Patent Publication Number: US-7895792-B1

Title: Stage system with connectable corner

Description:
RELATED PATENT DOCUMENTS 
     This patent document is a continuation under 35 U.S.C. §120 of U.S. patent application Ser. No. 10/842,703 filed on May 10, 2004 (U.S. Pat. No. 7,624,540) and entitled “Stage System with Connectable Corner,” which claims benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/469,621 filed on May 9, 2003. 
    
    
     BACKGROUND 
     Stages are designed for a wide variety of applications including, for example, smaller one-step platforms and large risers for auditorium seating applications. Generally, the manufacture, or design, of these stages can be broken down into two categories: fixed and portable. A fixed stage is designed and/or installed for permanency; once installed, there are typically no expectations that the stage is to be disassembled or moved. For the portable stage market, however, a good design is typically one that can be assembled, disassembled, expanded (or configured) and reconfigured, easily accessed for repair and movable. The market typically demands that portable stages be easily assembled and disassembled and sufficiently lightweight for moving. For both the fixed and portable stage market, a quality stage is durable for decades of heavy traffic while remaining structurally sound. 
     In either the fixed or portable markets, reducing the size and weight of each part used in a quality stage can be important for addressing most all of the above-mentioned features of the stage. Minimizing the amount of material used to build the stage can also serve to lessen the overall weight of the stage as well as both labor (e.g., for assembly) and material costs. 
     For some applications where the portability feature is used relatively frequently, ease of set up and take down can be a priority. Without the ability to easily and quickly be set up and taken down, a stage can lose its versatile character. For example, in certain applications where a stage is expected to be moved only 2-3 times over a given span of time, the labor costs associated with the disassembly and reassembly of the stage can \ exceed the depreciation-adjusted cost of a new stage when that time span lapses, and the value of the stage&#39;s portability can be negated. 
     A fixed stage benefits from the above-mentioned features in various ways as well. For example, even though reassembly is not expected to occur, if not designed properly, a fixed stage design may require heavy equipment and the associated expensive costs of assembly, thereby driving up the costs for initially assembling the stage. Lightweight fixed-stage components allow for ease of movement which is less rigorous work during the initial stage construction. Simple, lightweight-component construction makes a stage more marketable in view of the less-intensive training needed for the labor to build the stage. Although a fixed stage is intended to remain intact for a period of time, the inevitable discarding of the stage is facilitated by these same features that serve the portable stage market. Moreover, like portable stages, fixed stages become damaged and therefore should be designed with varying degrees of component access for maintenance and repair purposes. 
     In view of the above, there have been various attempts to provide stage systems and components that attempt to address all of the above features. For a variety of reasons, however, these stage systems and components fail to sufficiently address these above-discussed, and other market-demanded features. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to stage assembly methods and stage systems that address the above-discussed and other issues and that provide connectable stage components for realizing many if not all the above-discussed features. 
     In one embodiment, the present invention is directed to a platform-support system and method. The platform-support system has an external platform corner at which a platform surface structure is supported. The platform corner includes a rigid corner-support apparatus having a non-integrating outer-facing portion with opposing outer edges and having an inner portion. The system also includes a channel member having an elongated shape and an upper surface adapted to provide support to the platform surface structure, and includes a reinforcement member securely coupled to and extending from the inner portion. The reinforcement member securely supports the channel member. In a more detailed embodiment, the above-described system is adapted to provide a portable stage assembly. 
     In another embodiment of the present invention, a portable platform-support system having a supported platform corner at which a platform surface structure is supported includes a rigid corner-support apparatus having a non-integrated outer-facing portion with opposing outer edges and having an inner facing portion with a planar upper surface extension recessed from an upper portion of the rigid corner-support apparatus, a channel member having an elongated shape and an upper surface adapted to provide support to the platform surface structure, and a reinforcement member securely coupled to and extending from the inner facing portion, the reinforcement member being adapted to securely support the channel member. 
