Patent Application
20180309275
This invention relates generally to cable tray systems used to support electrical wiring, cables, conduit and data transmission lines (collectively “cables”), and more particularly to junctions which connect two or more cable tray sections or accessories.
Cable trays systems generally provide support for cables as the cables extend from a first location to a second location. Cable tray systems can be comprised of metal, plastic, or other suitable types of materials. One exemplary type of cable tray is referred to as a “mesh” or “basket” cable tray. These types of cable trays are comprised of interconnected members such as metal bars or wires. Most mesh cable trays include space apart U-shaped cross members which are connected by lateral support members along the sides and bottom of the cross members. The cross members are generally perpendicular to the longitudinal axis of the cable tray. The cables are generally supported by the bottom portion of the cross members as the cable tray system carries the cable from one point to another point.
Most cable trays are adapted to join with one or more other cable trays at intersections such as T-intersections or four-way intersections to create the cable tray system. Further, sometimes a radius or bend section is necessary to allow a single cable tray to turn a corner or change elevation. Other accessories used to connect portions of a cable tray system include reduces, benders, risers, and cross pieces. Collectively, these various accessories are sometimes referred to herein as “accessory sections.”
Most mesh or basket cable trays are designed to be field configured out of straight sections, meaning very few accessory sections exist to bend around corners or change elevations. The few that do are bulky and expensive to ship because they are created as a single section at the factory, and difficult to assemble/install.
Another problem with typical cable tray sections is that they are difficult to install when ceiling beams, pipes, and other obstructions are present. While the prior art describes the use of a “ladder” system that can be installed in a stair-step manner to get around such obstructions, the sections are rigid and of a predetermined length, and therefore cannot be easily configured to get around obstructions or change elevations. There is therefore a need in the art for a cable tray apparatus which overcomes these and other deficiencies in the prior art.
The present invention relates to an improved cable tray accessory section that is bendable allowing it to easily bend over or under obstructions, such as ceiling beams and pipes. The bendable cable tray comprises a plurality of cross members combined by first and second longitudinal side members. The cross members are not combined by any other means thereby allowing the first and second longitudinal members to be easily bent in the field by the user to a desired configuration. In some embodiments the cross members are “U” or “V” shaped. The bendable cable tray section is adapted to connect on each end to another cable tray or accessory section. In one embodiment the bendable cable tray has a first end combined with a first cable tray and a second end combined with a second cable tray. In some embodiments the bendable tray section starts with one end at a particular elevation, bends over or under an obstruction, then returns the second end to the original elevation. In other embodiments the bendable tray section starts with one end at a particular elevation then bends along its length (typically upward or downward) so that the second end is positioned at a different elevation.
The longitudinal side members are preferably made of any suitable material that allows for easy bending yet remains in the bent position after bending. In one embodiment the side members are made from a malleable metal that can be bent by hand such as low carbon steel wire. The steel wire may be galvanized, stainless, or powder coated.
Another aspect of the invention relates to a method of using the cable tray accessory section described above. The method includes taking a bendable tray section which has a plurality of cross members combined only by a first longitudinal member and a second longitudinal member. The first and second longitudinal members are manually bent to create a first corner wherein a first portion of the bendable tray section is angled relative to a second portion of the bendable tray section. The first and second longitudinal members are further bent to create a second corner wherein the second portion of the bendable tray section is angled relative to a third portion of the bendable tray section. The method further includes securing the first portion of the bendable tray section to a first cable tray section and the third portion of the bendable tray section to a second cable tray section.
Another aspect of the invention relates to a method of manufacturing the cable tray accessory section described above. The method includes connecting a first longitudinal side member with a second longitudinal side member using a plurality of cross member. The cross members may include a bottom member having a first side member extending from one end and a second side member extending from the other end to form a generally “U” or “V” shape. The side members have a first end combined with the bottom member and a second end combined with one of the longitudinal side members. In one embodiment the side members extend from the bottom member in the same direction at an angle of between 70 and 110 degrees. In another embodiment the side members extend from the bottom member in the same direction at about 90 degrees. The side walls created by this depth helps retain the cables within the tray.
As shown generally in
In order to allow the bending of the longitudinal side members 12, the bendable cable tray section 10 does not include any longitudinal supports that run parallel with the sidewalls 12 at the areas where bending may occur, such as the corners 16 shown in the figures. In other words, the bendable tray section 10 does not include any members that connect the cross members 14 except for the two side members 12. This allows the cross member 14 to easily move relative to each other as the assembly is bent at desired locations along the longitudinal side members 12. For example,
In the embodiment shown, the cross members 14 are generally “U” or “V” shaped. In other words, the cross members 14 include a bottom member 14a extending across a width and a side member 14b extending outward from each end of the bottom member 14a to provide some depth to the tray section 10. The side members 14b have a first end combined with the bottom member 14a and a second end combined with one of the longitudinal side members 12. In one embodiment the side members 14b extend from the bottom member 14a in the same direction at an angle of between 70 and 110 degrees. In the embodiments shown the side members 14b extend from the bottom member 14a in the same direction at about 90 degrees. The side walls created by this depth helps retain the cables within the tray.
As shown in
The longitudinal side members 12 of the bendable tray section 10 may be made of any suitable bendable material including meals and plastics. In one embodiment the material is rigid and malleable with minimal elasticity. The material may be a low carbon steel wire, which may be galvanized, stainless, or powder coated. The malleability is such so that a user can bend the side members 12 by hand and the elasticity is such so that once bent, the side member 12 remains in the bend position. This allows the side wall 12 to be easily bent by the user to a desired angle without returning to their original position after force is removed. The bendable tray section 10 is easily configured in the field to the appropriate shape without the need for any tools, cutting, or pre-fabrication.
In some embodiments, the bendable tray includes a means for connecting the bendable tray to the cable tray sections. In the embodiment shown in
Another aspect of the invention relates to a method of using the bendable cable tray section 10 described above. The method comprises manually bending the bendable cable tray section 10 to a desired angular configuration then connecting one or both of its ends to another portion of the cable tray system, such as a cable tray 20 or an accessory section. In one embodiment, a user manually bends a first portion of the bendable cable try section 10 to create corners 16 (this is shown as two corners to make the ninety degree bend) a predetermined distance from a first end of the bendable cable tray section 10. This create a first portion of the bendable cable tray section 10 that is generally horizontal and a second portion of the bendable cable tray section 10 extending at some angle relative to the first portion. In the embodiment shown in
Another aspect of the invention relates to a method of manufacturing the cable tray accessory section described above. The method includes connecting a first longitudinal side member 12 with a second longitudinal side member 12 using a plurality of cross member 14. The cross members 14 may include a bottom member 14a having a first side member 14b at one end and a second side member 14b at the other end to form a generally “U” or “V” shape. The side members 14b have a first end combined with the bottom member 14a and a second end combined with one of the longitudinal side members 12. In one embodiment the side members 14b extend from the bottom member 14a in the same direction at an angle of between 70 and 110 degrees. In another embodiment the side members 14b extend from the bottom member 14a in the same direction at about 90 degrees. The side walls created by this depth helps retain the cables within the tray.
Having thus described the invention in connection with the preferred embodiments thereof, it will be evident to those skilled in the art that various revisions can be made to the preferred embodiments described herein without departing from the spirit and scope of the invention. It is my intention, however, that all such revisions and modifications that are evident to those skilled in the art will be included with in the scope of the following claims.
