US20240271431A1

US20240271431A1 - Elevated flooring system and components thereof

Info

Publication number: US20240271431A1
Application number: US18/436,163
Authority: US
Inventors: Perry Allison Armstrong; Nathaniel J. Brancato; Weimin LIANG; Li Tian
Original assignee: Individual
Current assignee: Liri Architecture Technology Guangdong Co Ltd; Liri Tent Us LLC
Priority date: 2023-02-10
Filing date: 2024-02-08
Publication date: 2024-08-15

Abstract

An elevated flooring system having plurality of beams configured to support a respective portion of at least one flooring panel, and at least one saddle configured to support the at least one of the beams. The saddle has a generally horizontally oriented base plate with an alignment post extending generally vertically upwardly from the base plate. The beam has an alignment passage extending through a portion of the bottom of a first end of the beam, wherein the alignment passage is configured to receive a portion of the alignment post of the saddle such that a portion of the beam rests on a portion of the base plate. A method of installing the elevated flooring system includes lowering a first beam and a second beam onto the alignment post of a saddle such that respective portions of the alignment post are received by the alignment passage of the first beam and the alignment passage of the second beam.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority to U.S. Provisional Application Ser. No. 63/444,871, filed Feb. 10, 2023, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to tent and flooring support structures, and more specifically to an elevated flooring structure configured to support an elevated floor and/or a clearspan tent.

2. Description of Related Art

Modular tent/deck support structures designed for frequent assembly and disassembly are generally known in the art. Conventional structures of this type include an understructure consisting of upright legs spaced apart at standard distances with interconnecting structural beams, one or more deck panels supported by the understructure, and connector elements for supporting and securing a tent structure, all of which collectively can be attached together to make a unitary structure. Many of these structures can be difficult to assemble and disassemble due to the configuration and/or number of pieces used to provide a sturdy platform.

