Hollow beam

Abstract

A hollow beam for the construction of structures is disclosed. The hollow beam comprises a plurality of elongated side walls having a first end and a second end, wherein at least two of the plurality of elongated side walls each comprises: at least one access opening adapted to allow a hand to pass therethrough, at least one support opening adapted to receive and support an external element, and a plurality of fastener holes formed around at least one of the access opening and the support opening. The fastener holes are adapted to receive one or more fastener. The at least one access opening and the at least one support opening are formed in an alternating configuration between the first end and the second end.

Description

[0001] HOLLOW BEAM

[0002] TECHNICAL FIELD

[0003] The present invention relates to a hollow beam for the construction of temporary structures. The invention also relates to a kit of parts comprising the hollow beam, a system comprising the hollow beam and a method of assembling the system comprising the hollow beam. The invention also relates to a method of manufacturing the hollow beam.

[0004] BACKGROUND

[0005] Beams for the construction of temporary structures have been described previously.

[0006] US8418425B1 describes a tubular beam for construction of temporary structures which preferably includes a rectangular tube, a first end plate and a second end plate. A plurality of tube access openings are formed through each side of the rectangular tube and a fastener hole pattern is formed around each tube access opening.

[0007] WO2023249827A1 describes a tubular beam with mechanically fastened end plates which preferably includes a tubular member and at least one end plate. At least one cross plate may be secured within the tubular member with fasteners to strengthen thereof. The tubular member may have any suitable cross section including, square, rectangular, hexagonal, triangular or the like. A plurality of hand access openings, a plurality of beam fastening holes and a plurality of fastener holes are formed through a side wall of the tubular member.

[0008] Common for the above-described prior art beams is that all openings formed on the different sides of the beams are equal in both form and size. Thus, adapters are needed if these openings are to be used to safely support an external element. Also, the openings of these beams are large enough to allow a human hand to pass. Thus, the beams have to be relatively large and heavy in order to provide the necessary strength and load bearing capabilities. A disadvantage with this is that the beams become more difficult to handle during for example construction.

[0009] In for example the TV, film, theater and music industry, different structures may be used to suspend or support scenographic equipment such as lighting, curtains, speakers, smoke machines, backdrops and more. Furthermore, different structures may be used to build a stage or a set. Such structures are often temporary and may even be specifically designed for a particular purpose and never used again. Oftentimes, such scenographic structures comprise lighting rigs / stage rigs, which have a limited area of application. Additionally, scenographic structures can be made up of wood and other materials that are shaped or cut to fit the specific purpose. It is not certain that these materials can be reused for another scenographic structure later.

[0010] It is therefore an aim of the present invention to provide a hollow beam that is flexible, easy to use, and suitable for the construction of different scenographic structures.

[0011] It is also an aim of the present invention to reduce the use of single-use / non- reusable materials that are common in scenographic structures.

[0012] It is further an aim to reduce the cost of scenographic structures.

[0013] The present invention is not necessarily meant as a replacement for common rigging solutions, such as lighting rigs, but is at least meant to provide a useful supplement that can give extended possibilities.

[0014] It is further an aim of the present invention to provide a hollow beam with the ability to safely support an external element without the use of adapters. This can be advantageous, as it can save time and reduce the complexity during the construction of different structures.

[0015] It is also an aim of the present invention to provide a hollow beam that is easier to handle during the construction of different structures.

[0016] SUMMARY OF THE INVENTION

[0017] Viewed from a first aspect, the present invention provides a hollow beam for the construction of structures, the hollow beam comprising: a plurality of elongated side walls having a first end and a second end, wherein at least two of the plurality of elongated side walls each comprises: at least one access opening adapted to allow a hand to pass therethrough, at least one support opening adapted to receive and support an external element, and a plurality of fastener holes formed around at least one of the access opening and the support opening, the fastener holes being adapted to receive one or more fastener, wherein the at least one access opening and the at least one support opening are formed in an alternating configuration between the first end and the second end.

[0018] The structure may be a temporary structure. As such, the first aspect of the invention may provide a hollow beam for the construction of temporary structures. The temporary structure may be a scenographic structure. In addition to the hollow beam, the scenographic structure may comprise lighting, rods, support plates, wheels, curtains and other types of equipment that may be used in scenographic structures for TV, film, theater, music etc. The structure may also be a permanent structure, or at least a substantially permanent structure. The permanent structure may be a scenographic structure, e.g. for a theater stage. Another example of a permanent structure may be an arrangement for supporting LED screens in a store, e.g. for marketing purposes.

[0019] Each elongated side wall of the hollow beam may be substantially rectangular in shape. As such, each elongated side wall may comprise four sides where one pair of opposing sides are longer than the other pair of opposing sides to provide the elongated shape. The four sides of the elongated side wall may comprise a first end side, a second end side, a first lateral side and a second lateral side, where the first end side is opposite the second end side and the first lateral side is opposite the second lateral side. The lateral sides may be longer than the end sides. Thus, the first end side and the second end side may be the first end and the second end of the elongated side wall, respectively.

[0020] The thickness of each side wall may vary depending on the material the side walls are made of and / or the required strength of the beam. For example, each elongated side wall may have a thickness less than or equal to 10 millimeters (mm). However, the thickness may also be more than 10mm. Preferably, each elongated side wall has a thickness in the range of 3 to 5mm, such as a thickness of approximately 4mm. Each elongated side wall of the plurality of elongated side walls may have substantially the same thickness. In other words, each elongated side wall of the hollow beam may have the same thickness. However, the elongated side walls may also have different thicknesses.

[0021] The strength of the hollow beam also depends on the material it is made of. The plurality of elongated side walls may be made of metal, e.g. aluminium or steel. Preferably, the elongated side walls are made of aluminium. Alternatively, the elongated side walls may be made of other suitable materials such as polymers, plastics, or wood. It should be obvious to a skilled person that the choice of material and the thickness of the plurality of elongated side walls affect the strength of the hollow beam, and thus that the material used, and the thickness chosen, may be varied based on the required strength and / or the area of use.