     In another embodiment of the present invention, a portable platform-support system having a supported platform corner at which a platform surface structure is supported includes a channel member having an elongated shape and a pair of accessory tracks and an upper surface adapted to provide support to the platform surface structure, a rigid corner-support apparatus having an inner portion and a non-integrating outer-facing portion with opposing outer edges having a pair of track couplers along each of the opposing outer edges, and a reinforcement member securely coupled to and extending from the inner portion, the reinforcement member being adapted to securely support the channel member. 
     In yet another embodiment of the present invention, a portable platform-support system having a supported platform corner at which a platform surface structure is supported includes a channel member having an elongated shape and a pair of accessory tracks and an upper surface adapted to provide support to the platform surface structure, a rigid corner-support apparatus having a non-integrated outer-facing portion with opposing outer edges with a pair of track couplers along each of the opposing outer edges, and having an inner facing portion with a planar upper surface extension recessed from an upper portion of the rigid corner-support apparatus, and a reinforcement member securely coupled to and extending from the inner facing portion, the reinforcement member being adapted to securely support the channel member. 
     In another embodiment of the present invention, a method for providing an external platform corner at which a platform surface structure is supported is provided and includes securely coupling a rigid corner-support apparatus having a non-integrating outer-facing portion with opposing outer edges and having an inner portion with a reinforcement member, wherein the reinforcement member extends from the inner portion, and slidably connecting a channel member having an elongated shape and an upper surface adapted to provide support to the platform surface structure with a reinforcement member. 
     In another embodiment of the present invention, a portable stage deck is provided that includes a plurality of rigid corner-support apparatus, each having a non-integrating outer-facing portion with opposing outer edges and having an inner portion, a plurality of reinforcement members securely coupled to each of the plurality of rigid corner-support apparatus, wherein the each reinforcement member extends from the inner portion, a plurality of channel members having a first and second end, wherein the first end of a channel member is slidably connected to one of the plurality of reinforcement members, and the second end is slidably connected to another of the plurality of reinforcement members, and a platform surface structure supported by the plurality of rigid corner-support apparatus and the plurality of channel members. 
     The above summary of the present invention is not intended to describe each embodiment or every implementation of the present invention. Advantages and attainments, together with a more complete understanding of the invention, will become apparent and appreciated by referring to the following detailed description and claims taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a  illustrates an assembled stage with a C-shaped floor plan which can be incorporated with embodiments of the present invention; 
         FIG. 1   b  illustrates a blown-out view of a corner of the stage assembly illustrated in  FIG. 1   a.    
         FIG. 2   a  illustrates a top view of a portable stage deck usable in accordance with embodiments of the present invention; 
         FIG. 2   b  illustrates a blown-out view of a corner of the stage assembly illustrated in  FIG. 2   a  in accordance with embodiments of the present invention; 
         FIG. 3  illustrates a channel member which can be used in accordance with embodiments of the present invention; 
         FIG. 4  illustrates a corner support in accordance with embodiments of the present invention; and 
         FIG. 5  illustrates another corner support in accordance with embodiments of the present invention. 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not necessarily to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION 
     The present invention is believed to be applicable to a variety of different types of stages, and has been found to be particularly suited for portable stages. While the present invention is not necessarily limited to such devices, various aspects of the invention may be appreciated through a discussion of various examples using this context. 
     One embodiment of the present invention is directed to a stage that includes external platform corners having corner supports coupled to reinforcement members and side frames which can secure to decking, and posts. Side frames, also referred to as channel members, secure to reinforcement members coupled to corner supports to form the stage frame. A portion of the external edges of the corner supports are exposed in the assembled stage frame. The assembled stage frame supports the decking via side frames, corner supports, or both. Vertical supports connect to the corner supports adding the desired height to the stage. Vertical supports such as posts can be stabilized using horizontal supports, for example. 