BRIEF SUMMARY OF THE INVENTION

The present application is directed to an elevated flooring system. In one embodiment, the flooring system includes at least two support beams configured to support a portion of at least one flooring panel, and at least one saddle configured to support a respective first end of each of the at least two support beams. The saddle has a base plate with an alignment post extending upwardly from the base plate. Each support beam has a respective first alignment passage extending through a portion of the bottom of a first end of the beam. The alignment post is configured to be partially received by the first alignment passage of each one of the at least two support beams such that a portion of each support beam rests on a portion of the base plate.
In some embodiments, the alignment post is configured to guide the at least two support beams into close contact with each other when the alignment post is received by respective first alignment passages of each of the at least two support beams. In some embodiments, each one of the at least two support beams may include a first beam aperture, and the saddle may comprise a first saddle aperture for each one of the at least two support beams. In such embodiments, each first beam aperture and each first saddle aperture may be respectively positioned such that, when the alignment post is received within a respective alignment passage, the first beam aperture and the first saddle aperture are coaxially aligned. A fastener can be positioned through the beam aperture and saddle aperture to removeably lock the saddle and support beam together.
In one embodiment, the at least two support beams include a first support beam and a second support beam. The respective first alignment passages of the first support beam and the second support beam can be configured to receive respective first and second sides of the saddle post so the first and second support beams can be substantially aligned at their respective first ends and positioned in close contact relative to one another.
In a further embodiment, the first alignment passage of each support beam extends upward from the bottom of its respective support beam a distance between approximately one-quarter and approximately three-quarters of the height of the beam. In an embodiment, each respective first alignment passage extends a distance of approximately half the height of the beam.
In yet another embodiment, each of the at least two support beams includes a first end wall extending downward from the top of the beam along at least an upper portion of the first end. The first end wall may be formed by an end cap inserted into the end of the beam. A lower portion of the first end wall of each support beam partially defines the first alignment passage. In some embodiments, an upper portion of the alignment post may have a guide portion with a retaining recess, where the lower portion of the first end wall is configured to be received in the retaining recess in close engagement when the beam engages the alignment post. Such engagement can be abutting or may leave room for factors including engineering tolerances or thermal expansion. The upper portion of the alignment post may further have a guide section configured to direct respective first ends of the first and second support beams into the retaining recess when the alignment post is received by respective first alignment passages of each of the at least two support beams. The alignment guide may be configured to receive at least a portion of the first end wall of each support beam. In an embodiment, the holding recess has substantially vertical side walls and the guide section has opposing sloped side walls. The alignment guide may be a notch or groove in the top of the post and may include angled walls extending inwardly and downwardly along each side of the guide to facilitate sliding each end wall into position within the notch or groove. The retaining recess can be generally configured to allow upward travel of each one of the at least two support beams when the respective beam engages the alignment post so the support beams may be installed and removed from the saddle with relative ease while achieving alignment and stability in the floor support plane.
In another embodiment, the base plate may be generally in a horizontal orientation, the alignment post may be generally in a vertical orientation, and the alignment post may be generally oriented perpendicular to the base plate.
The alignment guide may be a notch or groove in the top of the post and may include angled walls extending inwardly and downwardly along each side of the guide to facilitate sliding each end wall into position within the notch or groove.
In another embodiment, a floor panel is provided for use in an elevated flooring system wherein the floor panel has a frame constructed from frame beams connected to one another to define an enclosed frame. Each of the frame beams includes at least one channel extending along an inward facing side of the frame beam configured to retain one or more fastener components for securing the frame beams together. The at least one channel may have a c-shaped cross-section with an opening extending along the inner side of the frame beam. In some embodiments, the frame beams include at least two parallel channels extending along the inward facing side of the frame beams one above the other wherein each of the channels is configured to retain one or more fastener components for securing the frame beams together. The floor panel may additionally include corner brackets secured by fasteners along the inward facing sides of adjacent frame beams at each of the corners of the floor panel frame where the frame beams interface to secure the frame beams together. In this embodiment, the channels in the frame beams are configured to receive fastener components that secure the corner brackets to the frame beams. The floor panel may additionally include supports extending between the frame beams within the frame to support one or more floor boards. The frame beams may also include an outward flange configured to support a portion one or more floor boards.
In a further embodiment, the frame beams may additionally or alternatively include a utility channel along the outward facing side of the frame beams configured to receive fasteners for accessories or portions of accessories for use with the flooring system, such as railing, skirting, signage, lighting, speakers, and the like. The utility channel may include upper and lower engagement passages into which portions of fasteners or portions of the accessories may be received to hold the accessories in place along the length of the channel.
In another embodiment, the elevated flooring system may include at least one filler beam secured in abutting contact with one of the support beams. The filler beams may include a utility channel along the outward facing side of the filler beam as discussed above. The filler beams may also include one or more stability channels on the inward facing side of the filler beam to provide support to the beam. In one embodiment the flooring system includes filler beams and frame beams that have the same cross-sectional configuration.
The present invention is also directed to the components of the flooring system discussed above including the support beams, saddle, floor frames and filler beams, as well as to methods for assembling and using the same. In one embodiment, a method of assembling an elevated flooring system includes providing a plurality of saddles and providing a plurality of support beams, each saddle having a base plate and an alignment post extending upwardly from the base, and each support beam having a first end and a respective first alignment passage extending through a portion of the bottom of the first end. The method further includes the steps of installing the plurality of saddles in a substantially horizontal plane above a support surface and installing a first beam of the plurality of support beams on a first saddle of the plurality of saddles. The first beam may be installed on the first saddle by lowering the first end of the first support beam onto the first saddle so that the alignment post of the first saddle is partially received by the first alignment passage of the first support beam and a portion of the first support beam rests on a portion of the base plate of the first saddle.
In an embodiment, the first support beam further includes a second end with a respective second alignment passage extending through a portion of the bottom of the second end. The first beam may be further installed on the second saddle by lowering the second end of the first support beam onto the second saddle such that the alignment post of the second saddle is partially received by the second alignment passage of the first support beam and a portion of the first support beam rests on a portion of the base plate of the second saddle. In another embodiment, a second support beam may be installed on the first saddle by lowering the first end of the second support beam onto the first saddle such that the alignment post of the first saddle is partially received by the first alignment passage of the second support beam and a portion of the second support beam rests on a portion of the base plate of the first saddle. In a further embodiment, the first and second beams may be installed on the first saddle such that substantially a first half of the alignment post of the first saddle is received by the first alignment passage of the first support beam and substantially the second half of the alignment post of the first saddle is received by the first alignment passage of the second support beam. The first beam, the second beam and alignment post of each saddle may include respective apertures adapted to receive a fastener to secure the beams to their respective saddles.
The structure of the present invention is particularly well adapted to be adjusted for standing on uneven ground, and has a relatively small number of parts to reduce the complexity and increase the ease with which the structure can be assembled and disassembled (or partially disassembled). The configuration of the structure also allows for relatively easy access through the center of the structure (such as with a crane or forklift) to place tent frame elements.
Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a tent and elevated flooring system in accordance with an embodiment of the invention;

FIG. 2 is a perspective of a flooring structure of the tent and elevated flooring system of FIG. 1 with the tent structure removed;

FIG. 3 is a perspective of the flooring structure of FIG. 2 with floor panels removed;

FIG. 4 is a fragmentary perspective of the flooring structure of FIG. 2 with floor panels and filler beams removed therefrom, showing a portion of the scaffold, an end saddle, a portion of a universal beam, an end beam and an upright connector;

FIG. 5 is a fragmentary lower perspective of the flooring structure of FIG. 2 with floor panels and filler beams removed therefrom, showing a portion of the scaffold, an end saddle, a portion of a universal beam, an end beam and an upright connector;

