STRUCTURAL SUPPORT SYSTEM

Abstract

A truss element to form a structural support system. The truss element includes at least one wall forming a void space extending along a first dimension of the truss element. The void space includes a geometry to receive at least a portion of a connecting member of a connecting element. At least one corner element extends along the first dimension of the truss element adjacent the wall. A slot opening formed by selective removal of a portion of the corner element provides access to the void space of the wall. The access permits at least partial insertion of the connecting member into the void space of the wall. A method of assembling a structural support system is also disclosed.

Claims

1. A truss element comprising: at least one wall forming a void space extending along a first dimension of the truss element, the void space having a geometry to receive at least a portion of a connecting member of a connecting element, and at least one corner element extending along the first dimension of the truss element adjacent the wall; wherein a slot opening formed in a portion of the corner element provides access to the void space of the wall, the access permitting at least partial insertion of the connecting member into the wall.

2. The truss element of claim 1, wherein the slot opening is formed by selective removal of the portion of the corner element.

3. The truss element of claim 1, wherein the truss element further includes a hollow center portion.

4. A truss element of claim 1, wherein the truss element comprises a plurality of wall cavities and a plurality of corner elements, at least one of the plurality of corner elements is positioned adjacent two adjacent wall cavities of the plurality of wall cavities.

5. A structural support system comprising: a truss element, the truss element comprising: at least one wall forming a void space extending along a first dimension of the truss element, the void space having a geometry to receive at least a portion of a connecting member of one or more connecting elements; at least one corner element extending along the first dimension of the truss element adjacent the wall; and a slot opening in the at least one corner element formed in a portion of the corner element providing access to the void space of the wall; the connecting member at least partially inserted into the wall; and a securing element extending through the wall and the connecting member to secure the connecting element to the truss element.

6. The system of claim 5, wherein the slot opening is formed by selective removal of the portion of the corner element.

7. The system of claim 5, wherein the positioning of the securing element forms a structural double shear connection between the truss element and the connecting member.

8. The system of claim 5, wherein the connecting element and the truss element are oriented at an acute angle to each other.

9. The system of claim 5, wherein a first connecting element and a second connecting element are connected to at least one secondary part.

10. The system of claim 5, wherein the securing element is selected from the group consisting of a pin, a fastener, an adhesive, a magnetic component, and combinations thereof.

11. The system of claim 10, wherein the securing element is at least one pin penetrating through the wall and the connecting member.

12. The system of claim 11, wherein each of the wall and the connecting member have openings to receive the at least one pin, the openings aligning to receive a pin of the least one pin when the connecting member is at least partially inserted into the wall.

13. The system of claim 5, further comprising a plurality of truss elements and a plurality of connecting elements connected with one another to form a truss subassembly.

14. The system of claim 13, wherein a plurality of the truss subassemblies are connected together with the connecting elements to form a truss assembly, the plurality of truss subassemblies being arranged within the truss assembly to form a housing space defined by the plurality of truss subassemblies.

15. The system of claim 14, wherein the truss assembly further comprises at least one attachment feature.

16. A method of assembling a structural support system comprising: providing a truss element having at least one wall forming a void space extending along a first dimension of the truss element, the void space having a geometry to receive at least a portion of a connecting member of a connecting element, and at least one corner element extending along the first dimension of the truss element adjacent the wall; forming a slot opening to provide access to the wall; inserting one or more connecting members through the slot opening into the void space of the wall; and positioning a securing element through the wall and connecting member to secure the one or more connecting elements to the truss element.

17. The method of claim 16, wherein the forming of the slot opening includes selectively removing a portion of the corner element to form the slot opening.

18. The method of claim 17, further comprising a first opening through the wall and a second opening in the connecting member, the first opening and second opening aligning upon insertion of the connecting member into the wall.

19. The method of claim 16, further comprising connecting a plurality of truss elements and connecting elements to form a truss subassembly.

20. The method of claim 19, further comprising connecting a plurality of the truss subassemblies to form a truss assembly.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0012] FIG. 1 shows a perspective view of a truss element according to an embodiment of the present disclosure.

[0013] FIG. 2 shows an elevational view of a truss element 100 according to the present disclosure illustrating the insertion of a plane extension into the wall.

[0014] FIG. 3 shows an exploded, perspective view of a truss element with a plurality of a connect elements according to an embodiment of the present disclosure.

[0015] FIG. 4 shows a perspective view of the truss element and connecting elements of FIG. 3 in a connected configuration viewed from the opposite side.

