For example, in  FIGS. 1A-1C , the front of building  100  is constructed from panels  110 A,  110 B,  110 C. The left side of building  100  is constructed from panels  110 D,  110 E. The right side of building  100  is constructed from panels  110 F,  110 G. The back of building  100  is constructed from panels  110 H,  110 I. The roof of building  100  is constructed from panels  110 J,  110 K. A floor panel  110 L (not shown in  FIGS. 1A-1C ) may also be provided in some embodiments. In other embodiments, no floor panels may be provided and the surface on which building  100  sits may be the floor. The surface may be a pad made from concrete or other material, or may be the ground. 
         [0041]    In some embodiments, high strength fabric, polymer, and/or metal reinforcement straps may be included on or in any of the panels  110  discussed herein. These reinforcement straps may be coupled with earth anchors allowing the straps to be coupled with the ground to resist undesirable wind and/or seismic loading. Such reinforcement straps may also at least assist in strengthening panels  110 . 
         [0042]      FIGS. 2A-2E  show floor panel  110 L. In some embodiments, floor panel  110 L may be thicker than other panels  110  in building  100 , possibly to support loads placed thereon by people and/or objects. In the exemplary embodiment shown in  FIGS. 2A-2E , the thickness of: the THB may be about 7/16 inches; the foam may be about 1½ inches; and the sheet aluminum may be about 0.015 inches. In other embodiments, the thickness of: the THB may be between about ⅛ inches and about 1¼ inches; the foam may be between about ½ inches and 8 inches or more; and the sheet aluminum may be between about 0.010 inches and about 0.063 inches. Dimensions of other pieces in the invention, particularly joint pieces  120 , may be sized to accommodate different sized floor panels  110 L in different embodiments. 
         [0043]    In some embodiments multiple panels  110  may be used to create a floor. The multiple panels  110  may be joined using methods known in the art. In some embodiments, the method used to join multiple panels  110  may leave a seamless, or nearly seamless joint within building  100  so objects may freely be moved by sliding them across the joint without obstruction. When multiple panels are used to create the floor of building  100 , joint slots  210  may be present on one or more edges of each panel. When two panels are mated with slots  210  abutting each other, a piece of material, possibly THB, may be inserted into the slots, thereby assisting in joining the two panels together. Screws, glue and/or other fasteners known in the art may then be driven through the panels and couple the panels more fixedly with the piece of material inserted into the slot, thereby coupling the two panels with each other. In other embodiments, an ‘H’ shaped joint piece may be used to couple multiple panels  110  used to create the floor. 
         [0044]    In one method of the invention for constructing building  100 , floor panel  110 L is supported by a surface, and multiple base joint pieces  120 A are coupled with the edge of floor panel  110 L. Turning to  FIGS. 3A-3E , base joint piece  120 A is shown in greater detail. The edges of floor panel  110 L are inserted into channel  310 . Channel  310  may have press-fit features  320  such as sharp fins on one or more of the interior surfaces of channel  310  to engage floor panel  110 L. Press-fit features  320  may allow base joint piece  120 A to resist floor panel  110 L from being disengaged from the channel  310 . Other types of press-fit features  320  are possible within the scope of the invention. Other types of press-fit features  320  are detailed in U.S. patent application Ser. No. 11/366,352 entitled “Door Stabilizer for a Building,” the entire contents of which are hereby incorporated by reference for all purposes as if set forth fully herein. 
         [0045]    Base joint pieces  120 A may have angled ends  330 ,  340  to allow for flush meetings at the corners of floor panel  110 L. In embodiments with floor panels  110 L which are of greater lengths, multiple base joint pieces  120 A may be required for each edge of floor panel  110 L. In some embodiments, holes may be present in the walls of channel  310  (i.e. at the bottom of channel  350 ) to provide additional coupling to floor panel via screws or other fasteners known in the art. These holes may be near angled ends  330 ,  340  and/or may be distributed along the length of base joint pieces  120 A. In some embodiments, channel  310  may also be slightly narrower at its entrance than at its base, further resisting removal of floor panel  110 L from channel  310  once inserted. 