FIG. 6 is a fragmentary side elevation of the flooring structure of FIG. 2 with floor panels and filler beams removed therefrom, showing a portion of the scaffold, a standard saddle, a portion of a first universal beam and a portion of a second universal beam, with end portions of the first universal beam and the second universal beam being broken out;

FIG. 7 is a fragmentary section of the flooring structure with floor panels and filler beams removed therefrom taken through the line 7-7 of FIG. 6 ;

FIG. 8 is an exploded side elevation of an upper portion of the fragmented flooring structure shown in FIG. 6 with floor panels and filler beams removed therefrom;

FIG. 9 is an exploded lower perspective of an upper portion of the fragmented flooring structure shown in FIG. 6 with floor panels and filler beams removed therefrom;

FIG. 10 is an exploded upper perspective of an upper portion of the fragmented flooring structure shown in FIG. 6 with floor panels and filler beams removed therefrom;

FIG. 11 is a perspective of the standard saddle for a flooring structure in accordance with an embodiment of the invention;

FIG. 12 is a lower perspective of the standard saddle of FIG. 11 ;

FIG. 13 is a side elevation thereof;

FIG. 14 is a perspective of the end saddle for a flooring structure in accordance with an embodiment of the invention;

FIG. 15 is a perspective of a universal beam for a flooring structure in accordance with an embodiment of the invention;

FIG. 16 is an end elevation of the universal beam of FIG. 15 ;

FIG. 17 is a broken side elevation thereof;

FIG. 18 is a broken section thereof, taken through the line 18-18 of FIG. 16 ;

FIG. 19 is a perspective of an end beam for a flooring structure in accordance with an embodiment of the invention;

FIG. 20 is a section of the end beam of FIG. 19 through its center plane;

FIG. 21 is an enlarged fragmentary view of a gable end of the tent and elevated flooring system of FIG. 1 showing a railing, a filler beam, a flooring spacer, a universal beam and an end beam;

FIG. 22 is an enlarged fragmentary view of a side of the tent and elevated flooring system of FIG. 1 showing a portion of an end beam, a filler beam, a flooring spacer, a bolt and an upright connector;

FIG. 23 is a perspective of an end filler beam for a flooring structure in accordance with an embodiment of the invention;

FIG. 24 is an enlarged fragmentary view of an eave end of the tent and elevated flooring system of FIG. 1 showing a railing and a floor panel;

FIG. 25 is an exploded perspective of a floor panel for a flooring structure in accordance with an embodiment of the invention;

FIG. 26 is a plan of a floor panel frame of the floor panel of FIG. 25 ;

FIG. 27 is an enlarged section of the floor panel frame of FIG. 26 , showing a floor panel beam, a modified L-bracket and fasteners; and

