# Patent

## Title
Truss with lighting track

## Abstract

A lighting truss system uses metal truss sections with at least one powered main truss chord between end flanges. A fixture slot is disposed along an outside length of the powered main truss chord. Inside, an extruded aluminum support is positioned inside the powered main truss chord. This supports a pair of power buss bars with insulators that are accessible on one side through the fixture slot. A male-male plug can then be used during assembly on stage for interconnecting exposed open ends of corresponding powered main truss chords between the adjoining end flanges.

## Background
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to lighting truss systems typically used in homes, offices, retail space, stages and trade shows. In particular, the present invention relates to trusses with electrical buss bars, insulator supports, and extruded aluminum carriers disposed in at least one steel truss chord and accessible for track light fixtures through slots.
2. Description of Related Art
Trusses are widely used to support overhead lighting units powered by electrical power cords dressed along the truss raceways. Truss systems for stages and tradeshow floors are available in I-beam, triangle, and square truss sections made from aluminum or steel. Steel trusses are strong enough to permit 40-foot spans, and aluminum trusses have the advantage that they can be made from extruded pieces. Extrusions allow the possibility of including power tracks inside for track lighting heads.
Trussing typically comes in ten-foot sections, and can be interconnected with 2, 3, 4, 5, and 6-way corners. The interconnections at the ends can be the tube-in-socket kind, or by butting together and bolting truss end plates.
Track lighting is another very flexible and adaptable lighting system, but more so for permanent installations. The power tracks themselves are usually very flimsy and need to be supported by bolting them to walls, ceilings, or support rods.
Line voltage track systems are dangerous and require large raceways that make the overall structures relatively large and clumsy. Low voltage systems enabled with step-down transformers permit much smaller and moderate structural piece sizes that make for easier and simplified installations.
SUMMARY OF THE INVENTION
Briefly, a truss system embodiment of the present invention include steel trusses in which at least one chord of each span is slotted to receive lighting heads. A low-voltage set of buss bars are disposed inside each such chord An advantage of the present invention is that a truss system is provided that eliminates the usual tangle of wires common in prior art devices.
Another advantage of the present invention is that a method is provided for the interconnection of low voltage power between truss sections.
The above and still further objects, features, and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, especially when taken in conjunction with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective diagram of a stage lighting truss system embodiment of the present invention;
FIG. 2A is a close up perspective exploded assembly view showing how typical truss sections are assembled together with interconnecting plugs for the low voltage power daisy-chaining;
FIG. 2B is a close up perspective view showing how typical truss sections look after being assembled together;
FIG. 3A is an end view of a truss section with one of its three main chords outfitted with power busses and slotting to accommodate lighting heads, transformers, and other devices, as in FIG. 1;
FIG. 3B is a perspective view of the truss section shown in FIG. 3A;
FIGS. 4A-4C are end views and a perspective of a powered truss chord, as in FIGS. 3A and 3B, which has aluminum extrusions and insulator supports for two-wire power bus bars and slotting in the steel truss chord tubing to accommodate lighting heads as in FIG. 1;
FIGS. 4D-4F are end views and a perspective of a powered truss chord, as in FIGS. 3A and 3B, which has aluminum extrusions and insulator supports for four-wire power bus bars and slotting in the steel truss chord tubing to accommodate two circuits of lighting heads as in FIG. 1;
FIGS. 5A-5C are bottom, end, and top views of a 90-degree corner section that could be used with the parts shown in FIGS. 1-3A and 3B, inside the power tracks are interconnected through the sharp turns by internal wiring;
FIGS. 5D-5F are bottom, end, and top views of the 90-degree corner section like that of FIGS. 5A-5C, but with a hard plastic conduit connecting the power chord together and enclosing the interconnecting wiring;
FIGS. 6A-6C are bottom, end, and top views of a 45-45-degree corner section that could be used with the parts shown in FIGS. 1-3A and 3B, the power tracks are interconnected through the 45-degree turns by internal wiring;
FIGS. 7A-7B are perspective diagrams of a transformer power truss section to convert 110/220 VAC utility power into 12-VAC low voltage for the power tracks in FIGS. 1-6A, 6B, and 6C;
FIGS. 8A-8C are perspective diagrams of a transformer power truss T-section to convert 110/220 VAC utility power into 12-VAC low voltage for the power tracks in FIGS. 1-6A, 6B, and 6C;
FIGS. 9-11 are perspective view diagrams of short, medium, and long lengths of straight truss sections, with two, three, and four power slots respectively;
FIGS. 12A-12C are perspective view diagrams showing, in three steps, the assembly of a plastic elbow conduit and wiring for a corner truss section;
FIG. 13 is a perspective view diagram of a straight truss section with a utility line voltage powered pendulum lamp and strain relief support base;
FIG. 14 is a perspective diagram of a 4-transformer power truss 4-way cross connection to convert 110/220 VAC utility power into 12-VAC low voltage for the power tracks in adjoining truss sections;
FIGS. 15A and 15B are perspective view diagrams of two lengths of straight truss sections, showing how slots can be used to thread a power cord; and
FIGS. 16A and 16B are perspective view diagrams of two lengths of straight truss sections and a radius corner section, showing how slots can be used to thread a power cord through the corner.



DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents a stage lighting truss system embodiment of the present invention, and is referred to herein by the general reference numeral 100. Truss system 100 may be arranged in many configurations suitable for the dimensions and uses of a floor 102. In one configuration, truss system 100 is made primarily from steel and comprises a pair of vertical supports 104 and 106 with base footings 108 and 110. A three-chord member, triangular construction is shown in FIG. 1, but 2-chord (I-beam), and 4-chord (square) truss pieces can also be used. A unique aspect is at least one of the chords has an electrical track and fixture slot within to accommodate and power low-voltage lighting heads.
Each section is terminated with a welded triangular flange, e.g., 112 and 114. These bolt together and allow the modular assembly needed to custom configure each application of the system. An interconnector, shown in later Figs., allows daisy-chaining of the electrical power from one powered truss chord to the next.
A pair of 90-degree corner connectors 116 and 118 provide mounts overhead for a span of three horizontal truss sections 120, 122, and 124. Typically, three such sections would provide a 30-foot span. For example, low-voltage lighting heads 130-135 can be installed anywhere along the powered truss chord 140-146 using a fixture slot in the steel tubing that provides mechanical support aloft and electrical contact access to the electrified power busses inside.
A step-down transformer 150 provides low-voltage, 12/24 VAC, power converted from a 120/240 VAC power line cord 152. The low voltage connection from the step-down transformer can be detachable through the track fixture slot like the lighting heads, or wired-in for high amperage through a heavier feed cable connection.
FIG. 2A shows a close-up of the connection between sections, e.g., between flanges 112 and 114 in FIG. 1, and is referred to by the general reference numeral 200. Connection 200 requires an electrical interconnector 202 with two male ends. During on-site assembly, an insertion motion 204 puts this in place in one truss section end as shown by another interconnector 206. A powered truss chord 208 has a matching female socket that aligns with a similar powered truss-chord 210 and female socket in an adjoining truss section. These two truss sections are terminated in matching welded flanges 212 and 214, and all are made of steel for strength. A typical machine bolt 216 passes through holes 218 and 220 and is threaded and tightened to a machine nut 222. A fixture slot and power track 224 and 226, e.g., for lighting heads and transformers, are provided in each of the powered truss-chords 208 and 210 and are electrically bridged by interconnector 206. It's advantageous to have the longest fixture slots possible, and these are most practical when the chords are comprised of steel.
FIG. 2B shows the results of assembling connection 200.
FIGS. 3A and 3B represent a flange end of a three-chord truss 300. Three steel chords 301-303 are welded at their ends in a triangular pattern to a flange 304. Bolt holes 306-308 are provided to fasten this end to another adjoining truss section. Truss chord 303 is a powered truss chord and can receive a lighting head 310 and track connector 312 through an almost continuous fixture slot 314. The other chords 301-302 could also be powered.
How much of the length of powered truss-chord 303 that can be slotted is limited by the weakening effects a continuous fixture slot would have. If steel were used for the tubing, the slotting would have less of an effect on the truss strength. Such slots can be cut from the steel tubing by industrial lasers, which allow for clean straight cuts of any shape. The slotting in the steel tubing may be interrupted at the ends and every three or four feet to allow a web to brace together the open pieces. Other metals, of course, can be used for the tubing and flanges.
