Abstract:
A truss system designed to simplify the addition of lights, audio equipment, and other stage-related equipment through the use of essentially circular strut channel members. The system is designed to enclose such equipment, be lightweight, and facilitate easy set-up and take-down of truss assemblies. The lightweight truss system includes an open-sided structure with rigid ends, and a strut channel system that facilitates the installation of lights, audio equipment, and other stage-related devices.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is based on and claims priority to the U.S. Provisional Application Patent Application Ser. No. 61/627,596, filed on Oct. 14, 2011, which is expressly incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present system relates to truss systems where it is required that equipment or devices be mounted within the truss structure. Mounting equipment or devices within a truss section often are required for mobile entertainment systems. By mounting the equipment or devices within the truss section they can remain within the truss while the truss is being transported from venue to venue. Further it allows the truss section to be assembled at a remote location and then be transported to a venue. Devices typically mounted within a truss include sound or lighting equipment. The equipment mounted within a truss may also include chain motors to raise and lower other trusses below, scenery, and props. 
         [0003]    Some systems of this type are available today for large-sized truss sections. Two such systems are disclosed in U.S. Pat. No. 4,862,336 to Richardson et al., and another U.S. Pat. No. 5,278,742 to Garrett. These systems have complex components beyond the truss structure to mount additional equipment. U.S. Pat. No. 5,743,060 to Hayes et al., describes a truss assembly that is also complex but is easy to assemble and lightweight. None of these prior art systems allow for equipment to be mounted within smaller truss sections. The larger truss sections in the prior art require special bracketing or mounting features above and beyond the structures that bear the truss loads. None of them, however, describe a light duty truss utilizing unistrut-like members that facilitate the mounting of lights and other components. 
       SUMMARY 
       [0004]    An improved light-duty stage truss system. This truss utilizes strut channel members, which members readily accept numerous commercially available lighting and other attachments that are designed for attachment to such strut channel members. This feature saves time and money for the user, as compared to other truss systems. 
         [0005]    The present truss system includes a plurality of elongate strut channel members positioned along a channel member axis. These strut channel members are disposed between two end plates, which may be shaped in any desired polygonal shape. The elongate strut channel member includes two side segments extending radially along respective intersecting side segment axes. Each side segment has a proximal corner end at which the two segments are attached, and a distal side segment end. 
         [0006]    The strut channel member further includes a first curved segment, integral at a first curved segment proximal end with the side segment distal end of one of the side segments, and which first curved segment curves inward at a first curved segment distal end. There is a second curved segment, integral at a second curved segment proximal end with the side segment distal end of the other of the side segment, and which second curved segment curves inward at a second curved segment distal end. An important aspect of the present truss system is that the first curved segment distal end of the strut channel member is spaced apart from the second curved segment distal end to form a gap region therebetween. 
         [0007]    In a preferred embodiment, at least one curved segment distal end includes a terminal inwardly-angled segment. This terminal inwardly-angled segment is used to secure an attachment device, such as a screw, bolt/nut assembly, spring nut, or others known and used in the art. 
         [0008]    In an embodiment, at least one of the side segments includes a step segment. The step segment includes a length portion, extending inward along a short axis, which axis transects the side segment axis, and transecting the short axis at about a 90 degree angle. The step segment further includes a width portion having a length terminal end and a distal curved segment terminal end. 
         [0009]    One embodiment of the present system includes a plurality of rigid structural flanges extending inward along the channel member axis at about a 90 degree angle from each side plate. The flanges include opposed terminal ends, wherein each flange terminal end is attached to one side segment of two strut channel members. 
         [0010]    Another embodiment of the present system includes a plurality of rigid cross brace members having opposing ends. Each cross brace member is attached at each end to at least one side segment of two strut channel members. Further, each cross brace member is positioned between the two strut channel members at an acute angle thereto. In yet another embodiment, the present system includes reinforcement plates attached to the side plates and positioned adjacent each strut channel member extending from that side plate. 
         [0011]    Also described herein is a new truss assembly, comprising a plurality of truss systems of the type described above. 