[0016] FIG. 5 shows an elevational cutaway view of the truss and connecting elements of FIG. 3 viewed from the side.

[0017] FIG. 6 shows a perspective view of a truss subassembly according to an embodiment of the present disclosure.

[0018] FIG. 7 shows a top view of the truss subassembly of FIG. 6.

[0019] FIG. 8 shows a perspective view of a truss subassembly within a truss assembly according to an embodiment of the present disclosure.

[0020] FIG. 9 shows a perspective view a truss assembly according to an embodiment of the present disclosure.

[0021] FIG. 10 shows a perspective view a truss assembly according to another embodiment of the present disclosure.

[0022] FIG. 11 shows a perspective view a truss assembly according to another embodiment of the present disclosure.

[0023] Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Unless otherwise explained, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. The singular terms a, an, and the include plural referents unless the context clearly indicates otherwise. Similarly, the word or is intended to include and unless the context clearly indicates otherwise. The term includes means comprises. All patents and publications mentioned herein are incorporated by reference in their entirety, unless otherwise indicated. In case of conflict as to the meaning of a term or phrase, the present specification, including explanations of terms, control. Directional terms, such as upper, lower, top, bottom, front, back, vertical, and horizontal, are used herein to express and clarify the relationship between various elements. It should be understood that such terms do not denote absolute orientation (e.g., a vertical component can become horizontal by rotating the device). The materials, methods, and examples recited herein are illustrative only and not intended to be limiting.

[0025] The supporting system according to the present disclosure may be useful in various production stage support, working station support, construction safety support, and other load bearing supporting needs. The present disclosure relates to the system and method of using a structural system that has a reduced or eliminate reliance on welds to create connections. In particular, the present disclosure relates to a support system with a truss element that can be connected, extended, assembled, and disassembled with flexible and customizable configuration without needing of welding. The support system according to embodiments of the present disclosure is configured to be a lightweight but efficient load bearing structure. The support structure according to embodiments of the present disclosure may be configured to be modular and mobile, for example with wheels, for location and position adjustment or for the support structure transportation in part or as a unit. The support structure may be configured into various subassemblies and assemblies for using with other devices and/or equipment housed and/or supported with the supporting structure. An advantage of embodiments according to the present disclosure is that the assembly and support structure that is easier to manufacture, is less expensive, provides more modularity, portability, and more flexibility for configuration adjustment, which are particularly useful for stage and lighting support structures for live and/or touring entertainment productions. Unlike a conventional supporting structure, the support structure according to the present disclosure includes efficient and flexible configurations to provide support for various production needs, such as supporting lighting, sound, automation elements or other production equipment. The support system may be configured into various geometric structures. For example, the support system may be assembled in one configuration and disassembled and reconfigured to a different size and structure, depend on the desired use without welding. One embodiment of the present invention includes a custom aluminum truss element that allows high strength structural double shear connections between members using different sizes of slotted and coil or rolled pins. Another advantage of the present disclosure includes a method where the weld-free connections of the member joints are not exposed to the thermal conditions that results during welding. These thermal conditions may have an adverse effect on connection strength. With the process according to the present disclosure, connections retain the original alloy temper designation. Heat exposure in example of 6061-T6 Aluminum could reduce strength up to 50%. By eliminating the need for welding in the connections within the truss assembly, it is understood that any metal or non-metal materials with proper strength and weight may be utilized without the thermal effects.

[0026] FIGS. 1 and 2 show a truss element 100, which may be utilized to form a structural support system 300 (see also FIGS. 3-5). The truss element 100 includes at least one wall 106 forming a void space 103 extending along a first dimension 102 of the truss element 100. The wall 106 is formed in the wall portion of the truss element 100 and may include any suitable geometry that maintains structural integrity and strength for the truss element 100 and forms void space 103. The truss element 100 may be formed utilizing any suitable forming technique. For example, the truss element 100 may be extruded or formed via additive manufacturing. The truss element 100 may be fabricated from any suitable material for forming structural trusses. For example, truss element 100 may be formed from aluminum or steel. The void space 103 includes a geometry to receive at least a portion of a connecting member 202 of a connecting element 204 (see, for example, FIGS. 2-4). As shown in FIG. 1, truss element 100 also includes corner elements 104 extending along the first dimension 102 adjacent the wall 106. By adjacent, as utilized herein, it is meant that corner element 104 forms a structure that close proximity to and/or in contact with wall 106 is capable of being opened into the void space 103 of wall 106.

