Patent Publication Number: US-8978310-B2

Title: Staging system and method

Description:
TECHNICAL FIELD 
     The present disclosure is directed to staging systems for public and private use facilities. More particularly, the present disclosure relates to a modular staging system. 
     BACKGROUND 
     Staging systems are constructed on-site. However, installation of staging systems can require tedious welding, drilling, and/or tapping. Thus, installation requires several tools, parts, and/or power sources in addition to the components of the staging system being constructed. Such systems also have limited adjustability and are not typically interchangeable with other components. Staging systems that are durable, have adaptable design capabilities, and are convenient to work with would complement both large- and small-scale construction projects. 
     SUMMARY 
     Embodiments of the disclosure are directed to a system comprising a first beam, a second beam, at least two attachment nodes, at least four support assemblies, and a platform. Each of the first and second beams has a top surface and a bottom surface. The top surface comprises at least one top channel along the length of the beam having a first top channel width at the top surface that is smaller than a second width of the top channel located within the beam. The bottom surface has at least one bottom channel along the length of the beam having a first bottom channel width at the bottom surface that is smaller than a second width of the bottom channel located within the beam. At least one attachment node is secured in the at least one top channel of the first beam, and at least one attachment node is secured in the at least one top channel of the second beam. At least two support assemblies are secured to the at least one bottom channel of the first beam, and at least two support assemblies are secured to the at least one bottom channel of the second beam. The platform is positioned on the at least two attachment nodes. 
     Additional components, and/or entire system sections, can be connected with the above-described system to expand a staging area. The staging system can have a variety of configurations including varying shapes, heights, and accessory features. 
     Further embodiments of the disclosure are directed to a method comprising providing at least two beams, where each beam has a top surface and a bottom surface. The top surface comprises at least one top channel along the length of the beam having a first top channel width at the top surface that is smaller than a second width of the top channel located within the beam. The bottom surface has at least one bottom channel along the length of the beam having a first bottom channel width at the bottom surface that is smaller than a second width of the bottom channel located within the beam. One or more attachment nodes are secured in the at least one top channel of each of the at least two beams, and two or more support assemblies are secured to the at least one bottom channel of each of the at least two beams. The at least two beams are aligned in an upright position where the at least one bottom channel faces down and the two or more support assemblies of the first beam are positioned opposite the two or more support assemblies of the second beam. A lateral brace is attached between each of the opposing support assemblies on the first and second beams. One or more platforms are positioned on the one or more attachment nodes. 
     These and other features and aspects of various embodiments may be understood in view of the following detailed discussion and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a staging system, in accordance with various embodiments; 
         FIG. 2  is a cross-section view of a support beam, in accordance with various embodiments; 
         FIGS. 3A-C  are respective side, perspective, and bottom-up views of an attachment node assembly, in accordance with various embodiments; 
         FIG. 4  is a perspective view of a support beam with attachment node assemblies engaged, in accordance with various embodiments; 
         FIGS. 5A-D  are respective top-down, perspective, and side views of a support assembly plate, in accordance with various embodiments; 
         FIG. 6  is a side view of a staging system, in accordance with various embodiments; 
         FIGS. 7A-C  are side views of platform attachments to a staging system, in accordance with various embodiments; and 
         FIG. 8  is a flow chart of a method, in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description of various exemplary embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration various embodiments in which this disclosure may be practiced. It is to be understood that other embodiments may be utilized, as structural and operational changes may be made without departing from the scope of the present disclosure. 
     To facilitate on-site construction, a modular staging system provides an alternative to complex and time consuming installations. The described staging modules can be erected with the use of minimal tools enabling efficient assembly times and reducing or removing the need for a power source at the assembly location. In addition, the staging modules use a minimal number of interchangeable components to increase assembly efficiency. The staging systems provide for flexible adjustment of modular components and are readily reconfigurable and customizable. 
     In accordance with various embodiments, a modular staging system includes assemblies of understructure and supporting platforms. While a single platform can be supported by four support assemblies, or legs, when linked together multiple platforms can share supporting understructure in a modular effect. The understructure of the various embodiments disclosed is based on support beams with one or more channels running along the lengths of the top and bottom surfaces of the beams. These channels are used to secure various staging components. When the top and bottom surfaces have the same number and shaped channels, the top and bottom are interchangeable. Similarly, the beams are interchangeable at different positions in an assembled staging system, e.g., edge positions and intermediate support positions. While, certain of the embodiments described herein include support assemblies, or legs, certain embodiments do not. Certain embodiments can involve beams, lateral bracing, and platforms to provide a staging floor, for example, for an already level surface or a pool cover. The described components can be assembled in a variety of configurations for customizable staging assemblies. 
     In general, an assembled section  100  of a staging system includes platforms  800 , support beams  200 , and support assemblies  500 , as shown in  FIG. 1 . Here, an assembled staging section  100  includes nine support assemblies  500 , three support beams  200 , and ten platforms  800 . In addition, the assembled section  100  includes six lateral braces  600  and twenty-four diagonal braces  700 . The assembled section is shown constructed on a relatively flat surface  150 , e.g., the ground, or flooring. However, staging sections according to the disclosed embodiments can be constructed on a variety of uneven surfaces using adjustable support assemblies  500  or over open space using no, or a minimal number of, support assemblies  500 . The assembled staging section  100  can also be connected with additional staging sections by repositioning one or more platforms  800  on beams  200 . Each of these components is discussed further below. 
       FIG. 2  illustrates the cross section of a support beam  200 . The support beam includes a top surface  202  and a bottom surface  204 . The top and bottom surfaces  202 ,  204  are flat and parallel to each other. Beam  200  can be constructed of a variety of materials such as metal, plastic, wood, etc. However, to satisfy safety and weight bearing regulations, as well as to enable efficient transport and assembly, beam  200  can be a light-weight extruded aluminum (e.g., 6061-T6 aluminum). In certain embodiments, the body, or center portion  250  of beam  200 , is hollow. The exterior sides of the beam  200  can be flat or include ridges or other decorative and/or functional features. For example, beam  200  could include attachment features for wiring, storage devices, or other understructure components. Beam  200  can be a variety of lengths such as 6, 12 or 24 feet, or be customized for a specific embodiment and can be a variety of heights, e.g., 6 inches. 
     Each of the top and bottom surfaces includes one or more grooves, or channels  206 ,  207 ,  208 , and  209 . For example, beam  200  includes two top channels  206 ,  207  and two bottom channels  208 ,  209 . While beam  200  is shown with four channels, the number of channels is limited only by the dimensions of the beam  200 . For example, beam  200  could include two channels, one each on the top and bottom surface. Also, the top and bottom surfaces do not necessarily include the same number of channels. Each of the channels  206 ,  207 ,  208 ,  209  is recessed into the body of beam  200 . The channels  206 ,  207 ,  208 ,  209  run along the length of the beam  200  and are open at at least one end of the beam  200 . 
     As shown, the channels  206 ,  207 ,  208 ,  209  are shaped with varying widths. Using top channel  206  as an example, the width at the top surface  202  (shown with arrow  210 ) is smaller than the width of the channel  206  within the body of beam  200  (shown with arrow  220 ). The narrower width  210  creates a lip over both sides of the channel  206 . This lip can be various shapes, for example, including a protruding portion into the channel  206  as shown. Similarly, bottom channel  208  has a width  240  larger than the width  230  at the bottom surface  204 . While channels  206 ,  207 ,  208 ,  209  are illustrated as being rectangular, the channels can be any variety of shapes such as square, triangular, or circular. Each of the channels  206 ,  207 ,  208 ,  209  can have the same shape, or the shapes can differ. When each of the channels has the same shape and the top and bottom surfaces  202 ,  204  include the same number of channels, the top and bottom surfaces  202 ,  204  are interchangeable. Thus, the terms “top” and “bottom” are merely used for reference and do not denote a required configuration for beam  200 . The shape of channels  206 ,  207 ,  208 ,  209  is designed to receive various components, such as support plates and attachment nodes, which are further discussed below. 
     An attachment node assembly  300  is illustrated in  FIGS. 3A-C . The attachment node assembly  300  includes an attachment node  310 , a node nut  320 , and a node washer  330 . The node nut  320  is sized and shaped to be inserted into a channel of a support beam such as top channels  206 ,  207 . Using channel  206  as an example, node nut  320  is rectangular. While the node nut  320  is located within the channel, the attachment node  310  sits on top of the support beam  200 . 
     The node nut  320  secures the attachment node  310  at a specific location on the top surface of a support beam  200 . First, the node nut  320  is rotated until it contacts node washer  330 . The node nut  320  is then inserted into a beam channel, with attachment node  310  above the beam/channel. The node assembly  300  is then slid along the channel to a desired location on the beam  200 . Once in position, the attachment node  310  is rotated until the node nut  320  is contacting both sides of the channel (e.g., across width  220 ) and the attachment node  310  is seated on the top surface of the beam  200 . To facilitate contact with the sides of the channel, node nut  320  may have a parallelogram shape as shown in  FIG. 3C . As discussed above, node nut  320  may have a variety of shapes corresponding to the shape of a beam channel. 
       FIG. 4  illustrates a plurality of attachment node assemblies  300  secured to a support beam  200 . The attachment nodes  310  are positioned to align one or more platforms on a staging assembly. A platform includes one or more cavities for receiving an attachment node  310 , which then positions and/or locks the platform in place on the staging assembly. Therefore, the positioning of the attachment node assemblies  300  on beam  200  dictates the alignment of the platform(s). For example, adjacent attachment node assemblies  300  in the same channel can be received by adjacent platforms. Likewise, adjacent node assemblies  300  in adjacent channels can also align adjacent platforms. The attachment node assemblies  300  can be positioned using a variety of methods including using a locator template and using predefined markings on the support beam  200 . 
     On the opposite side of the beam from the attachment node assemblies, support assemblies are attached. The support assemblies are connected to the bottom channel(s) of the beam with a support plate  510 . Various views of a support plate  510  are illustrated in  FIGS. 5A-D . The top-down view of  FIG. 5A  illustrates four channel nuts  520 , two channel nuts  520  are aligned in each of two parallel grooves  525 . The grooves  525  are recessed in a top surface  530  of support plate  510 . The grooves  525  are optional features of support plate  510  since the channel nuts  520  could also lay flat against the top surface  530 . However, grooves  525  assist in aligning the channel nuts  520  for insertion into one or more bottom channels of a support beam. 
     The perspective view of  FIG. 5B  illustrates a pin  540  used to secure the support plate  510  to a column of a support assembly. The pin  540  provides an efficient attachment and alignment mechanism that does not require additional tools. Also shown are spring-loaded bolts  550  connected to each channel nut  520 . A spring-loaded bolt  550  engages a channel nut  520  by pushing the channel nut  520  up out of the groove  525 . The channel nut is then turned less than one hundred eighty degrees, and preferably closer to ninety degrees, to no longer align with the groove  525 . The spring-loaded bolt is then released. In the example of  FIG. 5B , this would leave channel nut  520  resting on the top surface  530  of the support plate  510 . However, if the channel nuts were aligned with a support beam, such as beam  200 , the channel nut  520  would be inserted into a bottom channel when the spring-loaded bolt  550  is engaged and would rest inside the bottom channel on the lip when the spring-loaded bolt  550  is released. Thus, one or more channel nuts  520  secure the support plate  510  to a support beam  200 . The side views of  FIGS. 5C-D  show that the channel nuts  520  can extend beyond the end of the grooves  525  and/or top surface  530  of the support plate  510 . Similar to the node nuts  320 , the channel nuts  520  may have a parallelogram shape, as shown, to facilitate contact with the sides of a beam channel. However, the channel nuts  520  may have a variety of shapes corresponding to the shape of a beam channel. 
     The attachment of a support plate  510  to a beam  200  is further illustrated in the portion of an assembled staging section of  FIG. 6 . Support plate  510  is secured to beam  200  with first and second channel nuts  521 ,  522  and corresponding first and second spring-loaded bolts  551 ,  552 . The support plate  510  is connected to a column  560  with pin  540  to form a support assembly. The column  560  is connected to additional support assemblies with first and second lateral braces  601 ,  602 . Lateral braces  601 ,  602  can be of a variety of lengths, such as a length corresponding to the length of a platform. For example, lateral braces  601 ,  602  can provide a span of up to sixteen feet (4.88 m). The first lateral brace is secured to the column  560  with a first connector  571  of a first plurality of connectors at a first height on the column  560 . The second lateral brace is secured to the column  560  with a second connector  572  of a first plurality of connectors at a first height on the column  560 . While the first plurality of connectors can take a variety of shapes and sizes, the illustrated connectors  571 ,  572  are movable so as to slide horizontally around at least a portion of the circumference of the column  560  at the first height. This allows the connectors to be used at various positions around column  560  providing for a customizable assembly. The connectors include an aperture for receiving a pin to secure the lateral braces  601 ,  602  to column  560 . While securing the lateral braces  601 ,  602  with a pin provides an efficient assembly without requiring additional tools, connectors  571 ,  572  can also be used with a variety of other fasteners such as screws, bolts, nails, etc. 
     Similarly, a second plurality of connectors at a second height on column  560  is used to secure first and second diagonal braces  701 ,  702  to column  560 . To speed an assembly process, diagonal braces  701 ,  702  can be pre-attached to respective lateral braces  601 ,  602 . Alternatively, the diagonal braces  701 ,  702  can be secured to the respective lateral braces  601 ,  602  during assembly of a staging system. The diagonal braces  701 ,  702  are secured to the lateral braces  601 ,  602  with any variety of fasteners (e.g., bolts, screws, pins) that enable the diagonal braces to rotate around the connection point. This can allow a pre-attached diagonal brace  701  to fold up into, or along, the lateral brace  601  for ease of storage and transportation. The opposing ends of the diagonal braces  701 ,  702  connect to the column  560  at the second plurality of connectors with a first and second connector  581 ,  582 . Similar to the first plurality of connectors, the second plurality of connectors can take a variety of shapes and sizes, the illustrated connectors  581 ,  582  are movable so as to slide horizontally around at least a portion of the circumference of the column  560  at the second height. This allows the connectors to be used at various positions around column  560  providing for a customizable assembly. The connectors include an aperture for receiving a pin to secure the diagonal braces  701 ,  702  to column  560 . While securing the diagonal braces  701 ,  702  with a pin provides an efficient assembly without requiring additional tools, connectors  581 ,  582  can also be used with a variety of other fasteners such as screws, bolts, nails, etc. 
     Column  560  extends to the staging support surface, for example, the ground. Column  560  can be either straight or bent to accommodate a staging area. The column  560  terminates with a ground support piece which may take many shapes, such as a stationary, flat foot or a high capacity swivel caster. A leveling rod or other height adjustable mechanism can allow hand or automatic leveling of the staging system while allowing the support assembly to support heavy loads. The components of the support assembly, including the lateral and diagonal braces, can be constructed of a variety of materials, including, for example, aluminum. 
     The illustrated staging section includes a first and a second platform  801 ,  802 . The platforms can be of a variety of sizes and shapes. Platforms are constructed of any variety of materials including marine grade wood, metal, plastic, composite materials, or glass. However, the platforms must satisfy applicable safety and load bearing regulations. The first platform  801  is positioned with a first attachment node (not shown) that is secured to a first top channel in beam  200  with a first node nut  321 . The second platform  802  is positioned with a second attachment node (not shown) that is secured to a second top channel in beam  200 , adjacent and parallel to the first channel, with a second node nut  322 . While the attachment nodes position and align the platforms  801 ,  802 , the platforms  801 ,  802  can be further tightened to each other and the support structure with additional support features such as by activating coffin lock connectors between platforms, to create a uniform stage surface. The plurality of top channels in beam  200  provides for a variety of optional platform configurations using the same beam  200 . 
       FIGS. 7A-C  illustrate optional platform configurations according to embodiments of the disclosure.  FIG. 7A  illustrates a configuration for an edge portion of a staging assembly. Similar to  FIG. 6 , a support plate is secured to a beam  200  with at least two channel nuts in two adjacent bottom channels. Since the beam  200  is supporting an outer edge of the staging assembly, it needs to support one or more platforms in only one direction. Thus, platform  803  is secured to beam  200  with one or more attachment node assemblies  323  in a single, outer top channel of the two top channels. Here, the outer top channel is the left top channel. Positioning and securing platform  803  with the outer channel, provides a flush outer edge of the staging assembly. Since the illustrated staging section represents an outer edge, only one lateral brace is attached to the support assembly. This leaves one or more connectors  570  unengaged. Since the connectors can slide around the circumference of the support assembly column, connector  570  can be slid, and optionally secured, underneath platform  803  to maintain the flush outer edge of the staging assembly. 
       FIG. 7B  illustrates a configuration for an intermediate portion of a staging assembly.  FIG. 7B  is similar to  FIG. 6  where a single beam  201  supports platforms  803 ,  804  in opposing directions. Platform  803  is secured to beam  201  with at least attachment node assembly  324 , while platform  804  is secured to beam  201  with at least attachment node assembly  325 . The configuration of  FIG. 7B  can be utilized in an intermediate edge position or in a central position in a staging assembly. The relationship between the configurations of  FIGS. 7A-B  is illustrated in  FIG. 7C . 
       FIG. 7C  illustrates a cross-section of a staging assembly that is two platforms in width and involves three support beams  200 ,  201 ,  202 . The left edge of the staging assembly utilizes the configuration of  FIG. 7A . The center support is the configuration of  FIG. 7B . The right edge of the staging assembly utilizes a configuration that is a mirror opposite of that of  FIG. 7A . For example, platform  804  is supported by attachment node assemblies secured to the outer, right top channel of beam  202 . The cross-section of  FIG. 7C  can be either an edge of a staging assembly or a cross-section taken from an intermediate position of the staging assembly (e.g., at the middle of the stage). Because the top and bottom channels run the length of the support beams  200 ,  201 ,  202 , support plates are not required to attach directly under attachment nodes. The top and bottom support components can attach at any position along the beams so long as the resulting staging assembly is structurally supported to satisfy any applicable safety regulations. The assembly of a staging portion is further discussed below. 
     As discussed above, assembly of the staging system requires minimal tools and components. A method of such assembly is illustrated in  FIG. 8 , where a section of a modular staging system is erected. In an embodiment, the components involved in a single staging section include two support beams, four attachment node assemblies, four support assemblies, two lateral braces, and one platform. The two beams each have a top surface and a bottom surface, the top surface having at least one top channel along the length of the beam. The cross-section of the channel has a horseshoe shape with a first width at the top surface being smaller than a second width of the channel located within the beam. Similarly, the bottom surface has at least one bottom channel along the length of the beam. The cross-section of the bottom surface channel also has a horseshoe shape with a first width at the bottom surface being smaller than a second width of the channel located within the beam. 
     To assemble the staging section, one or more attachment nodes are secured in a top channel of each of the beams  810 . Here, two attachment node assemblies are secured to each of the two beams. To secure an attachment node assembly a node nut is rotated until it contacts a node washer. The node nut is then inserted into the beam channel, with the attachment node located above the beam/channel. The entire assembly is then slid along the channel to a desired location on the top of the beam. Once in position, the attachment node is rotated until the node nut contacts both sides of the channel and the attachment node is seated on the top surface of the beam. Thus, the attachment node assemblies can be secured by hand. For this configuration, the attachment node assemblies are positioned at each end of the respective beams. 