         [0012]    There are several advantages of the present system. One advantage of the present system is the limited number of components and relatively simple construction. Another advantage of the present system is that by locating the fastening point of the equipment integral with structural members, more room is available for the equipment. In the case of lighting equipment, this aspect allows for more area for the light to exit the truss structure without being obstructed by the truss components. 
         [0013]    A still further advantage is that, due to the nature of the system, the components, including the strut channel members, may be manufactured from aluminum, thus reducing the overall weight of the truss system. The present truss system also allows for fastening light fixtures and other equipment inside the truss. This results in reduced setup and strike time for users of the system. 
         [0014]    These and other objects and advantages of the present system will become apparent to those skilled in the art in view of the description of the best presently known mode of carrying out the invention as described herein and as illustrated in the drawings. 
     
    
     
       DRAWINGS 
         [0015]      FIG. 1  is an isometric view of the present truss system, including installed lights components. 
           [0016]      FIG. 1A  is another isometric view of the present truss system. 
           [0017]      FIG. 2  is a cross-section view of the truss system of  FIG. 1 . 
           [0018]      FIG. 3  is a cross-section view of a strut channel member of the present system. 
           [0019]      FIG. 3A  is cross-section view of a strut channel member of the present system, apart from other elements of the present system. 
           [0020]      FIG. 3B  is a cross-section view of the strut channel member of  FIG. 3A , showing a clamp system in position around the exterior of the strut channel member. 
           [0021]      FIG. 4  is an isometric close-up view of one end of the present truss system. 
           [0022]      FIG. 5  is a cross-section view of a corner of the truss system of  FIG. 1 , showing a lighting fixture mounted to the truss section. 
           [0023]      FIG. 6  is an isometric view of an assembly of truss systems, configured for use as a stage riser. 
           [0024]      FIG. 7  is a cross-section view of the truss assembly of  FIG. 6 . 
           [0025]      FIG. 8  is a close-up view of one corner of  FIG. 7 . 
           [0026]      FIG. 9  is a view of an assembly of truss systems fastened together forming an overhead truss. 
           [0027]      FIG. 10  is an alternate triangular configuration of the present truss system. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    Referring first to  FIG. 1 , an embodiment of the present truss system  100  is shown. The truss system  100  includes two opposing end plates  102 , and a plurality of strut channel members  103  connected to and extending between the two end plates  102 , all along a horizontal axis H. The system  100  further includes a plurality of cross brace members  108  extending along and between parallel strut channel members  103  to provide structural support to the system  100 . 
         [0029]    In the illustrated embodiment of  FIG. 1 , the end plates  102  are configured in a square shape. The square shape optimizes the ability to stack, store, and transport the system  100 . In alternative embodiments, the end plates  102  are oval, round, triangular, or polygonal, depending on the intended use of the system  100 . 
         [0030]    Connected to each end plate  102  are a plurality of elongate strut channel members  103 . The end plates  102  have structural flanges  106  that extend between the strut channel members  103 . These structural flanges  106  increase the stiffness of the end plate  102 , and provide rigidity to the truss system  100 . The structural flanges  106  are fastened to the interior portion of the truss members  103 , as described in further detail below. 
         [0031]    The truss system  100  is further strengthened structurally by a plurality of cross brace members  108 . The cross brace members  108  are connected between two strut channel members  103  that are positioned opposite each other along a vertical axis V that transects the horizontal axis H. The cross brace members  108  are secured to each strut channel member  103  at generally a 45 degree angle. 
         [0032]    As shown in further detail in  FIG. 1A , the strut channel members  103   a ,  103   b ,  103   c  are fastened to end plate  102   a  at selective end plate corners  105   a ,  105   b ,  105   c ,  105   d , respectively. In a preferred embodiment, each strut channel member  103  is attached to opposing corners  105  of the two end plates  102  along horizontal axis H. The strut channel members  103  are fastened to the corners  105  using methods known and used by those in the relevant art. Preferably the fastening is welding. Alternate methods of joining could be used, such as bolts or screws. 
         [0033]    In a similar manner, the strut channel members  103   a ,  103   b ,  103   c ,  103   d  are fastened to the opposing end plate corners  105   e ,  105   f ,  105   g ,  105   h  (not shown) of the end plate  102   b . All of the strut channel members  103  are parallel to one another when assembled. The length of the strut channel members  103  will vary for different applications. Short strut channel members  103  may be only a few feet in length, whereas long members  103  may be as long as about 10 feet. In a preferred embodiment, square-shaped end plates  102  are about 1-2 feet in length per truss system  100 . These dimensions are typical of trusses in use today. The specific length of strut channel members  103  is a function of the application of the truss system  100  in which the strut channel members are used. Examples of various assemblies of the present truss system are disclosed and discussed in further detail below. 
         [0034]    In the illustrated embodiment of  FIG. 1A , and by way of example, cross brace member  108   a  is connected to strut channel members  103   a  and  103   b  at an approximately 45 degree angle. The illustrated configuration of cross members  108  is ideal for creating a structural truss system. As with the end plate  102  fastening to the truss member  103 , the preferred fastening method is welding. Preferably the entire length of the structural members  103  is populated with cross brace members  108 . Half of the cross brace members  108  are shown as orthogonal to the other half of the cross brace members  108 . An alternate configuration orients all of the cross brace members  108  in the same orientation. 
         [0035]      FIG. 2  shows a cross-section of the strut channel member  103 . In a preferred embodiment, all of the strut channel members  103  have a similar cross-section. The strut channel members  103  preferably are arranged in a radial manner along the horizontal axis H extending from the center of the truss system  100 . As shown, a reinforcement plate  109  preferably is included to increase the structural connection of the truss member  103  to the end plate  102 . A plurality of reinforcement plates  109  are secured to the inboard surface of the end plates and are fastened to both the end plates  102  and the corresponding strut channel members  103 . In a preferred embodiment, the reinforcement plates  109  are attached by welding. 
         [0036]    In an embodiment, the reinforcement plate  109  includes a plurality of reinforcement mounting holes  111  to enable a plurality of truss systems  100  to be fastened together end to end. These holes  111  extend though the end plate  102 . In a preferred embodiment, each strut channel member  103  includes a complementary reinforcement plate  109 . The reinforcement plates  109  extend radially from the outer corner of the end plate  102  inward toward the center of the truss system  100 . 
         [0037]    Referring to  FIG. 3 , the cross-section of the strut channel member  103  is shown in further detail. Strut channel member  103  includes a corner segment  110  having two side segments  104   a ,  104   b  extending radially outward from the segment along a first axis A 1  and a second axis A 2 , respectively, and which are coplanar with the structural flanges  106  of the end plate  102 . In the illustrated embodiment, the side segments  104  are flat, to facilitate stacking and storing the systems. This coplanar arrangement allows for an essentially flat surface for the side, top and bottom of the truss system  100 . In alternative embodiments, the side segments are curved. The side segments  104   a ,  104   b  are filleted by the corner segment  110 . 
         [0038]    Extending outward from the terminal end of each side segment  104   a ,  104   b  is an inverted L-shaped step segment  112 , having a length  112 L extending inward at essentially 90 degrees from the side segment axis and width  112 W extending outward at essentially 90 degrees from length  112 L, and along the axis of length  112 L. In the illustrated embodiment, side segment  104   a  extends along axis A 1 , and the step segment length  112 L extends at 90 degrees inward therefrom, along axis A 2 , while the step segment width  112 W then extends 90 degrees outward therefrom and along axis Al. A complementary configuration exists for the opposing side segment  104   b . The length  112 L is at least the width of the associated structural flange  106  which is positioned adjacent the step segment  112 . 
         [0039]    In the illustrated embodiment of  FIG. 3 , curved segment  113  of the strut channel member  103  is contiguous with the step segment  112 . The curved segment  113  curves, at one end, inward from the terminal end of the step portion  112 . The curved segment  113  is contiguous, at the other end, with an inverted L-shaped inwardly-angled segment  114 . 
         [0040]    In an alternative embodiment, and as shown in  FIG. 3A , the curved segment  113  is contiguous with the side segment  104 . As stated above, the side segment  104  may be flat or curved, but the curved segment  113  is configured to curve inward to form an essentially circular interior channel region  116 . 
         [0041]    In a preferred embodiment, the inwardly-angled segment  114  extends from the terminal end of the curved segment, and is oriented about 45 degrees inward from the corresponding curved segment  113 . As illustrated, the two opposing inwardly-angled segments  114  extend toward each other, and are spaced apart from each other to form a gap region  115  therebetween. The gap region  115  is preferably slightly greater than ½ inch wide to accommodate a ½ inch bolt therewithin. The function of the gap region  115  is to fasten equipment to the strut channel member  103 , as described further below. The interior channel region  116  of the strut channel member  103 , as defined by the corner segment  110 , and the opposing side segments  104 , curved segments  113 , and inwardly-angled segments  114  is hollow, forming the channel  116  therethrough. In a preferred embodiment, the wall thickness of the strut channel member  103  is approximately ⅛ inch. 
         [0042]    As illustrated in  FIG. 3A , the specific configuration of the strut channel member, follows an essentially concentric configuration, regardless of whether or not the side segments  104  are flat/straight or curved. This allows industry standard C-clamps to be clamped to the surface of the strut channel member  103 , as illustrated in  FIG. 3B . Typically, C-clamps are designed for a 2-inch diameter pipe or tube. The present specific configuration of the strut channel member  103  facilitates the fastening of the industry standard C-clamps. 
         [0043]    In addition, by including an inwardly-angled segment  114 , the specific configuration of the strut channel member  103  provides a secure structure to which a light fixture or other unit may securely be attached using standard attachment devices, such as a nut/bolt device or a spring nut device, that fit within the interior channel member  116 . By providing this unique strut channel configuration, the truss system  100  has superior flexibility, with respect to the range of elements that can be attached to the system, while providing an overall structural integrity to the system. 
         [0044]    In a preferred embodiment, and as shown in  FIG. 4 , each strut channel member  103  includes two adjacent channel member sides  107  positioned at  90  degrees from each other, and corresponding to the side segments  104 . Each structural flange  106  includes opposing fastening end portions  117 , located at each end of the flange  106 . 
         [0045]    In a preferred embodiment, the structural flange  106  is integral with the end plate  102 , formed by bending the end plate  102  at an angle of 90 degrees along the flange seam  118 . The short ends of the structural flange  106  then is welded to the side channel member  107 , and ground for a flush fit along the top edge of the side channel member  107 . 
         [0046]    In another embodiment, construction of the strut channel member  103  includes securing the fastening end portion  117  of each structural flange  106  to the interior wall of a corresponding channel member side  107  at the side segment  104 . In that embodiment the fastening end portion  117  of each structural flange extends at least a portion of the width of the corresponding channel member side  107 . The extra area at each end of each structural flange  106  that defines the fastening ends  117 , increases the strength of the union of the strut channel members  103  to the end plate  102 . All structural flanges  106  of the system are similarly fastened to the corresponding strut channel members  103 , as illustrated. In a preferred embodiment, the fastening end portion  117  is welded to the interior surface of the corresponding structural flange  106  and ground for a flush fit. 
         [0047]    Referring to  FIG. 5 , a cross-section of the truss system  100  is shown, including a lighting fixture  119 . The yoke base  120  is shown fastened to the inwardly-angled segments  114  with a bolt  122 . In a preferred embodiment, and depending on the specific dimensions of the subject system  100 , the bolt  122  is a ½ inch bolt. The bolt  122  is fastened with a nut plate  123 . In the embodiment having a ½ inch bolt, the nut plate also will be a corresponding ½ inch. The nut plate  123  is situated in the interior channel region  116  of the strut channel member  103 . The yoke base  120  is connected to the lighting fixture  119  by yoke arm side members  121 . 
         [0048]    In a preferred embodiment, the yoke base  120  includes a yoke arm side member  121  at both ends of the yoke base  120 . The lighting fixture is typical of the type used in stage lighting. Most lighting fixtures are configured with a 9/16″ hole or a 14 mm hole to facilitate mounting to either unistrut or to an industry standard C-clamp of the type discussed above. This hole typically is located in the center of the yoke base  120 . 
         [0049]    Other equipment and devices can be mounted to the strut channel members  103 . Examples, but not limited to, include sound equipment and rigging devices or equipment. 