     In accordance with the present invention, the exposed portion of the corner support includes outer-facing rigid walls and provides the stage frame with added durability because the exposed corners are made of one piece of metal and portions of the corners are reinforced to lessen the chance that the corners will bend or break apart when subjected to heavy use and transport. The increased durability of the stage frame increases the overall durability of the stage, thereby increasing stage quality. 
     In another embodiment of the present invention, side frames and rigid corner-support pieces provide protection for the sides of the decking and support the decking laterally by recessing the decking below a portion of the outside edges of the side frames and external platform corners. 
     In another implementation of the present invention, external corner-support pieces can be constructed so that the height of the external corner is tall enough for the decking to be recessed while the side frames can be constructed without deck recessing capabilities. Corner supports provide lateral and vertical support for decking and side frames provide vertical support for the decking. 
     In another implementation of the present invention, external corner-support pieces are used to secure decking to the stage frame by forming a cradle, wherein the deck is secured to the assembled stage frame from the bottom, sides and top. 
     In a similar implementation of the present invention, decking can be secured to the stage frame using locking members. The locking members lock the decking to the external corner-support pieces, side frames or both. 
     In yet another implementation of the present invention, decking can be secured laterally to the stage frame by extending members. The extending members can extend from external corner-support pieces, side frames, or decking. 
     In a substantially similar implementation of the present invention, adhesive material laterally secures the decking material to the side frames, external corner-support pieces, or both. 
     In another implementation of the present invention, friction bonding material on the external corner-support pieces, side frames, or both laterally secures the deck to the stage frame. 
     Combinations of the above-mentioned embodiments of the present invention can also be integrated to form further embodiments of the present invention. 
       FIG. 1   a  illustrates an embodiment of an assembled stage  11  which can be constructed in accordance with embodiments of the present invention. Assembled stage  11  is constructed in a C-shaped deck plan having stairway  13 . Because the assembled stage  11  includes multiple individual portable stage decks  10  which can be configured in a variety of ways, the deck plan depicted in  FIG. 1   a  is one of many possible configurations that assembled stage  11  may take. Each portable stage deck  10  includes a rigid deck  14  supported by channel members  12 . The channel members  12  can be supported by corner-support pieces  1 , vertical supports  16  and horizontal supports  18  or can be supported by bridging one portable stage deck  10  with another portable stage deck  10 . In addition to incorporating stairway  13  with assembled stage  11 , the assembled stage  11  can also include hand railings, ramps, chairs and risers, for example. 
     A blown-out view of a corner of a portable stage deck  10  from  FIG. 1   a  is illustrated in  FIG. 1   b . The corner portion of the stage deck includes a rigid corner-support piece  1  having outer facing walls  2  and  3  (hidden), and an inner portion  4 . The outer-facing walls  2  and  3  join to form an apex  7 . Outer-facing walls of the rigid corner-support piece have a non-integrating character that allows for a portable stage deck to be situated adjacent to other portable stage decks while not locking to the other decks at the corners. Channel member  12  having an elongated shape and upper surface is joined with the corner-support piece  1  via reinforcement member  6 . Channel member  12  provides support to the portable stage deck. Reinforcement member  6  securely couples to the corner-support piece  1  and extends from the inner portion  4  of the corner-support piece  1 . Reinforcement member provides support to channel member  12  and thus provides support to the portable stage deck. 
       FIG. 2   a  illustrates a top view of the portable stage deck  10  with corner-support pieces  1 , channel member  12  and a rigid deck  14  which can be used in accordance with embodiments of the invention. 
