EP1375772A1

EP1375772A1 - Foldable support structure with hinged sawtooth wall members

Info

Publication number: EP1375772A1
Application number: EP03014246A
Authority: EP
Inventors: Ralph L. Schipani; Richard K. Strayer; Mark Brauer; Walter Croll; Paul Miklautsch; Patrick M. Hamilton; Charles Austen Angell; Jennifer Dianne Astwood; Shaohui Qiu; Lee Powers; Kyle Gudmunson; Brian Clemens; Brett R. Johnson; Charles Graves
Original assignee: INTERLOCK STRUCTURES INTERNATIONAL Inc
Current assignee: INTERLOCK STRUCTURES INTERNATIONAL Inc
Priority date: 2002-06-28
Filing date: 2003-06-25
Publication date: 2004-01-02
Anticipated expiration: 2023-06-25
Also published as: CA2433764A1; ATE303479T1; DE60301448D1; EP1375772B1

Abstract

A foldable truss member suitable for commercial displays includes a plurality of side members that are adjacently hinged together. The side members include support members and bridging members having extensions. The side members are joined into a foldable structure with a hinge member between the support member and extensions of adjacent side members. The truss may include a locking frame that is removably attached to ends of the side members. A display structure may also be formed by connecting a locking frame between two truss members.

Description

PRIORITY

The present application claims the benefit of priority of the following pending United States Patent Applications: US patent application serial number 10/186,285 filed on 28 June 2002; and US patent application serial number 10/186,241 also filed on 28 June 2002 and claiming common inventorship.

FIELD OF THE INVENTION

The present invention relates to portable support structures for use in temporary structures used in, for example, trade shows and conventions, and particularly to a portable folding truss system having hinging side elements.

BACKGROUND OF THE INVENTION

Commercial displays such as those used in trade show booths require strong structures that can be easily transported and configurable in a wide variety of forms. Such structures need to be lightweight, portable, and able to be quickly set up and broken down.
Prior art solutions have utilized truss members with folding elements that utilize rigid wall members coupled with rotatable wall members. The rotatable side members allow the truss to collapse. The trusses include internal diagonal pivoting members that serve to lock the truss into an open position. Although useful in some applications, this approach has deficiencies.
Using differently designed, rigid, and rotatable wall members increases the inventory of piece parts needed to build the truss, thereby making the truss more complicated and expensive to manufacture. Also, the non-symmetry of the assembled structure (due to the non-rigidity of rotatable wall members) gives such a truss non-uniform load bearing characteristics when deployed horizontally. Therefore, if a user is not careful and/or cognizant of the requirements of a certain orientation, a structure might be deployed in an unsafe manner with potentially catastrophic results.
US Patent 5,822,945 to Muller, issued on 20 October 1998 teaches a foldable truss having three cords and webbing connecting two of the three truss cords. The one central truss cord includes hinge segments which allow the truss to occupy a closed position, in which the truss is folded for transport, and an open position, in which the truss is expanded into a triangular configuration.
Additionally, US Patent 6,149,021 to Beaulieu, issued on 21 November 2000 teaches a display system having a plurality of truss members an connection structures for connecting the truss members together. The truss members include a pair of brace members having parallel frame tubular members interconnected by fixed wire members.
The prior art solutions however, fail to provide a collapsible/foldable truss member that is strong, easily fabricated, and easily assembled into a temporary or permanent structure for a commercial display or other structural application.
Additionally the prior art solutions fail to provide a truss member that can be configured to provide horizontal support regardless of the truss member's orientation.
The prior art fails to disclose a truss assembly having a plurality of hinge members pivotally joining side members to adjacent side members, wherein the hinge members allow relative rotation with respect to the adjacent side members.
The prior art also fails to disclose truss member having locking members and locking frames adapted to prevent relative rotation of adjacent side members.
The prior art also fails to disclose hinge members configured to resist relative rotation at the deployed configuration of the truss members and hinge member providing increased friction to resist relative rotation at the deployed configuration of the truss members.
The prior art also fails to teach a hinge member able to elastically deform to resist relative rotation at the deployed configuration of the truss member.
It can be seen that there is a need for a collapsible/foldable truss member that is strong, easily fabricated, and easily assembled into a temporary or permanent structure for a commercial display or other structural application.
It can also be seen that there is a need for a truss member that can be configured to provide horizontal support regardless of the truss member's orientation. The present invention fulfills these and other needs, and addresses other deficiencies characterized by prior art implementations.