FIGS. 4A-4F provide more details of what's inside a powered truss chord 400. It includes a steel outer tubing 402 in which is disposed an aluminum extrusion 404. Such, in turn, provides for two insulator supports 406 and 408 as seen in FIGS. 4A-4C. These can be made of any good electrical insulating material that is also mechanically strong and able to resist breaking and cracking, e.g., polyvinyl chloride (PVC) and other plastics. A pair of copper bus bars 410 and 412 carry a low voltage current to power track lighting and other devices. The electrical contact can be made directly in between anywhere along the exposed sides. An access fixture slot 414 in extrusion 404 allows a lighting head connector, e.g., 312 in FIGS. 3A and 3B, to be inserted through to make contact with power buss bars 410 and 412. A similar, matching fixture slot 416 is cut into the adjacent section of the steel main truss chord 402. One of the easiest and least expensive ways to secure the aluminum extrusion 404 inside powered truss-chord 402 in the correct position relative to fixture slot 416 would be to use a set screw 420 that threads into a socket 422. Such would also allow for maintenance and disassembly. FIGS. 4C and 4F have cutaways in tuning 402 to better show the details of set screw 420 and socket 422.
FIGS. 4D-4F include instead a 4-wire bus bar extrusion 430, a first pair of insulators 432 and 434, a top pair of copper buss bars 436 and 438, a second pair of insulators 440 and 442, and a bottom pair of copper buss bars 444 and 446.
FIGS. 5A-5C represent one kind of 90-degree corner section that could be used with the parts shown in FIGS. 1-3A and 3B, and is referred to herein by the general reference numeral 500. Corner 500 comprises three main chords 501-503 and end-plate flanges 504 and 506, e.g., made of steel. Slots 508 and 510 are respectively cut in the outer edge of powered truss chord 502. Power busses are aligned with slots 508 and 510 and connected by a pair of wires through a plastic elbow 512. Male-male interconnectors 518 and 520 provide for power connections to the adjoining truss sections.
FIGS. 5D-5F are bottom, end, and top views of a 90-degree corner section 540 like those of FIGS. 5A-5C, but with a hard plastic conduit 542 enclosing a wiring interconnecting power slots 502 and 510 in the power chord 502.
FIGS. 6A-6C represent a 45-45-degree corner section that could be used with the parts shown in FIGS. 1-3A and 3B, and is referred to herein by the general reference numeral 600. Corner 600 comprises three main chords 601-603 and end-plate flanges 604 and 606, e.g., made of steel. Slots 608, 610, and 612, are cut into the corresponding straight runs of powered truss chord 602. Slot 610 allows a power cord to be threaded in the tubing to the outside. Power busses, like that shown in FIG. 4, are aligned and connected through the sharp turns by wire pairs. Male-male interconnectors 624 and 626 provide for power connections to the adjoining truss sections through matching female sockets.
FIGS. 7A-7B represent a transformer power truss section 700 to convert 120 VAC or 220 VAC utility power into 12 VAC low voltage for the power tracks in FIGS. 1-6A and 6C. The power truss section 700 comprises three truss chords 701-703, of which chord 702 carries the low voltage wiring and lighting tracks. A utility power supply pigtail 704 leads in through a slot 705 in chord 701 and has a ground connection 706. Two step-down transformers 708 and 710 convert, e.g., 120 VAC to 12 VAC and are respectively protected by circuit breakers 712 and 714. These each have a pushbutton reset (shown for 714) that a user can get to easily on the outside. A low voltage output from step-down transformer 708 connects through a wire lead 716 to an interconnector 718. Similarly, another low voltage output from step-down transformer 710 connects through a wire lead 720 to an interconnector 722. These respectively plug into a power track 724 and 726. FIG. 7B shows how the electrical components can be enclosed.
FIGS. 8A-8C represent a transformer power truss T-section 800 to convert 120 VAC or 220 VAC utility power into 12 VAC low voltage, e.g., for the power tracks in FIGS. 1-6A, 6B, and 6C. The power truss T-section 800 comprises three truss chords 801-803 which T-intersect with three other truss chords 804-806. Chords 802 and 805 carry the low voltage wiring and lighting tracks. A utility power supply pigtail 807 leads in through chord 804 and has a ground connection 808. Three step-down transformers 810-812 convert, e.g., 110-VAC to 12-VAC, and are respectively protected by circuit breakers 814-816. These each have a pushbutton reset on the corresponding arm's flange plate 818-820 that a user can get to easily on the outside. A low voltage output from step-down transformer 810 connects through a wire lead to a fixture slot 822 and interconnector 824. Similarly, another low voltage output from step-down transformer 811 connects through a wire lead to a fixture slot 826 and an interconnector 828. These respectively plug into a power track 824 and 826. A third low voltage output from step-down transformer 812 connects through a wire lead to a fixture slot 830 and interconnector 832.