     Next, the support assemblies are secured to a bottom channel of each of the beams  820 . In this embodiment, two support assemblies are secured to each of the two beams. Each support assembly involves a column with a support plate secured to the top and a foot or ground support piece at the opposing end. On the column are two pluralities of connectors positioned at two different heights, measured from the ground. The support plate includes one or more channel nuts, where each nut is connected to a spring-loaded bolt. One or more channel nuts are aligned with one or more bottom channels. A channel nut is then inserted into the channel by depressing the spring-loaded bolt. The bolt, and corresponding channel nut is rotated in the channel such that when the bolt is released, the channel nut rests in the channel on the edges, or lip, formed by the narrower channel opening. Engagement of the spring-loaded bolts can be performed with a single tool, e.g., a ball nose allen wrench. The support assemblies can be positioned at any point along the bottom channel. However, in the present embodiment, the two support assemblies attached to the second beam are located in positions corresponding to the support assemblies attached to the first beam. Similar to positioning the attachment node assemblies, a template, a measuring device such as a tape measure, or predetermined markings on the beam can be used to position the support assemblies. 
     With the support assemblies attached, the two beams are placed in an upright position, resting on the support assemblies. The two beams are aligned with their support assemblies opposing each other, and lateral braces are attached between the two sets of opposing support assemblies  830 . The lateral braces are attached to a first set of connectors located at a first height on the support assembly column. The lateral braces are connected at each end to a support assembly connector. As discussed above, a variety of fasteners may be used; however, attaching the lateral braces with a pin on each end reduces the number of tools needed for the overall staging assembly process. With the lateral braces secured in place, the staging understructure is freestanding. The height of each of the support assemblies can be adjusted to level the understructure and provide a level top surface for the assembled staging section. The platform is then positioned on the attachment nodes  840 . Depending on the height adjustment mechanism, the height of the staging section can be adjusted before, or after, the platform is positioned. 
     In addition to the lateral bracing, diagonal bracing can provide additional support to the staging section. In the above embodiment eight diagonal braces, two on each support assembly can further stabilize the staging section. A first diagonal brace can connect the lateral brace with the support assembly. As discussed above, a second plurality of connectors at a second height, usually lower than the height of the first set of connectors, is used to attach diagonal bracing. To decrease the number of tools involved in assembly, the lateral braces can have two diagonal braces pre-attached. Thus, once the lateral braces are secured, a diagonal brace can be rotated into position and attached with a pin to a connector (of the second set) on the support assembly. 
     A second diagonal brace can connect the same support assembly with a connector of the second set to the support beam using a support plate similar to that of the support assembly. The diagonal brace support plates can be secured to the beam when the support assemblies are secured since the diagonal brace support plates secure with the same mechanism (e.g., channel nuts with corresponding spring-loaded bolts). They can also be positioned with templates, individual measurements, or predetermined markings on the beam. When diagonal braces are pre-attached to the support beams, once the understructure is free-standing the diagonal braces can be rotated into position and attached to a connector with a pin, similar to the first diagonal brace. Since connection of the diagonal brace support plate involves the same tool(s) as connection of the support assemblies, no additional tools are required when diagonal bracing is utilized. 
     In addition to the above embodiment, the staging system can be arranged in a variety of configurations. For example, a single support beam can include two parallel top channels. One of the channels can be used to position and support a first platform, or set of platforms, while the second channel can be used to position and support a second platform, or set of platforms. The parallel channels are used to align adjacent platforms. Thus, the final stage area is determined by the number and sizes of the platforms used. 
     The modular staging system may be used with various accessories and devices. For example, seating, hand railings, stairs, risers, bridging, canopies, foot rails, signage, and other accessories may be suitably arranged at any desirable location on the staging system. These accessories may be attached to the platforms, support assemblies, or to other components attached to the staging system. 
     Unless otherwise indicated, all numbers expressing quantities, measurement of properties, and so forth used in the specification and claims are to be understood as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and claims are approximations that can vary depending on the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the present application. Not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, to the extent any numerical values are set forth in specific examples described herein, they are reported as precisely as reasonably possible. Any numerical value, however, may well contain errors associated with testing or measurement limitations. 
     It is to be understood that even though numerous characteristics of various embodiments have been set forth in the foregoing description, together with details of the structure and function of various embodiments, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts illustrated by the various embodiments to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.