SUMMARY OF THE INVENTION

To overcome limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses a foldable truss member having a plurality of adjacently connected side members, together forming a peripheral boundary of the truss member. Each side member may include an elongated support member with a side surface, a first end, and a bridging member fixedly connected to the side surface of the support member at an attachment point of the support member.
The bridging member may have an extension at an edge of the bridge member opposite the attachment point. A plurality of hinge members may pivotally join the extension of each side member to the support member of the adjacent side member. Each hinge member may allow relative rotation of adjacent side members. The truss member may also includes a locking frame with a plurality of locking members. Each locking member may be attachable at the first end of at least two of the side members. The attached locking frame may be adapted to prevent relative rotation of adjacent side members.
Each bridging member may include a sawtooth-shaped member having a first and second set of oppositely disposed peaks. The first set of peaks may be attached to the attachment point of the associated support member. The extensions of each bridging member may be formed by the second set of peaks.
The first ends of the side members may be configured to include a recess. Each of the locking members of the locking frame may include a locking post, the locking posts may be receivable into the recesses of the side members. The locking frame can be made lockable with the first ends of the side members. In one configuration, at least one locking member of the locking frame may further include a locking hole. The first end of the associated side member further may also include a locking hole. The locking frame may be attachable with the first ends of the side members so that the locking hole of the locking member is in alignment with the locking hole of the associated side member. An elongated interference member may be passed through the locking holes of the locking member and the associated side member to prevent relative motion of the side member with respect to the locking frame.
At least one of the hinge members may be configured to resist relative rotation of the associated extension at the deployed configuration of the truss member. A hinge member may include an increased friction to resist relative rotation of the associated extension at the deployed configuration of the truss member. A hinge member may also include a feature to elastically deform the associated extension to resist relative rotation of the associated extension at the deployed configuration of the truss member.
Each hinge member may include a mounting surface and a hinge channel breaking a portion of the mounting surface. The extensions of the bridging member of the adjacent side member may be locatable within the hinge channel. The mounting surfaces may fixedly attach to the support members. The hinge channel of each of the hinge members may further include a first and second end, and the first and second ends may be flared.
In another embodiment of the present invention, a foldable truss member may include a plurality of side member means. Each side member means may have a receiving means located at a lower edge of the side member means. The side member means may be adjacently arranged so that the lower edges of the adjacently arranged side member means form a closed shape. A plurality of pivoting means may be connected between adjacently arranged side member means. The pivoting means may allow relative rotation between adjacently arranged side member means so that the side member means are foldable into a substantially flat assembly. A frame locking means may be attachable to the receiving means of the side member means to rigidly couple the side member means.
Each of the side member means may include a sawtooth-shaped member and an elongated support member. The sawtooth-shaped member may have a first and second set of oppositely disposed peaks. The first set of peaks may be fixedly attached to the support member. The second set of peaks may form hinge extensions of the side members. The hinge extensions may pivotally attach to the associated pivoting means. Each of the pivoting means may include a mounting surface and a hinge channel breaking a portion of the mounting surface. The mounting surface of each of the pivoting means may fixedly attach to the support member of each of the side member means. The hinge extension of the adjacent side member means may be locatable within the hinge channel. The hinging means may include friction means to resist relative rotation between adjacently connected side member means at a deployed configuration of the truss member. The hinging means may include elastic deformation means to resist relative rotation between adjacently connected side member means by elastically deforming a portion of the side member means at a deployed configuration of the truss member.
In one configuration, the receiving means of the side member means may be able to slidably interface with the frame locking means. A fastening means for locking and fastening the frame locking means to the receiving means of the side member means may also be provided.
In another embodiment of the present invention, a foldable display structure, may include first and second truss members. The locking frame may include a first and second side, a first set of locking members on the first side, and a second set of locking members on the second side. The locking frame may be disposed between the first and second truss members. The first set of locking members may be removably connected to the first ends of the first truss member, and the second set of locking members may be removably connected with the first ends of the second truss member.
In another embodiment of the present invention, a method of assembling a display structure may involve forming a first and second truss member by adjacently coupling a set of four side members to form a peripheral boundary for each of the truss members. Each of the side members may include an elongated edge pivotally attached to the adjacent side member. The adjacent side members may be relatively rotated about the elongated edges so that the peripheral boundaries of the truss members are substantially rectangular. A receiving edge of at least two of the side members of the first truss member may be slidably attached to a locking frame to make the first truss member rigid. A receiving edge of at least two of the side members of the second truss member may be slidably attached to the locking frame to rigidly couple the first truss member to the second truss member.
The method may further involve attaching a fastening member to the first and/or second truss member and the locking frame to create a positive mechanical engagement therebetween. Forming a first and second truss member may further involve coupling an extension of each side member to an attachment point of the adjacent side member with a hinge member. Further, forming a first and second truss member may involve trapping the extension of each side member between the attachment point of the adjacent side member and a hinge channel of the hinge member.
In another aspect of the method, putting the side members of the truss members in a deployed configuration may further involve relatively rotating the adjacent side members until a resistance to relative rotation is encountered between the hinge members and the associated extensions coupled therein. Putting the side members of the truss members in a deployed position may involve relatively rotating the adjacent side members through an intermediate position where a resistance to relative rotation is encountered between the hinge members and the associated extensions coupled therein, and the relative resistance to rotation decreasing at the deployed configuration of the truss member.
The above description of the present invention is not intended to describe each embodiment or every implementation of the present invention. Advantages and attainments, together with a more complete understanding of the invention, will become apparent and appreciated by referring to the following detailed description and claims taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
Fig. 1 is a perspective view of a foldable truss according to an embodiment of the present invention;
Fig. 1A is a perspective view of a foldable truss according to another embodiment of the present invention;
Fig. 2 is a side view of a side member according to an embodiment of the present invention;
Fig. 3A is a perspective view of a hinge member according to another embodiment of the present invention;
Fig. 3B is a perspective view of the hinge member interacting with a bridge member extension according to another embodiment of the present invention;
Fig. 3C is a perspective view of an alternate hinge member illustrating locking features according to another embodiment of the present invention;
Fig. 4 is an end view of the foldable truss member showing a partially folded configuration;
Fig. 5 is a perspective view of a locking frame according to another embodiment of the present invention; and
Fig. 6 is a partial side view of a display structure according to another embodiment of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail herein. It is to be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS

In the following description of the illustrated embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration, various embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural and functional changes may be made without departing from the scope of the present invention.
Referring now to Fig. 1, a truss member, generally indicated by reference numeral 100, includes a plurality of side members 102. The side members 102 are adjacently connected to form a peripheral boundary of the truss member 100, such that lower (or upper) edges 101 of the side members 102 form a closed shape (e.g., a rectangle). The side members 102 include a support member 104 and a bridging member 106. The bridging members 106 in the illustrated embodiment are formed of a continuous length of tubular material formed into a generally planar sawtooth shape. The bridging members 106 include one or more extensions 107 located at an edge opposite where the bridging members 106 join the support members 104. In the configuration illustrated, the extensions 107 are located at distal angular corners of the sawtooth shape. The truss member 100 is formed by joining multiple side members 102 using a plurality of hinge members 108.
The edges 101 of the side members 102 may include receiving members 114. The receiving members 114 can be used to join multiple truss members 100 together to form a structure. The receiving members 114 in Fig. 1 are shown as recesses in the support members 104, although alternate configurations are possible.
The hinge members 108 shown in Fig. 1 are fixed to the support members 104 and pivotally join with the bridging member 106 of an adjacent side member 102. The hinge members 108 allow relative rotation of adjacent side members 102 while preventing the adjacent side members 102 from separating. In an especially useful configuration, the truss member 100 contains four, pivotable, side members 102, thereby allowing the truss member 100 to be folded substantially flat for storage and shipment.
The hinge members 108 can be configured to hold the truss member 100 in a deployed configuration. In a deployed configuration, the side members 102 are rotated and oriented such that the truss member 100 takes on the desired shape of the intended installation. Typically, this shape is a rectangle or square (as exemplified in Fig. 1), although it may be desirable for the deployed shape to be a parallelogram, triangle, or other polygon. The hinge member 108 can include locking or frictional features that hold the side members 102 in position once the side members 102 are oriented in the deployed configuration. Details of the locking and/or frictional features of the hinge members 108 will be described herein below.
Referring now to Fig. 1A, another truss member, generally indicated by reference numeral 100a, which also includes a plurality of side members 102a. The side members 102a are adjacently connected to form a peripheral boundary of the truss member 100a such that the lower edges 101a of the side members 102a form a closed shape (e.g. a rectangle). The side members 102a include a support member 104a and a bridging member 106a. The bridging members 106a are formed of a continuous length of tubular material formed into a generally planar sawtooth shape. The bridging members 106a include one or more extensions 107a located at an edge opposite where the bridging members 106a adjoin the support members 104a. In the configuration illustrated, the extensions 107a are located at distal angular corners of the sawtooth shape. The truss member 100a is formed by joining multiple side members 102a using a plurality of hinge members 108a.
The hinge members 108a shown in Fig. 1A are affixed to the support members 104a and pivotally join with the bridging member 106a of an adjacent side member 102a. The hinge members 108a allow relative rotation of adjacent side members 102a while preventing the adjacent side members 102a from separating. In another embodiment, the truss member 100a contains four, pivotable, side members 102a, thereby allowing the truss member 100a to be folded substantially flat for storage and shipment.
The hinge members 108a can be configured to hold the truss member 100a in a deployed configuration. In a deployed configuration, the side members 102a are rotated such that the truss member 100a takes on the shape desired for the intended installation. Typically, this shape is a rectangle or square (as exemplified in Figs. 1 or Fig. 1A), although it may be desired to make the deployed shape a parallelogram, triangle, or other polygon. The hinge member 108a can include locking or frictional features that hold the side members 102a in position once the side members 102a are oriented into the deployed configuration. Details of the locking and/or frictional features of the hinge members 108a will be described below.
The foldable truss member 100a can also be made to form a rigid support structure through use of a locking frame 110a or by other means such as cross member braces detailed elsewhere herein. The locking frame 110a is a rigid assembly with locking members 112a that interface with two or more support members 104a of the truss member 100a in a deployed configuration. The example illustrated in Fig. 1A shows a square or rectangular locking frame 110a with a locking member 112a at each corner.
The locking members 112a interface with receiving ends 114a of the support members 104a by sliding the locking frame(s) 110a generally in the direction indicated by the broken lines. The receiving ends 114a can be formed as recesses or open ends of the support members 104a. The locking members 112a typically extend from a top and bottom side of the locking frame 110a, enabling multiple truss members 100a to be assembled end-to-end into a rigid support structure.
It is appreciated that alternate forms of a locking frame 110a can be used with a truss member 100a according to the present invention. Alternate structural elements may be used to couple two or more side members 102a to make the truss member 100a more rigid. For example, the locking frame 110a may be fabricated as plate with protruding locking members 112a, or as a bar with two locking members 112a at each end. The locking members 112a can be made to encompass the receiving ends 114a and thereby allow the use of solid support members 104a.
Turning now to Fig. 2, a side view of an embodiment of a side member 102 is shown. The truss member 100 is formed by adjacently connecting a plurality of side members 102 to form the outer walls of the truss member. Note that the side members 102 can be made substantially identical. Not only does this reduce the number of fabricated parts required to manufacture the truss member 100, it is appreciated that a truss member 100 utilizing substantially identical side members will have symmetric transverse load characteristic (i.e. loads that are perpendicular to the longitudinal axis of the truss member). This makes such a truss member 100 ideal for horizontal installations, as there is no need for a preferred orientation of the side members 102.
The side member 102 is formed by fixedly attaching a bridging member 106 to a support member 104. The support member 104 is preferably formed from a tubular material, although it need not be hollow. Any cross-sectional shape of the support member 104 is appropriate, although a rectangular, square, or round cross sectional shape is typically the most useful. The illustrated support member 104 is formed from a square tube material.
The bridging member 106 is affixed to one side of the support member 104 at attachment points 204. The bridging member 106 can be a tubular or bar member bent to a sawtooth shape and attached (e.g., welded or clamped) to the support member 104. It is appreciated that the bridging member 106 can alternatively be formed from various elements, including a pattern cut from a sheet or any elongated member (e.g., a bar) formed into the desired shape. Although the bridging members 106 and other truss member components are typically made from metals (e.g. steel, aluminum, copper, brass, zinc, etc), the components may also be made of alternate materials such as woods, plastics, carbon fiber and composites.
The bridging member 106 includes extensions 107 that interface with hinge members 108 of an adjacent side member 102. The hinge members 108 are attached to the support member 104 at a location on the support member 104 generally in alignment with the bridging member extensions 107. The hinge members 108 are typically removably (as opposed to being permanently attached), thereby making assembly easier and allowing for disassembly/re-assembly of the truss member 100 for repairs.
Fig. 3A illustrates an embodiment of an attachable hinge member 108. The hinge member 108 includes a mounting surface 302 with mounting holes 305. The mounting holes 305 align with holes on the support member 102 (not shown). The mounting holes 305 are adapted to receive fasteners, such as bolts, screws, rivets, locking pins, etc. The hinge member 108 includes a hinge channel 306 for receiving the extension 107 of a bridging member 106 therethrough. The hinge channel 306 "breaks through" (i.e. compressively engage and overcomes a bias) a portion of the mounting surface 302 and includes flared ends 308 that allow a generally curved extension 107 to freely rotate about 180 degrees within the hinge channel 306.
The hinge member 108 may include features that allow the truss member 100 to maintain its deployed configuration during installation. These features are detailed in Figs. 3B and 3C. In Fig. 3B, a portion of a bridging member 106 is shown in solid line with the extension 107 located within the hinge channel 306 oriented in a typical deployed configuration of the truss member 100. The orientations of the bridging member 106 corresponding to the folded configurations of the truss member 100 are shown using broken lines. Between the orientations illustrated are intermediate configurations, where the bridging member 106 is located when truss member 100 is being folded or deployed. In one embodiment, the hinge member 108 includes features that hold the extension 107 in a deployed configuration by using either friction and/or elastic deformation of the extension 107 to resist rotation of the bridging member 106.
An example of hinge features that resist rotation of the bridging member 106 are shown in Fig. 3C. In Fig. 3C, the flared end 308 of the hinge channel 306 includes three portions of differing geometry. These portions include one or more terminal portions 310, a center portion 312 and one or more intermediate portions 314. These portions 310, 312, 314 correspond to the orientation of the extension 107 within the hinge member 106 when the truss member 100 is in the folded, deployed, and intermediate configurations, respectively. The terminal portions 310 are designed to offer little or no interference with the extension 107, thereby allowing easy rotation of side members 102 in the folded configuration. The intermediate portions 314 offer resistance at least where the intermediate portions 314 are adjacent the center portion 312. The center portion 312 typically offers some resistance to rotation of the extension 107, although preferably less resistance than the intermediate portions 314. Having less resistance at the center portion 312 gives the user feedback that the truss member 100 has attained the deployed configuration, because the extensions 107 will "snap" into the center portion 312.
The portions 310, 312, 314 can offer changing resistance to rotation of the extension by various means. In the example of Fig. 3C, the portions 310, 312, and 314 are formed by fillets that form the hinge channel 308. It is appreciated that forming a fillet radius different than the inner bend radius of the extension 107 will cause the fillets to ride (interfere) at contact points against portions of the extension 107. Also, the portions 310, 312, 314 are arrayed generally radially about a rounded portion 318 of the hinge channel 306. The rounded portion 318 has a substantially constant semicircular profile throughout the hinge channel 306 in order to effectively restrain the side members 102 during deployment of the truss member 100. The portions 310, 312, 314 may have varying shapes and be located varying radial distances from the rounded portion 318 in order to increase or decrease interference with the extension 107. For example, the intermediate portions 314 are located radially closer to the rounded portion 318 than the other portions 310, 312 and are somewhat flattened, thereby giving the flared end 308 a peaked appearance. In this way, the intermediate portion 314 causes an increase in friction and/or elastic deformation of the extension 107, thereby resisting rotation of the extension 107.
Truss members 100 may be constructed that have a large number of extensions 107 along the side members 102. In this case, it may be desirable to include a mixture of hinge members 108 alternately configured according to both the configurations shown in Fig. 3A and Fig. 3C. This allows the folding action of the truss assembly 100 to be "tuned", so that holding forces are not excessive.
A truss member 100 can be assembled by locating the extensions 107 of a first side member 102 within the channels 306 of associated hinge members 108. The associated hinge members 108 are then attached to the support member 104 of a second side member 102, trapping the extensions 107 of the first side member 102 between the associated hinge members 108 and the support member 104 of the second side member 102. This process is repeated for all side members 102, so the side members 102 form a closed periphery.
After assembly, the truss member 100 can be expanded for use or folded into a substantially flat folded configuration for storage or transport. Fig. 4 illustrates an end view of a partially folded truss member 100. The truss member 100 is folded by moving the side members 102 in the direction indicated by the curved arrows in Fig. 4. While being folded, the adjacent side members 102 rotate relative to each other at the edges of the side members 102 joined by the hinge members 108. Expanding the truss member 100 to the deployed configuration involves moving the side members 102 in a direction opposite that indicated by the curved arrows and installing a locking frame 110.
Fig. 5 shows details of the locking frame 110 used to achieve rigidity of the assembled truss member 100. The locking frame 110 in Fig. 5 is a rigid frame having four sides 504 and four corners 506. Cross bracing 508 may be included for added strength. The locking members 112 in this embodiment are formed as posts that protrude generally perpendicularly to a plane defined by the four sides 504. The locking frame 100 is attached by slidably interfacing the locking members 112 of the locking frame 110 with receiving ends 114 of the truss member 100. Locking holes 502 are included in the locking members 112. The locking holes 502 align with locking holes 503 on the support members 104 (best seen in Figs. 1, 1A, and 2). An interference member (not shown) can be passed through holes 502, 503 to lock the truss member 100 to the locking frame 110.
Fig. 6 is a partial view of a display structure 400 created by connecting two truss members 100 to a locking frame 110. The first and second truss members 100 are expanded to the deployed configuration. The locking frame 110 is slidably attached to the receiving ends 114 on the lower edges 101 of the first truss members 101. The second truss member 101 is similarly attached to the locking frame 110 and thereby rigidly coupled to the first truss member 100.
A fastening member (e.g., an interference member) 602 can be used to create a positive locking engagement between the locking frame 110 and the truss members 100. The mounting holes 502, 503 are aligned such that fastening members 602 can be placed through the holes 502, 503. In the example, fastening members 602 include a quick release pin 604, a welded locknut/screw assembly 606 and a nut/bolt assembly 608. Other fastening members 602 such as clips, rivets, wire ties, snaps, latches, clamps, etc., can also be used to fasten truss and locking frames 100, 110.
In some display structures 400, the truss members 100 have sufficient strength to preclude the need for a locking member 110 at every junction. At those junctions, the display structure 400 can be connected by placing independent (i.e., not interconnected) locking members 112 between the receiving ends 114. Independent locking members 112 can be fixed with fastening members 602 as described above.
The truss member 100 and display structure 400 according to the present invention may be adapted for all manner of structural uses, particularly those of a temporary or seasonal nature. In particular, one such configuration desirable for uses such as displays or point of sale fixtures is described herein. A truss member 100 having approximately 12" x 12" cross sectional dimensions is preferable in these applications. The individual truss member lengths may vary from about 6" to about 80". The support members 102 may be formed from ¾ " to 1" square steel tubing welded and/or 3/16" wire lacing forming the bridging members 106. The hinge members 108 may be cast from steel and finished with a smooth finish along the hinge channel surfaces 306. Fabricating the truss assembly 100 from steel offers advantages of low cost, high strength, and magnetic properties for easy attachment of magnetic graphics. The steel is typically powder coated for appearance and corrosion resistance. The support members may be of different sizes and of different materials than stated above, such as round tubes and plastics, aluminum or other materials with sufficient strength. In general, the strength of coupled truss members 100 in this specific application should be able to be safely used over a 40 foot span with no load. Loads up to a few hundred pounds can be supported either centrally or distributed. Such load bearing capability would enable the truss to safely support items such as computers or TV monitors, lights and signage typically used in an exhibit/display. The weight of the truss member 100 may range from ½ pound to 10 pounds for truss lengths between 6" and 80".
It will, of course, be understood that various modifications and additions can be made to the preferred embodiments discussed herein above without departing from the scope of the present invention. Accordingly, the scope of the present invention should not be limited by the particular embodiments described above, but should be defined only by the claims set forth below and equivalents thereof.

Claims

A foldable truss member, comprising:

a plurality of side members, each side member having a lower edge and another side member adjacently arranged so that the lower edges of the adjacently arranged side member form a closed shape; and

a plurality of hinging means connecting adjacently arranged side members, the hinging means providing relative rotation between adjacently arranged side members so that the side members are foldable into a substantially flat assembly.
The truss member according to claim 1, further comprising:

receiving means located at a lower edge of each side member; and

a locking frame attachable to the receiving means of the side member to rigidly couple the side member into a deployed configuration of the truss member, the receiving means are able to slidably interface with the locking frame for locking and fastening the locking frame to the receiving means of the side members, the locking frame having a plurality of locking members, each locking member attachable at the first end of at least two of the side members of the truss in the deployed configuration, wherein the attached locking frame prevents relative rotation of adjacent side members.
The truss member according to claim 2, wherein each side member further comprises:

an elongated support member having a side surface and a first end;

a bridging member fixedly connected to the side surface of the support member at an attachment point of the support member, the bridging member having an extension at an edge of the bridge member opposite the attachment point, the plurality of hinging means pivotally joining the extension of each side member to the support member of the adjacent side member, each hinging means providing relative rotation of adjacent side members in a folded configuration of the truss member, the bridging member also including a sawtooth-shaped member having a first and second set of oppositely disposed peaks, the first set of peaks attached to the attachment point of the associated support member, and the extensions of the bridging member including the second set of peaks, wherein at least one of the hinge members resists relative rotation of the associated extension at the deployed configuration of the truss member.
The truss member according to claim 3, wherein each of the hinging means further comprise a mounting surface and a hinge channel compressively engages a portion of the mounting surface, the mounting surface of each hinging means fixedly attaching to the support member of each side member, wherein a hinge extension of the adjacent side members are locatable within the hinge channel, the hinging means include friction means to resist relative rotation between adjacently connected side members at a deployed configuration of the truss member, the hinging means also include elastic deformation means to resist relative rotation between adjacently connected side members by elastically deforming a portion of the side member at a deployed configuration of the truss member, the hinge channel of at least one of the hinge members further comprises a first and second end, and the first and second ends are flared, the first and second ends comprising:

a center portion contacting the associated extension when the truss member is in the deployed configuration;

at least one terminal portion contacting the associated extension when the truss member is in a folded configuration; and

at least one intermediate portion contacting the associated extension when the truss member is in an intermediate configuration between the folded configuration and the deployed configuration, wherein the at least one intermediate portion provides resistance to rotation of the associated extension, and the at least one terminal portion allows substantially free rotation of the associated extension, and the center portion provides resistance to rotation of the associated extension, wherein the resistance of the center portion is less than the resistance of the at least one intermediate portion.
The truss member according to claim 4, wherein the first ends of the side members include a recess, and each of the locking members of the locking frame include a locking post, the locking posts receivable into the recesses of the side members, the locking frame is lockable with the first ends of the side members, wherein at least one locking member of the locking frame further comprises a locking hole, the first end of the associated side member includes another locking hole, and wherein the locking frame is attachable with the first ends of the side members so that the locking hole of the at least one locking member is in alignment with the locking hole of the associated side member; and
an elongated interference member passable through the locking hole of the at least one locking member and the locking hole of the associated side member to prevent relative motion of the side member with respect to the locking frame, at least one of the hinge members provides increased friction to resist relative rotation of the associated extension at the deployed configuration of the truss member at least one of the hinge members includes an elastically deformable portion contacting the associated extension to resist relative rotation of the associated extension at the deployed configuration of the truss member.
The truss member according to claim 1, characterized in that the truss member is adaptable to construct a foldable display structure comprising:

at least two truss members, each truss member including a plurality of adjacently connected side members, the side members including an elongated support member having a side surface and a first end and a bridging member fixedly connected to the side surface of the support member at an attachment point of the support member, the bridging member having an extension at an edge of the bridging member opposite the attachment point, and each truss also includes a plurality of hinge members pivotally joining the extension of each side member to the support member of the adjacent side member, each hinge member allowing relative rotation of adjacent side members, and each truss member also includes a plurality of locking members disposed between the first ends of the first truss member and the first ends of the second truss member, the first ends of the first truss member being adjacent to the first ends of the second truss member, each bridging member of the truss members includes a sawtooth-shaped member having a first and second set of oppositely disposed peaks, the first set of peaks attached to the attachment point of the associated support member, and the extensions of each bridging member comprising the second set of peaks, wherein the first ends of the side members of the first and second truss members each include a recess, and the display structure also includes a locking member includes a locking post, the locking posts being receivable into the recesses of the side members, at least one of the locking members also includes a locking hole, the first ends of the associated side members of the truss members also include a locking hole, wherein the locking members are removably connected with the side members so that the locking hole of the locking members are in alignment with the locking hole of the side members, and the display structure also includes an elongated interference member passable through any of the locking holes of the locking members and the locking hole of the side member to prevent relative motion of the side members with respect to the locking members.
The display structure according to claim 6, wherein at least one of the hinge members of each of the truss members provides increased friction to resist relative rotation of the associated extension at the deployed configuration of the truss member, and at least one of the hinge members of each of the truss members elastically deforms the associated extension to resist relative rotation of the associated extension at the deployed configuration of the truss member, and each of the hinge members includes a mounting surface and a hinge channel breaking a portion of the mounting surface, the extensions of the bridging member of the adjacent side member being locatable within the hinge channel, and the mounting surface of the hinge members fixedly attaching to the support members, and the hinge channel of each of the hinge members also includes first and second ends that are flared, and each end of the hinge channels includes a center portion contacting the associated extension when the truss member is in the deployed configuration, at least one terminal portion contacting the associated extension when the truss member is in a folded configuration, and at least one intermediate portion contacting the associated extension when the truss member is in an intermediate configuration between the folded configuration and the deployed configuration, wherein the at least one intermediate portion offers a resistance to rotation of the associated extension, and the at least one terminal portion allows substantially free rotation of the associated extension, and the center portion offers a resistance to rotation of the associated extension, the resistance of the center portion being less than the resistance of the intermediate portion.
A method of assembling a display structure, comprising:

forming first and second truss members by adjacently coupling a plurality of side members to form a peripheral boundary for the first truss member, each of the side members including an elongated edge pivotally attached to the adjacent side member;

relatively rotating the adjacent side members about the elongated edges of the first truss member until a resistance to relative rotation is encountered to put the truss member in an intermediate configuration;

relatively rotating the adjacent side members about the elongated edges until a decreased resistance is encountered to put the first truss member in a deployed configuration;

slidably connecting an unconnected edge of a second truss member to an unconnected edge of the first truss member to connect first and second truss members.
The method according to claim 8, wherein connecting the first and second truss members includes slidably connecting a locking member between the first and second truss members, and attaching a fastening member to the first and second truss members to positively connect the truss members together to form a peripheral boundary, each of the side members including an elongated edge pivotally attached to the adjacent side member;
relatively rotating the adjacent side members about the elongated edges to put the side members of the truss members in a deployed configuration;
slidably attaching a receiving edge of at least two of the side members of the first truss member to a locking frame to make the first truss member rigid;
slidably attaching the receiving edge of at least two of the side members of the second truss member to the locking frame to rigidly couple the first truss member to the second truss member and attaching a fastening member to the first truss member and the locking frame to create a positive mechanical engagement therebetween.
The method according to claim 9, further comprising coupling an extension of each side member to an attachment point of the adjacent side member with a hinge member and coupling an extension of each side member with a hinge member to the elongated edge of the adjacent side member; and
putting the side members of the truss members in a deployed configuration by relatively rotating the adjacent side members until resistance to relative rotation is encountered between the hinge members and the associated extensions coupled therein and relatively rotating the adjacent side members through an intermediate position where resistance to relative rotation is encountered between the hinge members and the associated extensions coupled therein, wherein the relative resistance to rotation decreasing at the deployed configuration of the truss member.