FIG. 28 is an enlarged section of the floor panel frame of FIG. 26 , showing a floor panel beam, a cross structure with angle brackets, and fasteners.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Aspects of the technology described herein will become more apparent with reference to the figures provided herein. A tent and elevated flooring system in accordance with an exemplary embodiment of the invention described and claimed herein is identified generally as 100 in FIG. 1 . The tent and elevated flooring system 100 includes a flooring structure 102 and a tent structure 104 attached thereto. Referring now to FIGS. 2-3 , the flooring structure 102 includes a scaffold (or understructure) 106, a network of universal beams 120 and end beams 140 (collectively “support beams”), that may each be secured to an upper portion of the scaffold 106 via one or more standard saddles 160 and/or end saddles 190 (collectively “saddles”), a plurality of floor panels 112, 113 which may be supported by the support beams 120, 140 (as described in further detail below), a plurality of filler beams 200 that may be secured to the outermost of the support beams 120, 140, and a plurality of upright connectors 116 a, 116 b that may be spaced apart along the perimeter of the flooring structure 102 and supported by support beams 120, 140. As shown in FIGS. 1-2 , connectors 116 a are configured to support upright beams along the gable ends of the tent structure 104, while connectors 116 b are configured to support upright beams along the eave ends of the tent structure 104. In the embodiment shown in FIGS. 1-3 , the flooring structure 102 includes four lengthwise sections S, each being defined by a pair of successive end beams 140 on a first (“near”) end of the structure, a pair of successive end beams 140 on a second (“far”) end of the structure opposite the first end, four pairs of successive universal beams 120 arranged in line between respective end beams 140, ten floor panels 112 and one narrow floor panel 113 disposed between the parallel rows of beams.
It should be appreciated that a different number of panels and/or beams can be used to define sections of different sizes to increase or decrease the surface length of some or all of the flooring structure of alternative embodiments Likewise, as will be described in greater detail herein, panels and/or beams of differing lengths can be used to define sections of different sizes. Additionally, it should be appreciated that a differing number of lengthwise sections (i.e., fewer or more than four) can be utilized to increase or decrease the surface width of the flooring structure of alternative embodiments. Moreover, the width of the panels and spacing between successive beams can be changed to provide further variation in the surface width of the flooring structure in other embodiments of the present invention. While the flooring structure 102 shown in FIGS. 1-3 is generally square in shape, (in an exemplary embodiment measuring 10 m×10 m square) including four parallel sections S, it is contemplated that other embodiments of the present invention may have flooring structures with different combinations of sections that may vary substantially in shape, size and orientation.
Still referring to FIGS. 1-3 , while the upright connectors 116 a, 116 b are adapted to support structural elements of the tent structure 104 of FIG. 1 , it is contemplated that other types and/or configurations of connectors may be used with the flooring structure of the present invention to support one or more tent structures or other accessories without departing from the scope of the invention. In addition, the upright connectors may be omitted if an elevated flooring structure is desired without a tent.
Referring now to FIG. 3 , the scaffold 106 of flooring structure 102 includes a grid of upright legs 108 and horizontal posts 110 that are interconnected with ring connectors 111. As is conventional, it is contemplated that legs 108 may have varying heights or be height-adjustable to account for uneven terrains on which the tent and flooring system 100 may be installed. Each leg 108 has an opening in its upper end that is configured to receive a standard saddle 160 (see FIG. 6 ) or an end saddle 190 (see FIG. 4 ), depending on the position of the leg. In particular, the legs 108 located closest to the near end of the flooring structure 102 and the legs located closest to the far end of the flooring structure 102 support end saddles 190, while the remaining legs support standard saddles 160. In alternative embodiments, it is contemplated that some or all of the flooring structure may sit near ground level, obviating the need for one or more of the legs 108. In such case, one or more of the saddles 160, 190 may be installed on a ground-level plate or directly on the ground without departing from the scope of the invention.
Referring to FIGS. 6 and 11-13 , each standard saddle 160 includes a stem 162, a generally horizontal base plate 164 that is secured to the stem 162, and a saddle post 166 (or “alignment post”) that is secured to and extends generally vertically upward from the base plate 164. In the shown embodiment, the base plate 164 and the saddle post 166 are approximately perpendicular. It is contemplated that the base plate 164 and saddle post 166 may be oriented at different angles in other embodiments. Stem 162 is configured to be received within the opening at the top of leg 108. As is shown in FIG. 12 , each base plate 164 may include one or more receptacles 168 configured to securely receive a portion of a corresponding saddle post 166, such as the illustrated prongs 170. Referring again to FIGS. 11-13 , it is contemplated that the saddle post 166 is an upstanding plate that is configured to fit in the saddle post passages 138 (see FIGS. 9 and 10 —further features of which will described herein) of the support beams 120 or 140 when the beams are installed on the standard saddle 160. An upper-central portion of the saddle post 166 includes a cut-out recess that defines a guide 172 (or “alignment interface”) configured to receive an end plate 130 (see FIG. 10 ) located on either end of the beam to align the beam in a relatively precise horizontal position relative to the saddle 160, as will be described in further detail below. The guide 172 includes an upper region defined by two opposed sloped surfaces 174 and a central lower region defined by two generally vertical opposed surfaces 176 and a horizontal bottom surface 178. Sloped surfaces 174 extend outwardly and upwardly at about a 45-degree angle from the top edge of corresponding vertical surfaces 176 to the top surface of the saddle. A lower portion of the saddle post 166 includes two fastener apertures 180, one on each side of the post. As best seen in FIGS. 11-13 , the stem 162 and saddle post 166 are positioned generally along the center of the base plate 164 in the illustrated embodiment.