         [0046]    In some embodiments, particularly embodiments employing SIPs, floor panel  110 L may have a slot  220  in the edge allowing the thickness of floor panel  110 L to be reduced when put under compression, as shown in  FIGS. 2C and 2E . This will allow an assembler to more easily insert the edge of floor panel  110 L into channel  310 . As an assembler pushes floor panel  110 L into channel  310 , floor panel  110 L will compress at the edge and enter the channel more easily than if floor panel  110 L did not have slot  220  and compressed less under pressure. Once floor panel  110 L has engaged channel  310 , channel  310  will be in tension containing the compressed floor panel  110 L, and such forces will further resist disassembly of the two coupled components. 
         [0047]    Once the perimeter of floor panel  110 L is coupled with base joint pieces  120 A, the walls of building  100  may then be coupled with base joint piece  120 A and each other. The order in which the individual wall panels may be coupled with base joint piece  120 A discussed herein is exemplary, and in practice they may be coupled in multiple different possible sequences. 
         [0048]    In one embodiment, the bottom edge of side panel  110 E, seen in  FIGS. 4A-4O , may be inserted into channel  350  of one of the base joint pieces  120 A (note that one wall of channel  350  may be taller than the other, possibly as shown in  FIGS. 16A-16E  discussed below). In some embodiments, side panel  110 E, along with all other panels discussed herein, may be SIPs panels which may include foam between two pieces of THB or materials described herein. In an exemplary embodiment, the outside THB or other material may be about ⅛ inches thick; the foam or other interior material may be about ⅝ inches thick; and the inside THB or other material may be about ⅛ inches thick. In some embodiments, the outside THB or other material may be between about 1/64 inches and about ¾ inches thick, and may be finished on the outside surface with an aesthetically pleasing finish. In some embodiments the foam or other interior material may be between about ⅜ inches and about 6 inches thick or more. In some embodiments, the inside THB or other material may be between about 1/64 inches and about ¾ inches thick, and may be finished on the inside surface with a utilitarian finish such as a smooth finish to resist coating with undesirable materials such as dirt and dust over extended periods of time and use. In some embodiments, the interior or exterior THB, or other material, may be peg or slot board to assist in hanging objects on the side of panels  110 . In these or other embodiments, horizontal or vertical sections of the foam interiors of any of panels  110  may include reinforcement bands. These reinforcement bands may be made from any of the materials discussed herein, possibly THB, and provide locations where objects may be coupled with panels  110  with greater assurance that the object will be securely coupled to panel  110  (when compared to parts of panels  110  with foam interiors). In some of these embodiments, the exterior of the panels (i.e. the inside or outside of the building), may be marked or pre-drilled for ease of later coupling operations. 
         [0049]    Press-fit features  360  may assist in griping panels  110  inserted into the channel  350 . The bottom edge of side panel  110 E may have a slot in it as described with reference to floor panel  110 L to assist in coupling and holding side panel  110 E with base joint pieces  120 A. Once side panel  110 E is inserted into base joint piece  120 A, back panel  110 I would also be inserted into base joint piece  120 . Back panel  110 I is shown in  FIGS. 5A-5M . All of the hooked-tabs  510  on back panel  110 I may be inserted into corresponding hook-cavities  410  on side panel  110 E as shown in  FIGS. 6A and 6B . Directional arrows  610 A,  610 B show the directions that panel  110  with hooked-tab  510  may be inserted into hook-cavity  410 . After the panels  110  have been joined, a void  620  may be created in a portion of hook cavity  410  not filled by the hooked-tab  510 . A piece of material  630 , possibly a small wooden, plastic or other type of block (rectangular or square) may be inserted into void  620  to prevent hooked-tab  510  from disengaging hook-cavity  410 . 