[0027] To provide access to the void space 103 of wall 106, one or more slot openings 110 are formed in the corner element 104. While not so limited, the slot openings 110 may be formed by selective removal of a portion of the corner element 104. The forming of the slot opening 110 may be accomplished utilizing any suitable technique or process. For example, selective removal may include machining the corner element 104 to form slot opening 110. In another embodiment, the slot opening 110 may be formed during manufacture of the body of the truss element 100, such as during additive manufacture (e.g., 3D-printing) or metallurgical forming (e.g., casting, forging, etc.). This forming results in a slot opening 110 in a geometry or configuration that provides access to the void space 103 of the wall 106. The void space 103 corresponds to the geometry of a connecting member 202 of a connecting element 204. The access to the void space 103 permits at least partial insertion of the connecting member 202 into the wall 106. In certain embodiments, the slot opening 110 may be larger than the cross-sectional geometry of the connecting member 202. In addition, the number of slot openings 110 is not limited and may include any suitable number of slot openings 110 corresponding to the connecting members 202 to be inserted into the void space 103 of wall 106. In other embodiments, a slot opening 110 may be configured to permit insertion of connecting members 202 of varying geometries to allow flexibility of configuration.

[0028] In one embodiment of the present disclosure, as shown in FIGS. 3-5, in addition to the slot opening 110, truss element 100 may also include truss element openings 208 to receive securing elements 206. The openings may be formed into the truss member 100, such as by machining, or may be formed into the truss member 100 during manufacture, similar to the formation of slot openings 110.

[0029] In one embodiment, the connection between the truss element 100 and the connecting member 202 is weld-free. While not so limited, as shown in FIGS. 1 and 2, truss element 100 may have a center hollow space 108. The center hollow space 108 may, for example, provide reduced weight and/or use of less material.

[0030] FIGS. 3, 4 and 5 show a structural support system 300 according to an embodiment of the present disclosure. The structural support system 300 includes a truss element 100 and connecting elements 204. As shown and described with respect to FIG. 1, the truss element 100 has at least one wall 106 forming a void space 103 extending along a first dimension 102 of the truss element 100. The truss element 100 also includes slot openings 110 in the corner elements 104. The connecting member 202 is at least partially inserted into the wall 106 and a securing element 206 extends through the wall 106 and the connecting member 202 to secure the connecting element 204 to the truss element 100. Connecting elements 204 may include any structure that may be attached to the truss element 100. As best shown above in FIGS. 2-3 and 5, the connecting elements 204 include a connecting member 202, which is a portion of the connecting element 204 that is insertable through the slot opening 110 into the void space 103 of wall 106.

[0031] As shown in FIGS. 3-5, in one embodiment, while not so limited, truss element 100 and two connecting elements 204 may be connected at right angles to the truss element 100, where a secondary support 302 is further connected to each of the two connecting elements 204 to provide diagonal support between the orthogonal connecting elements 204. The presence of the secondary support 302 is to provide additional support and strength to the connection between the connecting elements 204 and the truss element 100.

[0032] In certain embodiments of the present disclosure, as shown in FIGS. 3-5, the connecting member 202 includes connecting element openings 210. Upon insertion of the connecting member 202, the connecting element openings 210 align with the truss element openings 208. A securing element 206 may be driven into the connecting element openings 210 and the truss element openings 208. Additional securing elements 206 may be used to further strength the structure between the connecting member 202 and the truss element 100. Securing element 206 is any suitable structure or mechanism for joining the connecting member 202 to the truss element 100. For example, securing element 206 may be for example, a pin, a fastener, an adhesive, a magnetic component, or combinations thereof. In one particularly suitable embodiment, the securing element 206 may be a rolled pin driven through connecting element openings 210 align with the truss element openings 208 to secure the connecting member 202 to the truss element 100.

[0033] While not so limited, connecting elements 204 may be further connected to bridging members 212. Bridging members 212 may be structural or non-structural members. For example, as shown in FIGS. 3-5, bridging members 212 may include bars or other similar structure connected to the connecting element 204 by pinned connections, the pinned connections having an arrangement and function similar to the connection between the truss element 100 and the connecting member 202.

[0034] In one embodiment, the connections within the structural support system 300, including the connections between the truss element 100, the connecting element 204 and, optionally the bridging members 212, are weld-free.

[0035] In other embodiments, the connecting element 204 may be a unitary component. For example, as show in FIGS. 6 and 7, connecting members 202 may extend and connect between multiple truss elements 100. The formed structure shown in FIGS. 6 and 7 is a truss subassembly 304. The truss subassembly 304 includes a configuration of truss elements 100 and connecting elements 204, connected as shown and described above with respect to FIGS. 1-5. As show in FIGS. 6 and 7, truss elements 100 are positioned in parallel to one another and are connected by a plurality of connecting elements 204. The connecting elements 204 may be at any suitable angle between the truss elements 100, including right angles and acute angles to the truss element 100. While not show in FIGS. 6 and 7, additional truss subassemblies 304 may be connected by connecting elements 204 positioned and inserted into the wall cavities 106 at the end of the truss subassembly 304.

[0036] FIG. 8 shows a truss assembly 306, according to an embodiment of the present disclosure, including placement of truss subassemblies 304 within the truss assembly 306. While the truss subassembly 304 placement shown in FIG. 8 includes a horizontal orientation, the present disclosure is not so limited and the truss subassemblies 304 may be oriented and/or attached to the other truss subassemblies 304 in any suitable arrangement for supporting production equipment 308 (see for example, FIG. 11). For example, truss subassemblies 304 may be oriented at right or acute angles to each other.

[0037] FIG. 9 shows a truss assembly 306, according to an embodiment of the present disclosure, made up of two truss subassemblies 304, each having connecting elements 204 connected to truss elements 100. While not so limited, FIG. 9 shows the connecting elements 204 being connected at right angles to the truss elements 100 to form a three-dimensional structure having a housing space 312. Housing space 312 provides an area or space in which production equipment 308 may be housed. The space within the truss assembly 306 may, for example, provide protection of the production equipment 308 for use in an entertainment production. For example, this protection may be particularly important during loading in a show, loading out a show and during transportation between shows. Production equipment 308 may include any equipment utilized for an entertainment production, such as lighting, sound, and automation related equipment. For example, truss assembly 306 may, for example, support speakers, winches, control systems, projectors, light fixtures, video components, tracks, such as for wiring or trolley systems, or any other equipment know for use in entertainment productions. Also shown in FIG. 9, the truss assembly 306 includes attachment features 310. Attachment features 310 may be attached to the truss elements 100 by any suitable connection mechanism. In one embodiment, the attachment feature 310 is attached to the truss element 100 by weld-free pinned joints, similar to the joints between the connecting elements 204 and the truss elements 100. Attachment features 310 are mechanical connectors that permit detachable engagement of the truss assembly 306 to other components, such as other truss assemblies 306. For example, a plurality of truss assemblies 306 may be connected by attachment features 310 to form a continuous truss to span a longer distance. The attachment features 310 allow the truss assemblies 306 to be broken down into individual truss assemblies 306 making them modular and easily transportable, for example in a cargo hold or in a truck. The attachment features 310 may be any suitable detachable, high strength connector. For example, the connection may be a clevis fastener-type connection that may be pinned to secure in place.

[0038] FIG. 10 shows a truss assembly 306, according to another embodiment of the present disclosure, made up of two truss subassemblies 304, each having connecting elements 204 connected to truss elements 100. The embodiment shown in FIG. 10 includes a similar arrangement of truss elements 100, connecting elements 204, attachment features 310, truss subassemblies 304 and production equipment 308, as described above, for example in FIG. 9. However, truss assembly 306 of FIG. 10 includes connecting elements 204 at distal ends of the truss elements 100, which are angled to provide a curve to the truss assembly 306. Also visible in FIG. 10 is secondary supports 302 providing additional support between connecting elements 204.

[0039] FIG. 11 shows a truss assembly 306, according to another embodiment of the present disclosure, made up of two truss subassemblies 304, each having connecting elements 204 connected to truss elements 100. The embodiment shown in FIG. 11 includes a similar arrangement of truss elements 100, connecting elements 204, attachment features 310, truss subassemblies 304 and production equipment 308, as described above, for example in FIG. 9. However, in FIG. 11, truss assembly 306 is shown with a variety of production equipment 308 including various placements of the production equipment 308. In addition, the truss assembly 306 is shown as including mobility components 314 to provide mobility along the ground, which may be particularly important in positioning the truss assemblies 306 prior to hoisting them into position, for example, above a stage. These mobility components 314 may include, for example, wheels (e.g., casters), tracks or other components that allow movement of the truss assembly 306 by production personnel.

[0040] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrative embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention.

[0041] While the exemplary embodiments illustrated in the figures and described herein are presently preferred, these embodiments are offered by way of example only. Accordingly, the present application is not limited to a particular embodiment but extends to various modifications that nevertheless fall within the scope of the appended claims. The order or sequence of any processes or method steps may be varied according to alternative embodiments.

[0042] It is important to note that the construction and arrangement of the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present application.