         [0050]    Referring to  FIG. 6 , a number of truss systems  100  can be connected to form a truss assembly  200 . In the illustrated embodiment of  FIG. 6 , the assembly  200  is a stage riser. In that illustrated embodiment, a transparent plastic panel  130  is installed between two or more strut channel members  103  to allow light to exit and to provide a place for users to step while installing the assembly. The mounting holes  111  located on the reinforcement plates  109  (not shown in this figure) and on the end plates  102  can be used to secure multiple truss systems  100  together to form various assemblies  200 . 
         [0051]      FIG. 7  shows a cross-section of the stage riser assembly  200  shown in  FIG. 6 . The transparent plastic panel  130  is shown extending across the strut channel members  103 . In a preferred embodiment, the thickness of the opaque plastic panel  130  is approximately ¼ inch. In a preferred embodiment, the plastic panel is made from a polycarbonate sheet. Alternatively, the panel may be made from PVC and acrylic sheets, and any other similar transparent, flexible, semi-rigid materials known and used by those in the field. 
         [0052]      FIG. 8  shows the corner detail of the strut channel members  103  in the assembly of  FIG. 6 . In the illustrated embodiment, the transparent plastic panel  130  is recessed in the step segment length portion  112 L of the strut channel member  103 . The top surface of the transparent plastic panel  130  is flush and generally planer with the side segment  104  of the truss member  103 . Thus, the inclusion of the step segment  112  provides a more precise fit between the strut channel member  103  and the transparent panel  130 , which allows for a more secure connection. The step segment  112 , particularly when used in combination with the transparent panel  130 , allows for a more secure connection between the strut channel member  103  and the structural flanges  106 . 
         [0053]    Referring to  FIG. 9 , this is a view of an alternative embodiment of an assembly  200  of the present truss systems  100  fastened together to form an overhead truss. Seven of the truss systems  100  are utilized to build the illustrated overhead truss assembly  200 . Three of the seven systems  100  are configured horizontally. Two of the systems  100  are configured as vertical towers to elevate the horizontal sections on the left side. The other two systems  100  are used to elevate the horizontal systems on the right side. It should be noted that an unlimited number of assemblies  200  can be imagined and deployed using the present truss system  100 . The specific configuration of each assembly is dependent on the space available and the available number of truss systems  100 . In a preferred embodiment, the truss systems  100  are fastened together to form the assemblies using bolts, or other connectors standard in the relevant industry, connected through mounting holes  111  (not shown in this  FIG. 9 ) that are aligned between the truss systems  100 . 
         [0054]      FIG. 10  shows an alternate embodiment of the present truss system  100 . In this embodiment, the end plates  102  are a triangular shape. For this embodiment, only three strut channel members  103  are required. As with the square embodiment previously described, the interior channel region  116  (not shown in this  FIG. 10 ) of the strut channel members  103  are oriented inward, toward the center of the truss system, facing the lighting fixture  119  or other installed component. 
         [0055]    The truss system  100  preferably is manufactured of extruded aluminum main truss chords/members. The integrated strut channel member  103  are specifically configured in a circular shape to allow the mounting of lights, speakers, and other equipment, which reduces the cost of constructing systems  100  as well as assemblies  200 . In addition, by having the mounting elements of the attached equipment contained within the interior channel  116  of the strut channel members, it limits accidental damage to the mounting elements and the attached equipment. 
         [0056]    In addition, because the present truss system  100  is configured to allow lights and other mounted equipment to be enclosed within the interior of the truss system  100 , it not only protects the equipment from damage, but it also facilitates fast setup and strike down of assemblies for users of the system. The entire system  100  can be left fully assembled with all attached equipment, transported from one location to the next, and then assembled into the desired assembly  200  configuration on location. 
         [0057]    The structural integrity of each system  100 , by inclusion of the cross brace members  108 , together with the entire construction of each system  100 , permits the system to be weight-bearing, i.e., a user may step on the system, if necessary, for example, during assembly of a desired assembly configuration. This is particularly true when the plastic panels  130  are positioned, as described. 
         [0058]    The above disclosure is not intended as limiting. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the restrictions of the appended claims.