Referring to FIGS. 4-5 and 14 , each end saddle 190 is configured with the same features as the standard saddle 160 except that the end saddle 190 includes an elongated base plate 194 (instead of a base plate 164) with an elongated end 195, and a Y-shaped bracket 197 extending between and connecting the elongated end 195 to stem 162. The elongated base plate 194 is configured to support an end beam 140 (and, optionally, an upright connector 116 a, 116 b above the end beam) above the elongated end 195 and a universal beam 120 above an end opposite the elongated end. The stem 162 and saddle post 166 are located off-center along the length of the elongated base plate 194, farther from the elongated end 195 than the opposite end.
Referring now to FIGS. 15-18 , each universal beam 120 includes an elongated rectangular shaped tube 122 with a proximal end 124 and a distal end 126, outwardly extending support angles 128 secured to opposing sides of the tube, and an end plate 130 and end spacers 132 secured in the proximal and distal ends of the tube. Two slots 134 (generally, openings) are located on the bottom of the tube 122 coincident with the proximal end 124 and distal end 126. Each end 124, 126 includes aligned apertures—namely, tube apertures 136 and end spacer apertures 137—on opposing sides of the tube 122 above the slot 134. The aligned apertures 136, 137 are configured to receive a fastener 182 as shown in FIGS. 7 and 9 . At each end 124 or 126 of the tube 122, two end spacers 132 are attached internally to the base of the tube on opposing sides of a respective slot 134, and a notched end plate 130 is attached to the respective end of the tube 122 adjacent the end spacers 132. Together, the slots 134, the end plates 130 and the end spacers 132 define a saddle post passage 138 (generally, an “alignment passage”) at each end 124, 126 of the universal beam 120. The saddle post passages 138 are generally dimensioned to receive and secure portions of respective saddle posts 166 when the universal beam 120 is installed on saddles 160 or 190, as will be described herein. The support angles 128 of the universal beam 120 are configured to support portions of the floor panels 112, 113 and/or filler beams 200, as is generally seen in FIGS. 1-2 . It will be appreciated that universal beams can be supplied in varying lengths (e.g., in 2.0 m, 2.5 m, and 3.0 m dimensions) to allow for flooring structures of varying lengths to be constructed using predetermined combinations of beams. As is generally shown in FIGS. 1-2 , floor panels such as the illustrated panels 112, 113 may be provided in similarly varying lengths to produce a floor surface of commensurate length.
Referring now to FIGS. 19-20 , each end beam 140 is substantially shorter in length than a universal beam 120 but includes substantially similar features: a tube 142 with ends 146, 148, slots 134 and apertures 136, 137, support angles 148, end plates 130 and end spacers 132. In reference to FIGS. 1-5 , it is contemplated that an upright connector 116 a or 116 b can be secured to the top of any end beam 140 as is known in the art such that the beam and corresponding upright connector can be placed at a predetermined location in the flooring structure 102 to support a corresponding element of the tent structure 104. The end beams 140 may be supplied in varying lengths or in a universal length (e.g., 0.25 m) to allow for flooring structures of varying lengths to be constructed using predetermined combinations of beams.
As is generally shown in FIGS. 6-10 , in the shown embodiment it is contemplated that a user may install up to two universal beams (120 a and 120 b, for illustrative purposes) on any of the standard saddles 160 by placing an end (124 or 126) of a first universal beam 120 a with a corresponding saddle post passage 138 generally above the saddle post 166 of the selected standard saddle. The user may then lower the first universal beam 120 a onto the saddle post 166 such that the notched portion of the end plate 130 engages the guide 172 and is directed downward along one of the sloped surfaces 174 generally toward the center of the guide. As is best seen in FIGS. 6-7 , the first universal beam 120 a may be lowered onto the standard saddle 160 until the bottom of the tube 122 rests on base plate 164 and approximately half of the saddle post 166 is surrounded by the end of the first universal beam. Then, the user may align the apertures 136, 137 of the universal beam 120 a with a corresponding fastener aperture 180 in the saddle post 166 and subsequently insert a fastener 182 (e.g., a pin or a bolt) through the aligned apertures. It will be appreciated that a second universal beam 120 b may be installed opposite the first universal beam 120 a on the same standard saddle 160 with a fastener 182 in a like manner, either before, simultaneous with or after the installation of the first universal beam 120 a, to surround substantially all of the saddle post 166. In this manner, the beams 120 a and 120 b are secured in abutting or near-abutting engagement and in alignment with each other.
As is generally shown in FIGS. 4-5 , a user may install one universal beam (120 c) and one end beam (140 a) on an end saddle 190 in a like manner. In the shown embodiment, it is preferred that the end beam 140 a be placed above the bracket 197 for improved support. As shown in FIGS. 4-5 , an upright connector 116 b is secured to the end beam 140 a, necessitating the installation of the universal beam 120 c before the end beam 140 a.
In the illustrated embodiment, it will be appreciated that each universal beam 120 is configured to interface with and be supported by one saddle (either a standard saddle 160 or an end saddle 190) at each end 124, 126. It will further be appreciated that each end beam 140 is configured to interface with and be supported by a single end saddle 190. It will further be appreciated that each standard saddle 160 and end saddle 190 is capable of supporting a single beam that is configured to receive the entire saddle post 166. In some embodiments, a single saddle structure (e.g., standard saddle 160) may be used uniformly across the flooring system 102 to support all universal beams 120 and end beams 140.
Referring now to FIGS. 2-3 and 21-23 , the flooring structure 102 includes a plurality of filler beams 200, which are installed adjacent the outermost row of universal beams 120 and end beams 140 on either side of the structure. The filler beams 200 are configured to provide enhanced support for railings 114 (FIG. 1 ), as will be described in further detail herein, or for other components or accessories that may be provided along the outer edges of the structure. Each filler beam 200 may be configured to be secured in abutting engagement with one or more universal beams 120 or end beams 140. As an illustrative example, the filler beam 200 shown in FIGS. 21 and 22 is approximately the same length as a combination of one universal beam 120 and one end beam 140 and may be installed adjacent said universal beam 120 and said end beam 140 when the beams are installed on the flooring structure 102. Specifically, a bottom of the filler beam 200 rests on the respective support angles 128 of the universal beam 120 and the end beam 140 and an interior side of the filler beam 200 rests against an outwardly facing side of the tube of the beam. The filler beam is secured to the beams 120 and 140 in this position with a plurality of bolts 260.
As best seen in FIGS. 22-23 , each filler beam 200 of the shown embodiment includes a generally rectangular tubular structure with walls that define a central channel 204, an upper (or outward) flange 206, a utility channel 208 with upper and lower insert regions 210, and four stabilizing channels 212 a, 212 b, 212 c and 212 d arranged vertically opposite the utility channel 208. The upper flange 206 protrudes generally upward from the central channel 204 above the utility channel 208 to define a receiving cavity for a flooring spacer 240 that can be installed therein to extend the surface of the flooring structure 102 and provide enhanced support for structures installed on the upright connectors 116 a or 116 b located along the side edges of the system 100, such as the tent structure 104 shown in FIG. 1 . The stabilizing channels 212 a, 212 b, 212 c and 212 d are configured and collectively arranged to distribute loads and reduce torsion and strain in the filler beam 200 caused by lateral and vertical loads—e.g., when supports 115 are used to connect the rails 114 to the filler beam for additional support, as can be seen in FIG. 21 .
The stabilizing channel 212 a is the uppermost of the channels and includes an opening that faces generally outward from the filler beam 200 opposite the central channel 208. The channel 212 a is defined by a reinforced upper wall 214, an upper flange 216 protruding therefrom, an upper portion of the wall 218 that partially defines the central channel 204, a first intermediate wall 220 that divides the channels 212 a and 212 b, and an upper portion of a first intermediate flange 222 protruding from the first intermediate wall 220. The channel 212 b is defined by the first intermediate wall 220, a lower portion of the first intermediate flange 222, a middle portion of the wall 218, a second intermediate wall 224 that divides the channels 212 b and 212 c, and an upper portion of a second intermediate flange 226 protruding from the second intermediate wall 224. The channel 212 c is defined by the second intermediate wall 224, a lower portion of the second intermediate flange 226, a lower portion of the wall 218, a side portion of a lower reinforcement wall 228 that divides the channels 212 c and 212 d, and an upper portion of an inside wall 230 that is aligned with the flanges 216, 222 and 226. The channel 212 d is oriented perpendicular to the other channels 212 a-212 c but is configured with a similar geometry and size in the illustrated embodiment. The channel 212 d is defined by a portion of a bottom wall 232 of the filler beam 200, a vertical portion and a horizontal portion of the lower reinforcement wall 228, a lower portion of the inside wall 230, and a lower flange 234 joined perpendicularly to the inside wall 230.
As seen in FIG. 22 , each of the channels 212 a-212 d has a generally rectangular C-shaped cross sectional configuration that permits elongate objects (e.g., fastener heads) to be slid in from either end of the filler beam 200 and securely held in place. Further, the channels 212 a-212 d are aligned with one another to define a vertically oriented inner wall that rests in abutting engagement with a side of one or more beams (e.g., universal beams 120 and end beams 140).
Referring again to FIGS. 22-23 , the utility channel 208 of each filler beam 200 is configured with upper and lower flanges 236 that partially define retention passages 238. It will be appreciated that clips or other structures may be received and/or supported in one or both of the retention passages 238. As a first non-limiting example, FIG. 21 shows a support 115 for the railing 114 that is configured to be inserted into the utility channel 208 for support such that channels 212 a-212 d distribute loads transferred from the railing 114. As a second non-limiting example, an apparatus for retaining and supporting a screen, drape or skirt (not shown) can be inserted into the utility channel 208 to simplify the process of covering the scaffold 106 (shown generally in FIGS. 1-3 ). It is contemplated the utility channels 208 can be used with a variety of other structural, ornamental, or other equipment.
Referring now to FIGS. 24-28 , each floor panel 112 includes a floor panel frame 270 configured to support a walking platform 290 (e.g., a plate or board) that can be laid and/or secured in place. Four floor panel beams 272 are arranged to define an exterior of the floor panel frame 270. In the present embodiment, it is contemplated that the floor panel beams 272 have substantially the same structure and cross-sectional configuration as the filler beams 200, including stabilizing channels 212 e, 212 f, 212 g and 212 h, upper flanges 206 a and utility channel 208 a. The floor panel beams 272 are fastened together with modified L-brackets 274 (generally, corner brackets) in each corner of the frame 270 via the stabilizing channels 212 e-212 h, as will be described herein. The floor panel frame 270 further includes internal cross structures 280 which are fastened to the floor panel beams 272 and provide additional stability for the frame and support for the walking platform 290. The cross structures 280 include a primary beam 282 and several secondary beams 284, each having vertically oriented angle brackets 286 on their ends for fastening to the stabilizing channels 212 e-212 h, as will be described herein.
In the floor panel frame 270 shown in FIG. 25 , utility channels 208 a are arranged such that they face outward, while the stabilizing channels 212 e-212 h generally face inward. Further, the upper flanges 206 a are disposed around the exterior of the floor panel frame 270 such that they may surround the walking platform 290. It will be appreciated that the outward positioning of the utility channels 208 a on each floor panel frame 270 simplifies the arrangement and placement of floor panels on a flooring structure. Specifically, this configuration ensures that a utility channel 208 a will generally be exposed on an edge of the structure no matter the quantity or orientation of individual floor panels 112. Thus, it is contemplated that structural, ornamental or other equipment may be installed on an outermost utility channel 208 a of a flooring structure at its near and far ends in substantially the same way as described in connection with the filler beams 200 placed on the outermost beams 120, 140 (discussed in connection with FIGS. 21-23 ).
Referring now to FIGS. 26-27 , the floor panel beams 272 are secured together using the modified L-brackets 274 and a plurality of floor panel fasteners 276 (for example, T-bolts) that can be slid into the support channels 212 e-212 g and subsequently fastened in place (for example, by placing nuts on the respective T-bolts). As is seen in FIG. 28 , it will be appreciated that the angle brackets 286 of the cross structures 280 may be similarly fastened to the floor panel beams 272. In the illustrated embodiment, the L-brackets 274 and angle brackets 286 are configured to interface with the support channels 212 e and 212 g, though it is contemplated that the same or additional elements in alternative embodiments may use a different combination of the support channels 212 e-212 h or other functionally equivalent structures. Additional fastening components, such as bolts 294, may be used with floor panel beams 272 to secure ornamental or structural features, such as the clips 292 shown in FIGS. 25-27 . It will be appreciated that narrow floor panels 113 include substantially similar components as floor panels 112 and can be assembled by a similar process.
It is contemplated that the beams 120, 140, 200 and 272 can be extruded from metal such as aluminum. As discussed above, filler beams 200 and floor panel beams 272 may be extruded from metal such as aluminum having the same cross-sectional configuration.
In use, the tent and elevated flooring system 100 can be incrementally assembled and/or disassembled. For example, with reference to FIGS. 1-3 , in an exemplary embodiment, a user may commence the assembly process by fully constructing the scaffold 106 and saddles 160, 190, and subsequently placing a corresponding set of universal beams 120 and end beams 140 onto respective saddles to confirm the flooring structure 102 is aligned and level. After this preliminary assembly of the flooring structure 102 is completed, but before each universal beam 120 is fastened to respective saddles 160, a central region of the flooring structure can be partially disassembled with relatively ease to allow assembly equipment (not shown) to be used around the central region while roof structure 104 is installed. As an example, referring to FIGS. 1-2 , it is contemplated that several of the universal beams 120 around the longitudinal center of the flooring structure 102 (i.e., in the region generally located between gable support connectors 116 a) can be individually lifted upward and removed from corresponding saddles 160 to allow relatively quick access to a central portion of the scaffold 106.
After the individual universal beams 120 have been removed, a corresponding portion of the scaffold 106 (e.g., any upright legs 108 and horizontal supports 110, or equivalent frame elements that were beneath the beams prior to removal) can be disassembled, leaving an open space on the ground for the assembly equipment to stand upright and support an elevated portion of the tent structure 104 (for example, a crane configured to support a center portion of the ridge) while the tent structure is installed on upright connectors 116 b at the near and far ends of the partially deconstructed flooring structure 102. Finally, the assembly equipment can be removed, the central portion of the flooring structure 102 can be reinstalled, and the tent structure 104 can be completed. It is contemplated that other portions of the flooring structure 102 can be partially assembled and/or disassembled in a like manner without departing from the scope of the invention. It will further be appreciated that additional parts for the elevated flooring system, such as the filler beams 200, floor panels 112 and 113, rails 114 or cosmetic elements like a tent canopy (not shown), can be installed and/or removed at various times during the assembly process without departing from the scope of the invention.
It is contemplated that in other embodiments, one or more of the above-described features may be modified or used in varying combinations without departing from the scope of the invention. For example, in one embodiment a system may include a flooring structure 102 but no tent or upright supports. In another embodiment, a flooring structure may be positioned fully or partially around ground level (e.g., on an inclined surface) such that a user may replace one or more of the standard saddles 160 or end saddles 190 and any underlying scaffolding with a modified plate or other support that directly contacts the surface below. It will be appreciated that such a modified plate or other support can function as a saddle as described herein. Furthermore, it is contemplated that any embodiments contemplated herein can be used with additional structural equipment including straps, tethers, anchors and additional support structures.
From the foregoing it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense.
While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Claims