         [0050]    In the embodiment shown, note that the entry of the hooked-tab  510  may have sloped entryways (possibly 79 degrees as shown in detail ‘B’ of  FIG. 10H  and  FIG. 10M ), such as to encourage engagement of the hooked-tabs  510  with hook cavity  410 . Note that the shape of the hooked-tabs  510  can be modified from that shown in the figures in numerous fashions to achieve the same purpose of interlocking the panels. For example, in other embodiments, either the hooked-tabs  510  or the hook cavities  410  may be rounded. 
         [0051]      FIGS. 7A and 7B  show an axonometric and plan view of a hook-cavity-and-hooked-tab joint with a cover piece  130  covering the joint. As seen from the plan view, cover piece  130  may be shaped such that it may be slid over the length of the joint to hide and protect the joint. Cover piece  130  may also resist movement of the piece of material  630  from exiting void  620 , thereby further locking the joint into place. In some embodiments, the top of cover piece  130  may be shaped to conform with the orientation of the roof where it meets the walls of building  100 . Cover piece  130  may also be formed and/or shaped metal, plastic, polymer, composite. In an exemplary embodiment, cover piece may be formed and shaped vinyl. 
         [0052]      FIGS. 7C and 7D  show dual channel members  710 ,  720  which may provide another means of coupling to side panels  110  at a corner of building  100  from  FIGS. 1A-1C . In embodiments which employ dual channel members  710 ,  720 , the corners of building  100  which employ such members will not include hooked-tabs  510  and hook cavities  410 , but instead may have substantially featureless straight edges at the corner. These panels  110  may be inserted into channels  715 ,  725 , where press-fit features will assist in retaining the panels therein. In these or other embodiments, screws, glue, and/or other fasteners may also be employed to couple panels  110  with each other and/or dual channel members  710 ,  720  for added stability and strength. 
         [0053]    The same joint process may be repeated to form the back of building  100  with back panel  110 H and side panel  110 G. Back panels  110 H,  110 I may be joined using H-shaped joint piece  120 B as seen in  FIGS. 8A-8C . Back panels  110 H,  110 I are shown in  FIGS. 5A-5M . Side panels  110 D,  110 F may then be inserted into base joint piece  120 A and coupled with side panels  110 E,  110 G respectively using H-shaped joint piece  120 C. Side panels  110 D- 110 G are shown in  FIG. 4A-4O . In other embodiments, the foam layer of each panel  110  at a joint of two panels  110  may be recessed such that an additional piece (possibly made from any of the materials described herein) may be inserted in the gap formed by the two recesses. Glue, screws, and/or other fasteners may then be used to couple the two panels  110  with the additional piece. Such coupling methods may be used for any panel coupling discussed herein. In yet other embodiments, only one such panel  110  may have a recessed foam layer, with the mating panel  110  having an extended foam layer. Again, glue, screws, and/or other fasteners may then be used to couple the two panels  110 . In some embodiments, the back of building  100  may include fewer or greater than two panels. In an exemplary embodiment, the back of building  100  may be constructed from three panels  110  using ‘H’ shaped joint pieces to couple panels  110 . In these embodiments, the middle panel  110  of the back of building  100  may couple with the two roof panels  110 J,  110 K thereby adding rigidity to building  100  and roof. 
         [0054]    The same joint process may then be repeated with front panels  110 A,  110 B to couple them with side panels  110 D,  110 F. The top front panel  110 C (shown in  FIGS. 11A-11E ) may then be coupled with front panels  110 A,  110 B with H-shaped joint pieces 120 D,  120 E (shown in  FIGS. 12A-12D ). Note that in every location where a panel  110  is coupled with a joint piece  120 , the edge of the panel may have a slot as described above in reference to  FIGS. 2C and 2E  to allow for easier and more secure coupling of panel  110  to joint piece  120 . Also note that partial tabs  430 AB,  430  AC may combine with partial tabs  430 AG,  430 AN and be inserted into common cavities  1710 . This may add rigidity to the building as multiple wall panels  110  may be thereby coupled with the roof at the same cavity  1710 . 
         [0055]    A door  115  (as seen in  FIGS. 13A-13D ) may be added to building  100  Door  115  may have stabilizers, such as those discussed in U.S. patent application Ser. No. 11/366,352, coupled to one or more of its edges (for example, all edges except the hinged edge). These stabilizers may at least partially, if not completely (besides the hinged edge), frame and trim the door. A hinged U-shaped member (such as that shown in  FIGS. 15A-15H  (discussed below)), may frame and trim the hinged edge as well. In some embodiments, door  115  may be made from similar materials as panels  110 . The door opening frame may be comprised of U-shaped members  120 F, such as those shown in  FIGS. 14A-14J , coupled with the edge of the door opening frame. These U-shaped members may completely frame and trim the door opening frame, except possibly the hinged edge. Door may also have one or more cut-outs  1310  for locking and handle mechanisms. At the base of the door frame a piece of material may be inserted into channel  350  of base joint piece  120 A to smooth the threshold entryway. Channel  350  would otherwise be empty in the doorway because no panel  110  is coupled here to form a wall. In yet other embodiments, a portion of the channel at the entryway may be omitted or removed to smooth the threshold. 
         [0056]      FIGS. 15A-15H  show a hinge  120 G, in two pieces, which may be used to rotatably couple door  115 . Hinge  120 G may have water path features  1510  on each piece which nominally or substantially seal the interior of the building from the exterior along the length of hinge  120 G. The shape of water path feature  1510  may vary. Other types of water path features are discussed in U.S. patent application Ser. No. 11/366,352. Any other portions of hinge  120 G may also have water path feature to aid in removal of moisture from hinge  120 G. Pins may be inserted in pivot points  1520  to couple the two pieces of hinge  120 G together. Multiple pins may be used, and may be driven into the aligned pivot points  1520  to prevent disassembly of the hinge from the exterior of building  100  because only pins near the ends of hinge  120 G may be easily removed. The pins may be made from any of the various materials discussed herein, and in some embodiments may be aluminum and/or a polymer such as nylon, which may cause less friction and wear during insertation and usage. Thus in these or other embodiments, hinge  120 G may also form the trim and/or the frame of the door. 
         [0057]    Once walls are coupled with the base joint pieces  120 A, wall-and-base joint piece hold downs  1600  (as seen in  FIGS. 16A-16D ) may be used to secure the wall panels  110  to floor panel  110 L. The base section  1610  of the hold down  1600  may have holes  1620  through which traditional fasteners may be used to couple hold down  1600  to floor panel  110 L. Hook members  1630  may extend over portions on base joint pieces  120 A and into wall cavities  420  in wall panels  110 . The bottom portion of the hook members  1630  may compress some of the foam in wall panel  110  and thereby grip the inner layer of wall panel  110  as hold down  1600  is coupled with the floor panel  110 L, as shown in assembly sketch  1650 . Hook  1630  may also extend below the left wall of the channel in  120 A to which wall panel  110  is inserted, so that hook  1630  does not apply excess pressure to only wall panel  110 . In these configurations, hook will exert pressure on both wall panel  110  and the wall of the channel of joint piece  120 A, thus reducing the likelihood of damage to wall panel  110  if it experiences normal, unforeseen, and/or undesirable forces on any of the wall panels, floor panels, or roof panels of building  100 . 
         [0058]    An alternative embodiment is shown in  FIG. 16E . In this embodiment, the channel into which panel  110  is inserted in base joint piece  121 A may have a taller left wall  122  than right wall  123 . Alternative hold down  1601  may be shaped such that it can accommodate the different size of left wall  122 . These embodiments may be advantageous in that pressure applied by alternative hold down  1601  is distributed more evenly to both panel  110  and base joint piece  121 A. 
         [0059]      FIGS. 17A-17F  show roof panels  110 J,  110 K. Each roof panel has multiple cavities,  1710 . These cavities  1710  may mate with roof tabs  430  from side wall panels  110 D,  110 E,  110 F,  110 G, back wall panels  110 H,  110 I, and front wall panels  110 A,  110 B,  110 C. In some embodiments, roof panels  110 J,  110 K may be SIPs, and may include a first layer of metal, polymer or plastic; a second layer of THB, a third layer of foam; and a fourth layer of THB. In some embodiments the first layer may be about 0.015 inches thick, or between about 0.010 inches and about 0.125 inches thick; the second layer may be about ⅛ inches thick, or between about 1/64 inches and about ¾ inches thick; the third layer may be about ⅝ inches thick, or between about ⅜ inches and about 6 inches thick; and the fourth layer may be about ⅛ inches thick, or between about 1/64 inches and about ¾ inches thick. In some embodiments, the first layer may be any material which resists the elements and helps drain away any fluid from the roof of the building while protecting the roof panels  110 J,  110 K themselves. 
         [0060]    Before roof panels  110 J,  100 K are put in place, roof tab reinforcements  1750  (seen in  FIG. 17G ) may be put into place over the tops of side wall, back wall and/or front wall panels  110 . Tab reinforcements  1750  may be made from a metal, possibly aluminum or steel, and assist in reducing wear from the weight of roof panels  110 J,  110 K and/or from wind, snow and other accumulations. After tab reinforcements  1750  are attached to tabs  430  (as shown by directional arrows  1760 ), tab reinforcements  1750  may protect the backs  1780  of tabs  430  from damage cause by the weight of roof panels  110 J,  110 K and/or from wind, snow and other accumulations as it is applied on the tabs in the direction of force arrow  1770 . Tab reinforcements  1750  may be individual pieces for each tab  430 , or may be one piece to cover all tabs  430  for the top of each panel  110  where they are required. 
         [0061]    Tab reinforcements  1750  may be more advantageous for tabs  430  which are aligned in the direction of the slope of the roof panels  110 J,  110 K. Merely by way of example, in some embodiments, back wall panels  110 H,  110 I, and front wall panels  110 A,  110 B,  110 C may have tabs  430  where tab reinforcements  1750  are applied due to the slope of the top edge of the panel  110 . In contrast, side wall panels  110 D,  110 E,  110 F,  110 G may not require tab reinforcements  1750  because of the larger area available on the side of tabs  430  on those panels to absorb shear forces from roof pieces  110 J,  110 K. Wherever tab reinforcements  1750  are applied, they may be shaped to correspond to at least some portion of the edge of the panel  110  they are applied to. In some embodiments for example, the tab reinforcements  1750  may be multiple individual pieces possibly one for each tab) and merely cover the areas of the tabs  430  which may experience undesirable forces. Note also that in some embodiments, tabs  430  at the top edge of wall panels  110 D,  110 E,  110 F and  110 G may also be reinforced in a similar fashion, except the width of the tabs  430  may also be protected, in addition to, or in the alternative to, the ends of tabs  430 . 
         [0062]    Before or during mating of roof tabs  430  with cavities  1710 , roof joint piece  120 H (seen in  FIGS. 18A and 18B ) may be used to couple roof panels  110 J,  110 K with each other, either before or during mating with the top of building  100 . Each roof panel  110 J,  110 K may have one edge inserted into a channel  1810  of roof joint piece  120 H so as to couple roof panels  110 J,  110 K with each other. Each channel  1810  may have water path features  1820  to at least nominally seal the roof joint and press-fit features  1830  to resist roof panels from exiting the roof joint piece  120 H. 
         [0063]      FIG. 19  shows a cross section of roof edging  1900 . Roof edging  1900  may be made from suitable materials, particularly flexible polymers, and may be coupled with the edge of the roof of building  100  to provide an aesthetically pleasing finish and seal the edge of the panel from moisture, particularly where SIPs are employed. A slot in the edge of panel  110  may accept barbed insert  1910  and stretch arm  1920  in the direction of directional arrow  1930 , thereby creating two sealing points  1940 . This may at least nominally seal the edge of panel  110  from water draining down the top of panel  110 . The choice of outside materials and texture for the roof panels  110  may be chosen such that a water-resistant or water-proof seal will be created by edging  1900 . For example, a smooth texture outside material for roof panels  110  may be used such that sealing points  1940  evenly apply pressure to the surface of the roof panels. 
         [0064]    In some embodiments, at least some portion of the roof tabs  430  may have one or more holes extending at least partially through its width. Corresponding roof panels  110 J,  110 K may have holes extending from the edges of the panels to cavities  1710 , where the holes are substantially aligned with the holes in roof tabs  430 . Roof panels  110 J,  110 K may have roof edging  1900  pre-installed, with holes through roof edging  1900  as well. 
         [0065]    Once roof panels  110 J,  100 K are in place, locking pin mechanisms  2000  (as shown in  FIG. 20 ) may be inserted into the combined holes from the edge of roof panels  110 J,  110 K. Pin mechanism  2000 , once inserted, would extend from the edge of the panel  110 , through the panel  110 , into roof tab  430 , and through the opposite side of roof tab  430  and back into panel  110 . Pin mechanism  2000  includes a locking collar  2010  and a barbed pin  2020 . In its initial state, a head  2030  of pin  2020  is extended from locking collar  2010 . Note that for clarity reasons, these holes were not shown in  FIG. 17A   
         [0066]    Once pin mechanism  2000  is in position, a user may apply force to head  2030  and drive pin  2020  into locking collar  2010 . Shoulders  2040  on pin  2020  will extend beyond locking arms  2050 , therefore restricting pin  2020  from returning to its initial position. Additionally, the larger diameter of pin  2020  at shoulders  2040  may cause locking arms  2050  to radially extend outward further than in their initial position, thereby driving locking arms  2050  into the panel  110  to resist extraction from the holes. In other embodiments, pin mechanism  2000  may include only one piece more closely resembling the pin  2020 . In these embodiments, the barbs on pin  2020  may engage roof edging  1900  once driven into panels  110 . 
         [0067]    Instructions provided for an assembler of building  100  may include directions to position all roof panels  110 J,  110 K in their final position before applying force to head  2030  because it may be problematic, if not impossible, to remove pin mechanism  2000  from a panel  110  afterwards. Finally, an end cap  140 , manufactured to match the cross section of roof joint piece  120 H may be coupled with the ends of roof joint piece  120 H to seal voids  1840  that would be accessible at the front and rear of building  100 . In some embodiments, end cap  140  may cover the ends of roof edging  1900  and the otherwise exposed edges of panels  110  which the roof edging  1900  does not cover. In other embodiments, pins, nails, and/or other fasteners may be used instead of pins  2000 . Merely by way of example, and as shown in  FIG. 21 , plastic pins  2100  having a shoulder  2110  on their shaft may be used. The shoulder may at least assist in preventing the removal of plastic pin  2100  after inserting into roof edge. In another possible embodiment, and as shown in  FIG. 22 , a standard nail  2200  with a plastic covering  2210  on the head may be employed. In yet another possible embodiment, and as shown in  FIG. 23 , a standard nail  2300  with a plastic covering on both the head a portion of the shaft may be employed. In some embodiments, the plastic used in any of the above fasteners may the same plastic used for roof edging  1900 . 
         [0068]    A number of variations and modifications of the invention can also be used within the scope of the invention. Merely by way of example, orientation of the building roof and entryway could be changed; only one or more corners of the building could use interlocking hooked-tabs  510  and hook-cavities  410 ; fewer or greater number of panels  110  could be used to form the floor, roof, or any side of the building; traditional fasteners such as screws, nails, and/or stapler could be used in place of any of the joint pieces  120  and/or interlocking mechanisms; and/or a chemical sealant, such as paint or silicon, could be used to seal the edges of roof panels  110 J,  110 K. 
         [0069]    The invention has now been described in detail for the purposes of clarity and understanding. However, it will be appreciated that certain changes and modification may be practice within the scope of the appended claims.

Technology Classification (CPC): 4