FIGS. 9-11 represent a short, a medium, and a long length of straight truss sections, referred to herein by the general reference numerals 900, 1000, and 1100. For example, these could be four, six, and eight feet long. In FIG. 9, straight truss section 900 has two power slots 902 and 904. In FIG. 10, straight truss section 1000 has three power slots 10002, 1004, and 1006. In FIG. 11, straight truss section 1100 has four power slots 1102, 1104, 1106, and 1108. The power slots keep enough webbing between them to provide the structural strength necessary for the truss to provide good support without bending or flexing. For this reason, the longer lengths of straight truss sections need to be broken up with more slots, such that the webbing between them can be spaced no more than a few feet apart. For example, in FIG. 9, the distance between power slots 902 and 904 would be several inches.
FIGS. 12A-12C provide more detail on the wiring and interconnection of corner truss sections, like that shown in FIGS. 5D-5F. A corner truss 1200 has two plastic elbow sections 1202 and 1204 that clamp over and join the ends of intersecting power truss chords and electric tracks 1206 and 1208. A pair of screws 1210 and 1212 holds them together. Inside, a pair of electrical wires 1214 connect respective ends 1216 and 1218 of the electric tracks 1206 and 1208.
FIG. 13 represents a straight truss section 1300 that does not include an electric track or power chord. Instead, three truss chords 1302, 1304, and 1306, are used to support a pendulum lamp 1308. A clamp on support base 1310 provides a decorative base and strain relief for a power cord 1312. This feeds into a slot in chord 1302 and out one end, emerging as a pigtail 1314 for connection to a power source and/or junction box.
FIG. 14 represents a 4-way truss connecting section 1400. Such comprises four arms 1401-1404 of a power chord with slots 1405-1408. Other chords 1411-1416 are welded together from tubing to form the basic three-chord structural member with 4-way intersection. Interconnectors 1421-1424 provide for electrical, low voltage connections to other truss sections. Each has a respective circuit breaker 1431-1434 that can be easily reset by a technician if tripped. Four step-down transformers are represented by 1440 and 1444, and receive utility power through a slot 1444 using a power cord and pigtail 1446. Cover screens would normally be installed to protect workers from electric shock, and are not shown here so the internal components can be understood and described.
FIGS. 15A and 15B represent a truss section 1500 that illustrates how the utility power cords can be dressed inside the truss chords. A first straight truss has three chords 1501-1503 that join with a second straight truss section with three matching truss chords 1504-1506. These all have open ends that allow cords and other wiring to pass inside between them, and the truss sections bolt together with end flanges like 1507 and 1508 using fasteners like 1509. A first power plug and cord 1510 passes up inside chords 1504 and 1501 through a slot 1512. A pigtail 1514 appears at the open end of chord 1501. Another power plug and cord 1516 similarly passes up inside chords 1506 and 1503, but exits through a slot 1520 to appear as pigtail 1522.
FIG. 16 represents a corner assembly 1600 that uses a radius elbow section to join straight truss sections. The way the utility power wiring is threaded in the truss chord tubing members is the focus of this illustration. A first straight truss section has straight chords 1601-1603 that align with three corresponding radius chord members 1604-1606 in an elbow truss. These, in turn, connect to respective chords 1607-1609 in a second straight truss section. A detail B shows how flanges 1610 and 1611 mate and are bolted together. A power plug and cord 1620 threads into a slot 1622 in chord 1607 and runs up along inside chords 1604 and 1601. It is seen in a cutaway as cord 1624 and exits a slot 1626 with a pigtail end 1628. Standard twist-on wire connections can be used to complete the electrical connection, e.g., to a step-down transformer or line-voltage lamp. Cord 1624 is shown passing through a butt-joint 1630.
Although particular embodiments of the present invention have been described and illustrated, such was not intended to limit the invention. Modifications and changes will no doubt become apparent to those skilled in the art, and it was intended that the invention only be limited by the scope of the appended claims.
The invention is claimed, as follows.

## Claims

1. A lighting truss system, comprising:
a truss section with a plurality of powered main truss chords between end flanges;
a plurality of fixture slots disposed along an outside length of said powered main truss chords;
a plurality of extruded aluminum supports disposed inside said powered main truss chords; and
a pair of power buss bars supported inside the extruded aluminum supports by insulator supports and accessible on one side through one of the fixture slots.

2. The truss system of claim 1, further comprising:
a male-male plug for interconnecting exposed open ends of the powered main truss chords between said adjoining end flanges.

3. The truss system of claim 1, further comprising:
the plurality of fixture slots disposed along said outside length of said powered main truss chords and the extruded aluminum supports disposed inside said powered main truss chords, and the pair of power buss bars supported inside the extruded aluminum supports by insulator supports;
wires interconnecting at least two pairs of the power buss bars; and sockets formed at each end of the powered main truss chords at said end flanges providing for a male-male plug for interconnecting exposed open ends of the powered main truss chords between said adjoining end flanges.

4. The truss system of claim 1, further comprising:
a step-down transformer for providing low-voltage from a utility connection to the pair of power buss bars through one of the fixture slots.

5. The truss system of claim 1, further comprising:
a number of lighting heads connected through the fixture slots to the power buss bars and positionable anywhere along the fixture slots.

6. A truss transformer power T-section, comprising:
a truss T-section with a plurality of low-voltage powered main truss chords between three end flanges;
a plurality of slots disposed along an outside length of said powered main truss chords;
a plurality of extruded aluminum supports disposed inside said powered main truss chord relative to the slots;
a pair of power buss bars supported inside each of the extruded aluminum supports by insulator supports and accessible on one side through the fixture slots;
pairs of wires internally interconnecting the pair of power buss bars;
sockets formed at each of the ends of the powered main truss chords at said end flanges providing for a male-male plug for interconnecting exposed open ends of the
powered main truss chords between said adjoining end flanges; and at least one step-down transformer for converting a utility power input into a low voltage which is then applied to the pairs of power buss bars.