Patent Application
20150033661
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.
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.
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.
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
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
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
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
The perspective view of
The attachment of a support plate 510 to a beam 200 is further illustrated in the portion of an assembled staging section of
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.
As discussed above, assembly of the staging system requires minimal tools and components. A method of such assembly is illustrated in
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.