       FIG. 2   b  shows an expanded view of a corner of portable stage deck  10  illustrated in  FIG. 2   a  which can be constructed in accordance with embodiments of the present invention. The expanded view of the portion of portable stage deck  10  includes channel members  20  and  50 , rigid deck  30 , and corner support piece  40 . Channel member  20  includes a female connecting portion shown as internal guiding walls  22  and  24  that engages with and secures to the male attachment portions of reinforcement members  42  and  44 . Reinforcement members  42  and  44  can include flanges having machined holes for securing channel member  20  that allows secure coupling to corner support piece  40 . For example, channel member  20  can be secured to corner support  40  by drilling holes in channel member  20  and, when needed, the reinforcement members  42  and  44  can be securely coupled to support piece  40 , and by passing connectors  60  through the holes and attaching a securing device  62  to the connectors  60 . Channel member  50  is secured in a similar manner. Upon securing channel members  20  and  50  to corner support piece  40 , external corner  48  remains exposed. The under-side of corner support piece  40  further includes an elevating portion  46  that can take the form of a female portion for accepting elevating members such as posts. 
     In embodiments of the invention, external corner  48  and channel members  20  and  50  protect the horizontal edges of rigid deck  30  and laterally secure stage deck  10 . The rigid deck  30  can be made of various materials including plywood, fiberglass, natural wood, tongue and groove flooring and polypropylene. Corner support piece  40  can be made of cast metal, for example. The corner support piece  40  can protect the edges of channel member  20  because, rather than forming corners using the edges of channel members  20  and  50 , external corner  48  is positioned at each corner of portable stage deck  10 . Corner support piece  40  increases the durability of the portable stage deck  10  because, for example, corner support piece  40  can be fabricated from one piece of cast metal instead of from channel members  20  and  50  cut at 45-degree angles. 
       FIG. 3  illustrates an end view of a channel member  112  that can be included in portable stage deck  10 . Channel member  112  can be fabricated in a variety of ways including extrusion and milling processes. The channel member  112  includes, for example, an inner wall member  114 , a connecting upper wall member  116 , an outer wall member  118 , lip members  120  and  122 , and slotted channel members  124  and  126 . 
     Slotted channel member  124  is formed by right angle members having a horizontally oriented member  128  and vertically oriented member  130  pair, and by a horizontally oriented member  132  and vertically oriented member  134  pair in conjunction with the outer wall member  118 . The slotted channel member  126  is similarly formed with the exception of the top member  136 , which, at its upper region, has a support arch  138  at the lower junction of the top wall member  116 , a vertical member  140  and the outer wall member  118 . The lower portion of the slotted channel member  126  is formed by a vertically oriented member  142  and a horizontally oriented member  144  extending from the outer wall member  118 . A portion of the wall  118  forms part of the slotted channel member  126 . The slotted channel members together form a pair of accessory tracks for use in accessorizing the portable stage deck. 
     A support arch  146  bridges the junction of the top wall member  116  and the outer wall member  118 . A support arch  148  bridges the junction of the top wall member  116  and the inner wall member  114 . Lip member  122  includes an arch support  149 . A lip member  147  extends along the inner surface of the inner wall member  114 . 
     A top member  145  butts up to the vertical member  140 , which serves as a protective member for the edge of the top member  145 . Protection of the edge is especially significant when the platform members are stacked vertically for storage. The particular size of each component is determined by the particular application, and can be extruded from an aluminum alloy. 
       FIG. 4  illustrates a portion of an external platform corner including corner support  400  having reinforcement members  410 ,  420 ,  430 , and  440 , outer facing portion  450 , planar surface  460 , an inner portion  470 , and an elevating portion  490  for accepting elevating members. Corner support  400  can be made of cast metal and machined to a desired shape and can be cast either with or without connector holes  415  (hidden),  425 ,  435 , and  445 . If constructed without connector holes  415 ,  425 ,  435 , and  445 , corner support  400  can have said holes drilled into reinforcement members  410 ,  420 ,  430 , and  440  before incorporation into a portable stage assembly. 