What is claimed and desired to be secured by letters patent is as follows:

1. An elevated flooring system comprising:

at least two support beams configured to support a portion of at least one flooring panel, each of the at least two support beams having a first end; and

a saddle configured to support respective first ends of each of the at least two support beams, the saddle comprising a base plate and an alignment post extending upwardly from the base plate;

wherein each one of the at least two support beams includes a respective first alignment passage extending through a portion of the bottom of the first end;

wherein the alignment post is configured to be partially received by the first alignment passage of each one of the at least two support beams such that a portion of each support beam rests on a portion of the base plate.

2. The elevated flooring system of claim 1, wherein the alignment post is configured to guide the at least two support beams into close contact with each other when the alignment post is received by respective first alignment passages of each of the at least two support beams.

3. The elevated flooring system of claim 1, each one of the at least two support beams further comprising a first beam aperture and the saddle further comprising a respective first saddle aperture for each one of the at least two support beams;

wherein each first beam aperture and each first saddle aperture is respectively positioned such that, when the alignment post is received within a respective alignment passage, the first beam aperture and the first saddle aperture are generally coaxially aligned.

4. The elevated flooring system of claim 3, wherein each first beam aperture and each first saddle aperture are configured to receive a fastener when coaxially aligned.

5. The elevated flooring system of claim 1, wherein the at least two support beams comprise a first support beam and a second support beam, the respective first alignment passages of the first support beam and the second support beam being configured to receive respective first and second sides of the saddle post such that the first and second support beams are substantially aligned with respective first ends and positioned in close contact relative to each other.

6. The elevated flooring system of claim 1, wherein the first alignment passage extends upward from the bottom of its respective support beam to between approximately one-quarter and approximately three-quarters of the height of the beam.

7. The elevated flooring system of claim 6, wherein the first alignment passage extends upward from the bottom of its respective support beam to approximately half the height of the beam.

8. The elevated flooring system of claim 1, wherein each of the at least two support beams includes a first end wall extending downward from the top of the beam along at least an upper portion of the first end.

9. The elevated flooring system of claim 8, wherein a lower portion of the first end wall partially defines the first alignment passage.

10. The elevated flooring system of claim 9, wherein an upper portion of the alignment post comprises a guide portion with a retaining recess, and wherein the lower portion of the first end wall is configured to be received in the retaining recess in close engagement when the beam engages the alignment post.

11. The elevated flooring system of claim 10, wherein the upper portion of the alignment post further comprises a guide section configured to direct respective first ends of each of the at least two support beams into the retaining recess when the alignment post is received by respective first alignment passages of each of the at least two support beams.

12. The elevated flooring system of claim 11, wherein the retaining recess comprises substantially vertical side walls and the guide section comprises opposing sloped side walls.

13. The elevated flooring system of claim 10, wherein the retaining recess is generally configured to restrict horizontal travel of each one of the at least two support beams when the respective beam engages the alignment post, and wherein the retaining recess is generally configured to allow upward travel of each one of the at least two support beams when the respective beam engages the alignment post.

14. The elevated flooring system of claim 1, wherein the base plate is generally in a horizontal orientation.

15. The elevated flooring system of claim 1, wherein the alignment post is generally in a vertical orientation.

16. The elevated flooring system of claim 1, wherein the alignment post is generally oriented perpendicular to the base plate.

17. A method of assembling an elevated flooring system comprising:

providing a plurality of saddles, each saddle comprising a base plate and an alignment post extending upwardly from the base plate;

providing a plurality of support beams, each support beam comprising a first end and a respective first alignment passage extending through a portion of the bottom of the first end;

installing the plurality of saddles in a substantially horizontal plane above a support surface; and

installing a first one of the plurality of support beams on a first one of the plurality of saddles by lowering the first end of the first support beam onto the first saddle such that the alignment post of the first saddle is partially received by the first alignment passage of the first support beam and a portion of the first support beam rests on a portion of the base plate of the first saddle.

18. The method of claim 17, wherein the first support beam further comprises a second end and a respective second alignment passage extending through a portion of the bottom of the second end, the method further comprising:

installing the first support beam on a second saddle by lowering the second end of the first support beam onto the second saddle such that the alignment post of the second saddle is partially received by the second alignment passage of the first support beam and a portion of the first support beam rests on a portion of the base plate of the second saddle.

19. The method of claim 17, further comprising installing a second support beam on the first saddle by lowering the first end of the second support beam onto the first saddle such that the alignment post of the first saddle is partially received by the first alignment passage of the second support beam and a portion of the second support beam rests on a portion of the base plate of the first saddle.

20. The method of claim 19, wherein substantially a first half of the alignment post of the first saddle is received by the first alignment passage of the first support beam and substantially the second half of the alignment post of the first saddle is received by the first alignment passage of the second support beam when the first and second support beams are installed.