[0022] The plurality of elongated side walls may be adjoined along their respective lateral sides to form the hollow beam. The hollow beam may comprise at least three elongated side walls. Preferably, the hollow beam comprises four elongated side walls. Thus, the four elongated side walls may be adjoined along their respective lateral edges to form a rectangularly shaped hollow beam. As such, the hollow beam may have a substantially rectangular cross-sectional shape. Preferably, the hollow beam has a substantially square cross-sectional shape. In other embodiments, the hollow beam may have a triangular, a pentagonal or a hexagonal cross-sectional shape, or another cross-sectional shape depending on the number of side walls.

[0023] The elongated side walls may be welded together along their respective lateral sides to form the hollow beam. However, different methods may be used to connect the elongated side walls. The method used to connect the elongated side walls may also depend on the material the elongated side walls are made of. In a preferred embodiment, the hollow beam is formed by extrusion. As such, the hollow beam may comprise one single piece comprising the plurality of elongated side walls without any seems, welds or other connection interfaces.

[0024] One advantage of extrusion is that it may allow the hollow beam to be formed such that that the transition, or interface, between adjoined elongated side walls has an arched shape, or an arched profile. Such an arched profile between adjoining elongated side walls (i.e. between the side lateral sides of adjacent, or adjoining, elongated side walls) may increase the strength of the hollow beam and thus improve its load bearing capabilities. The arched profile also provides additional thickness for the transition between the elongated side walls, which contributes to increasing the strength of the hollow beam. A similar arched profile may be difficult, or even impossible, to achieve by welding. The access openings are shaped to allow a hand to pass therethrough. As such, it is possible for a person to reach the inside of the hollow beam, e.g. during assembly of a temporary structure. The access openings may have any shape suitable to allow a hand to pass therethrough. Additionally, a center point of each access opening may be substantially centered between the first lateral side and the second lateral side of the elongated side walls. In a preferred embodiment, the access openings are ovalshaped, or elliptically shaped. As such, the area of the access openings may be reduced while still allowing a hand to pass. This may increase the strength of the beam as each side wall then will have a larger bearing surface, or supporting surface. Preferably, the largest diameter of the oval-shaped openings, or elliptically shaped openings, is parallel with the longitudinal axis of the beam, i.e. parallel to the lateral sides of the elongated side walls. This increases the bearing surfaces between the access opening and the lateral sides of the elongated side wall, giving the beam more strength for the same size. One access opening may have a different shape than another access opening. However, each access opening preferably has substantially the same shape for ease of manufacturing.

[0025] The support openings are shaped to receive and support an external element. For example, the shape and area of each support opening may be adapted according to the shape and area of the external element, such as a cross-sectional shape and area of the external element. Thus, the support openings may each be configured to firmly support the external element. The support openings may be smaller than the access openings. Additionally, a center point of each support opening may be substantially centered between the first lateral side and the second lateral side of the elongated side walls, as for the access openings. The external element may for example be a beam, a rod or a tube that may form part of the temporary structure. Such external elements may for example be used to hang up different external equipment. The external equipment may be scenographic equipment, such as lighting or curtains. However, the external equipment may also be other equipment used for other purposes. The beam, rod or tube may be elongated and may have any cross-sectional shape, e.g. rectangular, triangular or circular. Thus, each support opening may have a corresponding or complementary shape in order to accommodate and directly support the external element. In this way, no adapters are needed to support the external element safely and stably in the support opening. Fastening means such as clamps may be used to ensure that the external element cannot slide out from the support opening. Furthermore, in case the external element is circular, fastening means may also be used to ensure that the external element does not rotate within the complementary support opening. One support opening of the hollow beam may have a different shape than another support opening of the hollow beam. Preferably, each support opening has substantially the same shape. In one embodiment, each support opening is adapted to receive and support a standard tube used in scenographic structures, for example a 48.3mm tube. Such tubes are commonly used in the TV and film industry to support lighting and other scenographic equipment.

[0026] The fastener holes are adapted to receive one or more fastener, for example to secure two adjacent hollow beams to one another. Additionally, or alternatively, the fastener holes may receive one or more fastener such as to attach different external equipment directly to the hollow beam. Such external equipment may comprise lighting, wheels, support panels or other equipment used in scenographic structures, as noted above. The fastener holes may be adapted to receive any suitable fastener. As such, two adjacent hollow beams may be secured to each other, and / or external equipment may be attached to the hollow beam. Each fastener hole may be adapted to receive a fastener. The suitable fastener may for example be a bolt and nut, a threaded connector such as a screw, or rivets, pins, anchors etc. Alternatively, the suitable fastener may be a fastener that uses more than a single fastener hole, for example a bracket, or similar fastener means. Depending on the thickness of the side walls of the hollow beam, the fastener holes may be threaded such that two adjacent hollow beams, or other external equipment, may be attached by use of screws without using a nut.

[0027] The fastener holes may be formed around a perimeter of said at least one access opening or support opening. The fastener holes may form a fastener hole pattern around said perimeter. The fastener hole pattern may be concentric relative to said access opening or support opening, for example a sequence of holes located around the circumference of the opening and each being equally spaced from the edge of the opening. The fastener hole pattern may comprise a number of main fastener holes. Where the elongated side wall, or the hollow beam, comprises more than one fastener hole pattern, the configuration of the main fastener holes is preferably uniform across the hollow beam. That is, the configuration of the main fastener holes around one access opening and / or support opening is preferably substantially equal to the configuration of the main fastener holes around another access opening and / or support opening. This makes the beams easier to manufacture and provides increased flexibility during the construction of structures, such as temporary structures. In a preferred embodiment, the fastener hole pattern comprises four main fastener holes.

[0028] The fastener holes may form a substantially rectangular fastener hole pattern around the perimeter of at least one of the access opening and the support opening. Preferably, the fastener holes form a substantially square hole pattern around the perimeter. Each main fastener hole may represent the corners of the rectangular fastener hole pattern. The fastener hole pattern formed around an access opening may be different from the fastener hole pattern formed around a support opening. The fastener hole pattern formed around a support opening may comprise additional fastener holes compared to the fastener hole pattern formed around an access opening. The additional fastener holes may allow for the use of more fasteners, for example when securing two hollow beams to each other, which may strengthen the connection. As such, the resulting structure may carry more load. In a preferred embodiment where the support opening is smaller than the access opening, such additional fastener holes may be formed around the support opening without compromising the strength of the hollow beam in any significant way. The additional fastener holes may have the same size as the main fastener holes.

[0029] Preferably, the number of additional fastener holes in the fastener hole pattern is four. Each of the four additional fastener holes may be formed substantially centered between two main fastener holes to provide the rectangular, or square, fastener hole pattern.

[0030] In one embodiment, at least one of the additional fastener holes may be larger than the other fastener holes. That is, at least one of the additional fastener holes may be larger than the other additional fastener holes and the main fastener holes. The at least one larger additional fastener hole may allow for larger fasteners to be used for improved connection strength, and / or, it may allow for other type of fastening devices to be attached, for example clamps or hooks. The clamps or hooks may allow the hollow beam to be suspended in wires, ropes or similar suspension means. Thus, it is preferred that the at least one larger additional fastener hole is substantially centered between the two lateral sides of the side wall to provide stability during suspension. The fastener hole pattern may comprise two larger additional fastener holes. Preferably, the two larger additional fastener holes are formed centered between the two lateral sides of the elongated side wall, and on each side of the support opening.

[0031] The fastener holes are preferably smaller than the support opening. As such, the external element configured to be received and supported by the support opening is not to be confused with common fasteners such as screws, bolts, rivets, pins, anchors etc. For example, the external element may be larger in diameter than the fasteners used with the fastener holes.

[0032] The at least one access opening and the at least one support opening are formed in an alternating configuration between the first end and the second end of at least two elongated side walls of the plurality of elongated side walls. The elongated side walls may each comprise at least two access openings, or, at least two support openings. Alternatively, the elongated side walls may each comprise at least two access openings and at least two support openings.

[0033] Preferably, each elongated side wall of the plurality of elongated side walls comprises at least one access opening and at least one support opening which are formed in an alternating configuration between the first end and the second end. Where each elongated side wall comprises at least one access opening and at least one support opening, the alternating configuration on adjacent elongated side walls may be different. A different alternating configuration implies that the order of access openings and support openings is different. It may alternatively, or additionally, imply that the number of access openings and / or support openings is different. In certain embodiments, different alternating configurations may imply that the alternating configurations are reversed.

[0034] For example, in some embodiments, one elongated side wall of the plurality of elongated side walls may comprise one access opening and one support opening between the first end and the second end of the elongated side wall. The access opening may be formed between the first end and the support opening, and the support opening may be formed between the access opening and the second end. A reversed alternating configuration on adjacent elongated side walls may thus imply that on the adjacent elongated side walls, the support opening is formed between the first end and the access opening, and the access opening is formed between the support opening and the second end.

[0035] In some embodiments, an elongated side wall may comprise two or more access openings and / or support openings between the first end and the second end. The alternating configuration may then imply that every other opening is an access opening and a support opening, such that the openings form an alternating pattern between the first end and the second end of the elongated side wall. The alternating pattern may for example comprise an “access opening - support opening - access opening (and so on)”-pattern between the first end and the second end. A reversed alternating configuration on adjacent elongated side walls may thus imply that on an adjacent elongated side wall, the alternating pattern may comprise a “support opening - access opening - support opening (and so on)”-pattern between the first end and the second end. The access openings and the support openings may be equally spaced apart between the first end and the second end on each of the elongated side walls.

[0036] One advantage of having a reverse alternating configuration on adjacent elongated side walls, for example in the form of a reverse alternating pattern, is that it may improve both the access to the hollow beam and also the flexibility of the hollow beam when constructing structures. For example, in the case of a square hollow beam, the alternating pattern provides the ability to easily reach through the beam with a hand for every opening step between the first end and the second end. It also provides the ability to support an external element for every opening step and also to insert an external element through the hollow beam for every opening step. This may provide better support of the external element and provide more flexibility in terms of possible structures that can be made.

[0037] In some embodiments, an access opening may not be formed adjacent to another access opening in the elongated side wall. That is, an access opening may only be formed adjacent to one or more of a support opening, the first or second end, or, a larger area of hole-free side wall. A larger area of hole-free side wall may refer to an area of the elongated side wall large enough to accommodate an access opening or a support opening, but which instead comprises a substantially solid side wall. It may also be large enough to accommodate an access opening or a support opening with associated fastener holes. Two or more support openings may be formed adjacent to one another in the elongated side wall.

[0038] Further, in some embodiments, an access opening may not be formed adjacent to another access opening on an adjacent elongated side wall. That is, an access opening may not be formed immediately adjacent to another access opening in the circumferential direction of the hollow beam, e.g. with centerlines of the access openings in close alignment. In this case being adjacent in the circumferential direction of the hollow beam may mean that a line encircling the hollow beam (or a cross-section through the beam perpendicular to its longitudinal axis) will pass through both of the “adjacent” openings. In other words, an access opening may typically only be formed immediately adjacent to a support opening or a larger area of hole-free side wall in the circumferential direction of the hollow beam. Two or more support openings may be formed adjacent to one another substantially in the circumferential direction of the hollow beam. Access openings may in some cases be formed with an overlap with another access opening on an adjacent elongated side wall, e.g. with an overlap in the circumferential direction of the hollow beam but with centerlines of the access openings spaced apart from one another, such as a spacing of at least a half of the maximum diameter / width of the access opening.

[0039] When the access openings are larger than the support openings, as is preferred, the above-described configuration provides larger continuous bearing surfaces on the hollow beam, and thus a higher strength for the same size and / or weight of the hollow beam. This in turn makes it easier for a person to handle the hollow beam during e.g. the construction of a structure. Additionally, the distribution of access openings ensures accessibility to the inside of the hollow beam to make the construction of structures easier. In a preferred embodiment, the hollow beam comprises four elongated side walls, such as to form a rectangular hollow beam. Preferably, the hollow beam has a square cross-sectional shape. In this embodiment, opposite side walls may have the same alternating configuration, while adjacent side walls may have a different alternating configuration. The alternating configuration on adjacent side walls may be reversed. In a preferred embodiment, the alternating configuration may imply that every other opening in the elongated side wall is an access opening and a support opening. In other words, an access opening may only be formed adjacent to one or more support openings and a support opening may only be formed adjacent to one or more access openings. Furthermore, every other opening in the circumferential direction may be an access opening and a support opening. Thus, an access opening may only be formed immediately adjacent to a support opening in the circumferential direction of the hollow beam, and vice versa. As such, the alternating configuration on adjacent elongated side walls is reversed and the alternating configuration on opposite side walls is equal.

[0040] As described earlier, the larger access openings make it easy to access the inside of the hollow beam, which further makes it easier to handle fasteners such as bolts and nuts during the construction of structures, such as temporary structures. In addition, the support openings, which are smaller, allow firm support of external elements, such as tubes, without needing adapters or other means to alter the size of the opening. This makes it easier and more effective to rig up and / or down different structures, especially structures comprising such external elements. Furthermore, the above-described alternating configuration according to the preferred embodiment provides a larger continuous bearing surface on the hollow beam, as each access opening, which is larger than a support opening, is only adjacent to support openings. Furthermore, a hand, and / or an external element, are allowed to be inserted through the hollow beam, which may provide advantages as discussed above. The alternating configuration thus provides the hollow beams with a unique combination of strength and access, in addition to increased efficiency and flexibility during the construction of structures.

[0041] The space between the center of one access opening or support opening to the center of and adjacent access opening or support opening on an elongated side wall, may be substantially equal to the length of the end sides of the elongated side wall. In a preferred embodiment, where the hollow tube has a substantially square cross- sectional shape, the outer surfaces of the elongated side walls of the hollow beam may be viewed as being divided into a number of square and equally sized side wall segments. The combined area of the side wall segments for each elongated side wall may be substantially equal to the surface area of the elongated side wall. Each side wall segment may comprise either an access opening or a support opening, alternatively with associated fastener holes. In a preferred embodiment, the sides of a side wall segment comprising an access opening only borders the sides of side wall segments comprising a support opening. The described square configuration makes the hollow beam especially flexible and suitable for a modular system. Such a modular system may be a temporary structure for scenographic purposes.

[0042] The hollow beam may comprise at least one end wall connected to either one of the first end and the second end of each elongated side wall. Preferably, the hollow beam comprises two end walls, one at the first end and one at the second end. As such, the hollow beam may be viewed as a closed hollow beam in the sense that each side is covered by either an elongated side wall or an end wall.

[0043] The at least one end wall may comprise an access opening or a support opening, or it may be a substantially solid end wall. A plurality of fastener holes may be formed around the access opening or the support opening as described above. Where the hollow beam comprises two end walls, each end wall may have the same hole configuration or they may have different hole configurations. Alternatively, one end wall may comprise an access opening or a support opening and the other may be a substantially solid end wall. The term “hole configuration” refers in this case to either an access opening or a support opening, possibly with accompanying fastener holes. Preferably, both end walls comprise a support opening. A plurality of fastener holes may be formed around each support opening as described above. As such, the end walls, and thus the ends of the hollow beam, may for example be secured to an end of another hollow beam, or, to a side wall of another hollow beam.

[0044] The thickness of the at least one end wall may, similar to the elongated side walls, vary depending on the required strength of the beam. The at least one end wall may have a thickness in the range 4 to 12 mm or a thickness less than or equal to 10 mm. However, the thickness may also be more than 10mm. The at least one end wall may be thicker than the elongated side walls. Preferably, the at least one end wall has a thickness in the range 4 to 8 mm, such as a thickness of approximately 6mm. The increased thickness of the end wall may increase the load bearing capability during connection to another component, which may be an end wall of another hollow beam.

[0045] Where the hollow beam comprises two end walls, the end walls may have different thicknesses. Preferably, the two end walls have substantially the same thickness.

[0046] The at least one end wall may be made of the same material as the elongated side walls. The at least one end wall may be welded to the ends of the hollow beam. Viewed from a second aspect, the present invention provides a kit of parts comprising at least one hollow beam according to the first aspect and at least one external component. The external component may for example be the external element discussed in connection with the first aspect, such as a tube. The external component may also be an external equipment discussed in connection with the first aspect. The external equipment may be a light, a wheel, a support panel or other equipment that may be used in scenographic structures. The external component may alternatively be a fastener, such as a bolt or nut. The external component may also be a hollow beam according to the first aspect. The hollow beam may have any of the other optional features discussed above in relation to the first aspect.

[0047] Viewed from a third aspect, the present invention provides a system comprising at least one hollow beam according to the first aspect and at least one external component, and wherein the at least one hollow beam and the at least one external component are connected to form a structure. The hollow beam may have any of the other optional features discussed above in relation to the first aspect. The structure may be a temporary structure, for example a scenographic structure. The external component may for example be the external element discussed in connection with the first aspect, such as a tube. The external element may be connected to the hollow beam by being inserted into at least one support opening of the hollow beam. The external element may be further secured by use of a fastening device, such as a clamp or other fastening devices as discussed above in connection with the first aspect. The external component may also be an external equipment as discussed in connection with the first aspect. The external equipment may be a light, a wheel, a support panel or other equipment that may be used in scenographic structures. As such, the temporary structure may be a scenographic structure. The external equipment may be connected to the hollow beam by one or more fasteners, as discussed above in relation to the first aspect. The external component may also be a hollow beam according to the first aspect. The hollow beam may have any of the other optional features discussed above in relation to the first aspect. Two such hollow beams may be connected by one or more fasteners, as also discussed in relation to the first aspect.

[0048] Viewed from a fourth aspect, the present invention provides a method of assembling a system according to the third aspect. The method may for example comprise connecting the at least one hollow beam to the at least one external component. The method may comprise connecting the hollow beam to the external component by use of one or more fastener.

[0049] Viewed from a fifth aspect, the present invention provides a method of manufacturing a hollow beam according to the first aspect, the method comprising the following steps; forming a plurality of elongated side walls by extrusion to form a single piece, the single piece comprising the plurality of elongated side walls, partly inserting an end wall into an end of the single piece, securing the end wall to the single piece by welding, and milling off an outer surface of the end wall, thereby reducing a thickness of the end wall.

[0050] The thickness of the end wall may be greater than a thickness of each of the side walls after milling. The outer surface of the end wall may protrude from the end of the single piece after milling. Preferably, milling is performed after the end wall has been secured to the single piece by welding. The end wall may be secured to the single piece by machine welding, preferably by robot welding. The end wall may be inserted into the single piece such that 3 -5mm of the end wall’s thickness is located inside the single piece. The thickness of the end wall may be reduced by approximately 2mm during milling. The end wall may have a thickness of approximately 8mm before milling and a thickness of approximately 6mm after milling. Milling the end wall after it has been secured to the single piece ensures a smooth and even end surface for the hollow beam, and also ensures that the end surface is substantially perpendicular to the elongated side walls. This in turn ensures that distortion does not occur during the construction of structures. The hollow beam may be manufactured with any of the other optional features discussed above in relation to the first aspect, and thus the method may include a step of providing such features.

[0051] LIST OF FIGURES

[0052] Certain embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which:

[0053] Figure 1 shows a perspective view of a hollow beam.

[0054] Figure 2 shows three hollow beams of different lengths, and from a different perspective than in figure 1.

[0055] Figure 3 shows eight hollow beams of different lengths.

[0056] Figures 4a and 4b illustrate a side view and a front view of a hollow beam, respectively. Thus, figure 4a shows a side wall and figure 4b shows an end of a hollow beam, which comprises an end wall.

[0057] Figure 5 shows a structure comprising three hollow beams.

[0058] Figures 6a and 6b show two different scenographic structures comprising the hollow beam, as well as different scenographic equipment such as lights.

[0059] Figure 7 shows a scenographic structure in the form of a light support rack. The scenographic structure comprises several hollow beams, as well as tubes, lights and wheels.

[0060] Figure 8a and 8b show additional scenographic structures comprising the hollow beam.

[0061] DESCRIPTION OF EXAMPLES

[0062] Figure 1 shows an example of a hollow beam 1 from a perspective view. As illustrated, the hollow beam 1 comprises four side walls 2 and two end walls 3. Each side wall 2 has two lateral sides 5 extending between end sides 4. Each side wall 2 comprises three access openings 10 and three support openings 11. The end walls 3 each comprise one support opening 11 (only one visible in the figure).

[0063] In the exemplary embodiment, the hollow beam 1 is made of aluminium. Aluminium alloy 6082 is preferably used, but other suitable aluminium alloys can also be used, for example aluminium alloy 6060.

[0064] The side walls 2 are adjoined along their respective lateral sides 5 to form a substantially square hollow beam 1. As such, the width of each side wall 2, or, the distance between each lateral side 5, is substantially equal. In the depicted embodiment, the width of each side wall 2 is about 125mm. Preferably, the side walls 2 are formed by extrusion so that they together form one single piece. This means that there is no seam, weld or other connection between the lateral sides 5. In the depicted embodiment, each side wall 2 is about 4mm thick.

[0065] As can further be seen, the transitions 8 between each adjoined side walls 2 have an arched shape, or an arched profile. The arched shape of transitions 8 increases the strength of the hollow beam 1 and thus improves its load bearing capabilities. The arched profile provides additional thickness in transitions 8, which in turn contributes to increasing the strength of the hollow beam 1. In other words, the thickness of the transitions 8 is more than 4mm in the depicted example.

[0066] The end walls 3 are welded together with the side walls 2 to form a closed hollow beam 1. The end walls 3 are thicker than the side walls 2. In the depicted example embodiment, the end walls 3 are 6mm thick. Advantages of having thicker end walls 3 are discussed further below.

[0067] During manufacturing of the hollow beam 1, the end walls 3 are inserted into each end of the single piece square tubular formed by the side walls 2, and then welded together with the side walls 2, preferably by robot welding for increased precision. The end walls 3 are inserted into the single piece square tubular such that part of each end wall 3 is inside the cavity formed by the side walls 2, and part of each side wall 3 is protruding from the end sides 4 of the side walls 2. Then, a certain portion of the outer surface area of the end walls 3 is milled away, possibly together with parts of the weld seam, to provide a smooth and even surface, which is also perpendicular with the side walls 2. Thus, the end walls 3, possibly together with any weld seam, forms the ends 6 of the hollow beam 1.

[0068] For example, in the depicted embodiment, each end wall 3 is preferably 8mm thick initially. During the manufacturing process, the end walls 3 are inserted about 3- 5mm inside their respective ends and welded in place, preferably by robot welding as mentioned above. Thus, 3-5mm of the end wall’s 3 thickness is located inside the cavity formed by the adjoined side walls 2, and the remaining thickness is protruding from the end sides 4 of the side walls 2. Finally, 2mm of the end walls’ 3 thickness is milled away, possibly together with parts of the weld seam, to provide a smooth and even outer surface, which is also perpendicular to the side walls 2. Other irregularities after welding is also evened out to provide smooth and even surfaces. As such, distortion due to uneven surfaces are avoided when constructing structures. The resulting end wall 3 is about 6mm thick as discussed above. The access openings 10 are large enough to allow a hand to pass therethrough. As such, a worker may reach the inside of the hollow beam 1 with a hand, e.g. to fasten a screw and a nut during the construction of a temporary structure. As can be seen, the access openings 10 have an oval-shape, or an elliptical shape. The oval shape allows the area of the opening to be smaller while still allowing a hand to pass freely. As can be seen, the largest diameter of the oval shaped, or elliptically shaped, access openings 10 is parallel with the longitudinal access of the hollow beam 1, i.e. parallel with the lateral sides 5. Additionally, the center point of the access openings 10 is substantially centered between the lateral sides 5. The access openings’ 10 oval shape, placement and orientation thus provide larger bearing surfaces between the access openings 10 and the lateral sides 5. This in turn increases the strength of the hollow beam 1. As can be seen in figure 1, each access opening 10 is substantially equal in size and shape. This also helps to simplify the manufacturing of the hollow beam 1. In the illustrated exemplary embodiment, the largest diameter of each oval access opening is about 105mm and the smallest diameter is about 90mm.

[0069] The support openings 11 are shaped to allow an external element to pass therethrough, and also to firmly support the external element. In other words, the shape and area of each support opening 11 are adapted according to the cross- sectional shape and area of the external element. In the illustrated embodiment, the support openings 11 are shaped to support a circular external element, such as a tubing. More specifically, the support openings 11 are shaped to support a 48.3mm tubing. Such tubing is commonly used in scenographic structures for the TV, film, theater and music industry to suspend lighting and other scenographic equipment. The center points of the support openings 11 is substantially centered between the lateral sides 5, like the access openings 10. The support openings 11 on the end walls 3 are substantially equal to the support openings 11 on the side walls 2. The support openings 11 on the end walls 3 are centered on the end walls 3.

[0070] As can be seen, a number of fastener holes 13, 13 ’,14 are formed around each access opening 10 and support opening 11. The fastener holes 13, 13 ’,14 are in the illustrated example each adapted to receive a fastener such as a screw. Thus, another hollow beam 1, or other equipment, may be secured to the hollow beam 1 by a screw and nut.

[0071] Four main fastener holes 13 are formed around each access opening 10 and each support opening 11 in a square pattern. The main fastener holes 13 represent each corner of the square pattern. Furthermore, each main fastener hole 13 is equally spaced from the edge of the respective access opening 10 or support opening 11, such as to form a concentric pattern. In the illustrated example, the main fastener holes 13 are shaped to receive an M8 screw. The square pattern of the main fastener holes 13 is repetitive and uniform across the hollow beam 1. That is, the pattern of the main fastener holes 13 around each access opening 10 is equal, and, the pattern of the main fastener holes 13 around each access opening 10 is in turn equal to the pattern of the main fastener holes 13 around each support opening 11. Thus, any pattern of main fastener holes 13 may be aligned in order to secure two hollow beams 1 to each other. This makes the hollow beam 1 flexible and suitable for a modular system.

[0072] As can further be seen, additional fastener holes 13 ’,14 are formed around each of the support openings 11. One additional fastener hole 13 ’,14 is formed between two main fastener holes 13 in the square pattern. The additional fastener holes 13’, 14 allow for more fasteners to be used, e.g. to provide a stronger connection to another hollow beam 1. The additional fastener holes 13’, 14 may also provide flexibility when it comes to attaching other equipment to the hollow beam 1.

[0073] As can be seen, the additional fastener holes 13 ’,14 formed around the support openings 11 on the side walls 2 comprise two regular additional fastener holes 13’ and two larger additional fastener holes 14. The regular additional fastener holes 13’ are substantially equal to the main fastener holes. I.e., in the illustrated example, the regular additional fastener holes 13’ are each shaped to receive an M8 screw. The larger additional fastener holes 14 are positioned substantially centered between the lateral sides 5 of each side wall 2, on each side of their respective support opening 11. The larger additional fastener holes 14 allow for larger screws to be used, for example to provide a stronger connection to another hollow beam 1, or to other equipment. In the illustrated embodiment, the larger additional fastener holes 14 are each shaped to receive an M12 screw. Furthermore, the larger additional fastener holes 14 may allow other types of fasteners to be used, for example fasteners that allow the hollow beam to be suspended. Suspension means may include wires, ropes or similar. The other types of fastener may for example include brackets, hooks, snap hooks or other fastener means. The illustrated, centered placement of the larger additional fastener holes 14 may provide stability during suspension.

[0074] As can be seen, the end walls 3 comprise four larger additional fastener holes 14, instead of just two, as on the side walls 2. The extra larger additional fastener holes 14 can be especially beneficial on the end walls 3, as the end wall connections may generally experience more momentum, or torque, in a temporary structure. As such, the extra larger additional fastener holes 14 can allow bigger fasteners which provide stronger connections and thus allow the temporary structure to support more load. As discussed above, the end walls 3 are thicker than the side walls 2. The thicker end walls 3 also contribute to provide stronger end wall connections. The fastener holes 13, 13 ’,14 are positioned as far as possible from their respective access opening 10 or support opening 11, but without being too close to another fastener hole 13, 13’, 14, for example a fastener hole on an adjacent side wall 2 or end wall 3. By positioning the fastener holes 13, 13’, 14 as far as possible away from the respective access openings 10 or support openings 11, the resulting connection can carry more load, as the torque on each associated fastener becomes smaller. As such, cross-plates, or support plates, are generally not needed to further strengthen the connection between two hollow beams 1.

[0075] In the illustrated embodiment, additional fastener holes 13 ’,14 are not provided around the access openings 10. Since the access openings 10 are larger than the support openings 11, the omission of additional fastener holes 13’, 14 is to provide a larger continuous bearing surface around the access openings 10, thus increasing the strength of the hollow beam 1. The support openings 11 are small enough to allow additional fastener holes 13 ’,14 without compromising the strength of the hollow beam in any significant way.

[0076] As can be seen, the access openings 10 and the support openings 11 are formed in an alternating configuration between the ends 6 of the hollow beam 1. For each side wall 2, every other opening is an access opening 10 and a support opening 11 that are equidistant from each other, thereby forming an alternating and repetitive pattern of access openings 10 and support openings 11 between the end sides 4. As can further be seen, the alternating pattern on adjacent side walls 2 is opposite, or reversed, while the alternating pattern on opposite side walls 2 is equal. As such, every access opening 10 is only immediately adjacent to support openings 10 both in the lengthwise direction and in the circumferential direction of the hollow beam 1.

[0077] The described alternating configuration provides a unique combination of strength and access, and increased efficiency during rig up and rig down of different structures. The distribution of the access openings 10 makes it easy to access the whole inside of the hollow beam 1, which in turn makes it easier to handle fasteners such as screws and nuts during rig up and rig down of structures. It also makes it possible to reach through the hollow beam with a hand, which can be advantageous during construction. The support openings 11 allow firm support of external elements, in the illustrated embodiments tubes, without the need for any adapters or other means to alter the size of the support opening 11. As such, the construction of structures requiring such tubes becomes even more efficient. The tubes may also be inserted through the hollow beam, which can provide better support and more flexibility in terms of possible structures that can be made. The fact that the larger access openings 10 are only immediately adjacent to the smaller support openings 11 ensures a larger, continuous bearing surface for the hollow beam 1. Additionally, the oval shape of the access openings 10 and their orientation, i.e. with the largest diameter of the oval opening parallel with the longitudinal axis of the beam, ensures a larger continuous bearing surface between each access opening 10 and the lateral sides 5 of the side walls 2. As such, the hollow beam 1 has a higher strength for the same size and / or the same amount of material used to manufacture the hollow beam 1. This in turn makes it easier for a person to handle the hollow beams 1 during the construction of a structure.

[0078] Figure 2 shows three further examples of hollow beams 1 (A, B, C) according to the disclosure. Each of the three hollow beams 1 are similar to the one depicted in figure 1, only they are shorter. Beam A only has one access opening 10 or one support opening 11 between the end sides 4 of each side wall 2. Thus, disregarding the end walls 3, beam A only has an alternating pattern in its circumferential direction. Beam B has one access opening 10 and one support opening 11 between the end sides 4 of each side wall 2. Beam C has two access openings 10 and two support openings 11 between the end sides 4 of each side wall 2. As is apparent, beams B and C have an alternating configuration of access openings 10 and support openings 11 both in the longitudinal and in the circumferential direction of the hollow beam 1. The arched transition 8 between the side walls 2 is also visible.

[0079] Figure 3 shows eight different examples of hollow beams 1 (A-H) according to the disclosure. Beams A, B and C correspond to beams A, B and C in figure 2. Beam D corresponds to the beam depicted in figure 1. As can be seen, the hollow beam 1 can be manufactured in several different lengths. Having hollow beams 1 of different lengths provides added flexibility during the construction of structures.

[0080] Furthermore, it can also save time, as one does not need to connect multiple hollow beams 1 to achieve a certain length. The longest hollow beam 1, beam H, has twelve access holes 10 and twelve support holes 11 for each side wall 2. However, even longer beams are envisaged. Except for beam A, each beam (B-H) has an even number of access holes 10 and support holes 11 for each side wall 2. The number of holes does not need to be even, however.

[0081] Figure 4a depicts a hollow beam 1 from a side view perspective and figure 4b depicts a hollow beam 1 from a front view perspective. In other words, figure 4a shows a side wall 2 and figure 4b shows an end 6 of a hollow beam 1. The end 6 of the hollow beam 1 comprises a side wall 3 and the end sides 4 of side walls 2. The end sides 4 of side walls 2 substantially comprise the weld seam. Figure 4a further illustrates the lateral sides 5 and the end sides 4. Additionally, the depicted side wall 2 comprises three access openings 10 and three support openings 11 formed in an alternating pattern between the end sides 4 of the elongated side wall 2, or between the ends 6 of the hollow beam 1. Main fastener holes 13, regular additional fastener holes 13’ and larger additional fastener holes 14 are also depicted in figures 4a and 4b. As discussed in relation to figure 1, the fastener holes form square fastener hole patterns around each access opening 10 and each support opening 11.

[0082] The side walls 2 of the hollow beam 1 may be viewed as being divided into a number of equally large, square side wall segments 7. Each side wall segment 7 comprises either an access opening 10 or a support opening 11, with associated fastener holes. As such, the shown side wall comprises six side wall segments 7, each with an access opening 10 or a support opening 11 (only one side wall segment illustrated). The combined area of the side wall segments 7 is equal to the area of the side wall 2. Furthermore, the side wall segments 7 have substantially the same area as the end 6 of the hollow beam 1. As such, hollow beams 1 can be secured through their ends 6 to every side wall segment 7 without the adjacent hollow beams 1 interfering with each other. As is obvious, any side wall segment 7 of one hollow beam 1 may also be secured to any side wall segment of another hollow beam 1, either crosswise or lengthwise. In addition, an end 6, or a side wall segment 7, of one hollow beam, may alternatively be secured across a side wall segment 7 of another hollow beam. Put differently, one hollow beam 1 may be secured so that it partly covers an access opening 10 and a support opening 11 of another hollow beam 1. This is possible as a longitudinal distance L between main fastener holes 13 formed around adjacent access holes 10 and support holes 11 is equal to a longitudinal distance L’ between main fastener holes 13 and regular additional fastener holes 13’ formed around the support openings 11. As such, main fastener holes 13 of one hollow beam 1 may be matched with a combination of main fastener holes and regular additional fastener holes 13’ of another hollow beam 1 in order to secure the beams to each other. Securing one hollow beam 1 to another implies inserting a fastener through matching fastener holes, e.g. through matching main fastener holes 13. The fastener can be a screw which is secured at the other end by a nut.

[0083] The above-described square configuration makes the hollow beams 1 particularly suitable for use as a modular system, as any side wall segment 7 of one hollow beam 1 may be fully, or partly, matched with any side wall segment 7 of another hollow beam 1 in any direction (crosswise or lengthwise), and / or, with either end 6 of another hollow beam 1.

[0084] Figure 5 illustrates a structure 100 comprising three hollow beams 1, 1 ’, 1 ” according to the invention. The structure 100 can for example be a temporary structure. An end 6 of hollow beam 1’ is secured to a side wall 2 of hollow beam 1. Furthermore, an end 6 of hollow beam 1 ” is secured to another side wall 2 of hollow beam 1. The beams are secured to each other by inserting a screw through the matching main fastener holes 13 and tightening the screw on the other end by a nut. Neither a screw nor a nut is depicted in figure 5. The alternating pattern of access openings 10 and support openings 11 makes it easy to access the inside of the hollow beams 1,1’,!” to fasten the screws and nuts.

[0085] Figures 6a, 6b, 7, 8a and 8b each show different structures comprising the hollow beam 1 according to the disclosure. The depicted structures are scenographic structures 101 that can be used for example in a TV studio or in a theater. The scenographic structures 101 may be temporary structures.

[0086] The scenographic structure 101 in figure 6a is a light stand comprising a vertical hollow beam 1, which is kept vertically stable by a support plate 32. Two tubes 20, in this example 48.3mm tubes that are commonly used in the TV and film industry, are inserted through- and supported by support openings 11 at two different heights The tubes 20 each supports two lights 31. Figure 6b illustrates a table comprising hollow beams 1 of different lengths and a table plate 33.

[0087] Figure 7 illustrates a scenographic structure 101 in the form of a light support rack. The light support rack supports a number of first lights 31’. Furthermore, the scenographic structure 101 comprises a tube 20 with other types of lights 31” attached, and wheels 34. The tube 20 may be further secured by for example a clamp (not shown) to prevent the tube 20 from rotating within the support openings 11, and / or to prevent the tube 20 from sliding out of the support openings 11.

[0088] Figures 8a and 8b show further scenographic structures 101 comprising hollow beams 1. The scenographic structure 101 in figure 8a comprises a stage curtain 35. The scenographic structures 101 depicted in figure 8b each comprises lights 31 supported on support plates 32 secured on top of vertically oriented hollow beams 1.

Claims

CLAIMS1. A hollow beam for the construction of structures, the hollow beam comprising: a plurality of elongated side walls having a first end and a second end, wherein at least two of the plurality of elongated side walls each comprises: at least one access opening adapted to allow a hand to pass therethrough; at least one support opening adapted to receive and support an external element; and a plurality of fastener holes formed around at least one of the access opening and the support opening, the fastener holes being adapted to receive one or more fastener, wherein the at least one access opening and the at least one support opening are formed in an alternating configuration between the first end and the second end.

2. The hollow beam according to claim 1, wherein each of the plurality of elongated side walls comprises at least one access opening, at least one support opening, and a plurality of fastener holes formed around at least one of the access opening and the support opening.

3. The hollow beam according to claims 1 or 2, wherein the alternating configuration on adjacent side walls is different.

4. The hollow beam according to claims 1, 2 or 3, wherein the alternating configuration on adjacent side walls is reversed.

5. The hollow beam according to any one of the previous claims, wherein the elongated side walls each comprises at least two access openings, or, at least two support openings.

6. The hollow beam according to any one of the previous claims, wherein the at least one access opening is larger than the at least one support opening, and wherein the support opening is larger than each one of the plurality of fastener holes.

7. The hollow beam according to any one of the previous claims, wherein the at least one access opening has an oval shape.

8. The hollow beam according to any one of the previous claims, wherein the support opening comprises a shape adapted to accommodate and directly support an external element in the form of a rod, a beam or a tube.

9. The hollow beam according to any one of the previous claims, wherein the hollow beam comprises an end wall connected to the first end and the second end of each elongated side wall, thereby forming a closed hollow beam.

10. The hollow beam according to claim 9, wherein the end walls each comprises a support opening.

11. The hollow beam according to claims 9 or 10, wherein the end walls are thicker than the elongated side walls.

12. The hollow beam according to any one of the previous claims, wherein the fastener holes are adapted to receive the one or more fastener for securing the hollow beam to another hollow beam, or, to an external equipment.

13. The hollow beam according to any one of the previous claims, wherein the fastener holes are formed around each access opening and each support opening.

14. The hollow beam according to any previous claim, wherein the hollow beam has a substantially square cross-sectional shape.

15. The hollow beam according to claim 14, wherein the alternating configuration on opposite side walls is equal and wherein the alternating configuration on adjacent side walls is different.

16. The hollow beam according to claim 15, wherein the alternating configuration on adjacent side walls is reversed.

17. A kit of parts comprising at least one hollow beam according to any of claims 1- 16 and at least one external component.

18. The kit of parts according to claim 17, wherein the external component comprises an external element, an external equipment, a fastener, or another hollow beam.

19. A system comprising at least one hollow beam according to any of claims 1-16 and at least one external component, and wherein the at least one hollow beam and the at least one external component are connected to form a structure.

20. A system according to claim 19, wherein the structure is a temporary structure.

21. A method of assembling a system according to any of claims 19 and 20, the method comprising connecting the at least one hollow beam and the at least one external component by means of one or more fastener.

22. A method of manufacturing a hollow beam, the method comprising the following steps; forming a plurality of elongated side walls by extrusion to form a single piece, the single piece comprising the plurality of elongated side walls, partly inserting an end wall into an end of the single piece, securing the end wall to the single piece by welding, and milling off an outer surface of the end wall, thereby reducing a thickness of the end wall.

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