     Reinforcement members  410  and  420  accept one end of a first channel member (not shown) and reinforcement members  430  and  440  accept one end of a second channel member (not shown). When reinforcement members  410  and  420  are inserted into a first channel member, the first channel member is secured to the reinforcement members using connector holes  415  and  425 , for example. Similarly, reinforcement members  430  and  440  are inserted into a second channel member, and are secured to the channel member using connector holes  435  and  445 , for example. External corner  450  having opposing outer walls will remain exposed upon securing the first and second channel members to reinforcement members coupled to corner support  400 . External corner  450  includes opposing walls that can be smooth, have cut-out portions, or have members attached thereto. 
     Planar surface  460  is recessed from a top portion  455  of corner support  400 , and inset from an inner portion  470  of the corner support. Planar surface  460  can be exposed when corner support  400  is incorporated with first and second channel members. For example, first and second channel members are cut to an angle which enables the ends of the channel members to rest against corner walls  462  (hidden) and  464  to form a rigid stage frame. Thus, planar surface  460  can provide support for decking surface alone or in combination with channel members. 
     Inner portion  470  of corner support  400  can include a reinforcing wall that is formed as a reinforcing arch  475 , for example. A reinforcing arch  475  allows corner support  400  to be durable and strong. This is because the reinforcing arch  475  will be fabricated with more material than compared to a 90-degree internal retaining wall of the same size because the apex  477  of platform retaining support wall  470  will be reinforced with a larger volume of material, such as cast metal, where the internal retaining wall  475  is rounded. 
       FIG. 5  illustrates yet another embodiment of the corner support in accordance with embodiments of the present invention. Similar to the embodiment described above, the corner support includes inner portion  570  having a reinforcing arch  575  and an external support wall  550 . The support wall in this embodiment, however, includes two outer facing planar surfaces  558  and  559  (hidden), each of which include recessed pockets  551  and  555  (hidden on the  559  surface). As can be seen in the illustration, both pockets extend towards the apex  577  of the support wall  550 , where the apex  577  is formed at the point where the two outer facing planar surfaces join. The pockets can be aligned with accessory tracks found on the above-described channel members. For example, recessed pocket  551  includes a supporting arch  552  and a squared off portion  553  which matches-up with a similar accessory track referred to as slotted channel member in  FIG. 3 . The recessed pockets matching and aligning with channel member slots facilitates retrofitting of accessories used in combination with portable stage deck  10 . Similarly, recessed pocket  555  includes two squared off portions  556  and  557  which matches-up with a similar accessory track found on the channel members. Recessed pockets can be located on one or both sides of the two outer facing planar surfaces  558  and  559 . 
     Additionally, planar surface  560  is flanked by recessed planar surfaces  566  and  568 . Planar surfaces  566  and  568  provide for further securing support for channel members (not shown). Channel members are cut at an angle complementary to the angles of planar surface walls  562  and  564 . Channel members can thus be laterally supported by planar surface walls  562  and  564 , vertically supported by planar surfaces  566  and  568 , and laterally and vertically supported by flanges  510 ,  520 ,  530  and  540 . Channel members can be secured to the corner support by fastening to fastener holes  515 ,  525 ,  535  and  545 . The under-side of the corner support further includes a female elevating portion  590  for accepting elevating members such as posts. 
     In embodiments of the invention, the top members of channel members are flush with planar surfaces of corner supports on a portable stage deck. Such a configuration allows both channel members and corner supports to provide support for a platform surface. Alternatively, one or more channel members of a portable stage deck can be recessed below the planar surface of a corner support, such that a platform is, supported by the higher elevated planar surfaces of corner supports or from channel members not recessed below the planar surface of the corner supports. In contrast, planar surfaces of the corner supports can be recessed below the top members of the channel members, such that channel members provide support to the platform surface. 
     The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. Based on the above discussion and illustrations, those skilled in the art will readily recognize that various modifications and changes may be made to the present invention without strictly following the exemplary embodiments and applications illustrated and described herein. Such changes may include, but are not necessarily limited to: fabricating the corner support using a rubber mold, or through forging, or sand casting followed by a finishing process, or by using powder metal. Such modifications and changes do not depart from the true spirit and scope of the present invention that is generally set forth in the following claims: