Abstract:
A threaded cable hanger attached to a stud includes a reverse (protuberant) dimple that provides a seat for the end of the stud, and permits the bar to make up to a full final turn to permit the bar to be in a desired orientation. A stud top containing the reverse dimple may be disposed across the path of the stud. The stud stop may slowly bend from a configuration extending toward the stud to a configuration extending away from the stud, during bending absorbing energy and resisting excessive torquing. A pair of overlapping arms may be provided, one of which is internally threaded to receive the stud and guide it toward the reverse dimple and stud stop. When a large external force attempts to pull the bar off the stud, or when torquing is extreme, the arms unfold and create a binding action on the stud.

Description:
BACKGROUND OF THE INVENTION 
     In the field of threaded cable hangers (cable-hanging metal bracket assemblies) for use in ships, and elsewhere, there are several factors that are of primary importance: 
     (a) that the electrical cables be hung effectively and strongly and permanently and easily, and in the desired locations and combinations; 
     (b) that the cost be low; and 
     (c) that it be very difficult or impossible to wreck the cable hangers by over-zealous application of muscle while threading the cable hangers onto threaded supporting studs. 
     Relative to the above factor (a), it should be possible to merely weld threaded studs to the wall (bulkhead) or ceiling (overhead), thread the cable hangers onto the studs until they are properly and permanently seated and are in the right orientations, and connect the cables to the hangers. Then, the hangers should strongly support the cables for as long a time as desired. 
     Relative to factor (b), the cable hangers should be capable of being made on a punch-press of one piece of sheet metal. Because of the high cost of punch-press dies, a single configuration of hanger should be readily capable of very different cable-hanging applications. 
     Relative to factor (c) it is emphasized that the sizes and shapes of some cable hangers are such that very strong persons can apply huge forces to the mated threads at the surfaces of threaded studs. It would be very desirable if even stripping of the original threads of the cable hanger or stud did not permit the cable hanger to move off the stud. 
     SUMMARY OF THE INVENTION 
     In accordance with a first embodiment of the invention, which may be called a heavy duty T-bar cable hanger, a strong bar is so constructed that there are three ways of strongly and properly associating it with a threaded stud. One is a reverse (protuberant) dimple that provides a seat for the end of the stud, and that permits the bar to make up to a full final turn so as to tightly relate the bar to the stud and also permit the bar to be in a desired orientation. 
     The second way is a stud stop that is disposed across the path of the stud, and that contains the above-indicated reverse dimple. The stud stop is so associated with the remainder of the bar that it may slowly bend from a configuration extending toward the stud to a configuration extending away from the stud, during all of which bending it absorbs energy and resists excessive torquing. 
     The third way is a pair of overlapping arms one of which is internally threaded to receive the stud and guide it toward the reverse dimple and stud stop. When there is a very large external force attempting to pull the bar off the stud, or when the torquing is so extreme that not only is the stud stop pushed over center from one side to the other but the torquing is continued thereafter, the arms start to unfold and accordingly create a binding action on the stud. This binding action is so effective that it holds the bar on the stud even if the original threads are stripped. However, it is a feature that—despite the binding—the bar may when desired be intentionally removed from the stud by reversing the direction of torquing. 
     The above elements, especially the overlapping arms and the stud stop, perform plural functions. Thus, for example, the threaded one of the arms is the normal threaded element that receives the stud, even if there is (as often occurs) only enough torquing to collapse the reverse dimple and not bend the stud stop or cause the arms to unfold. As another example, the stud stop is defined between two parallel slots; these receive bands that support the cables. 
     In accordance with a second embodiment of the invention, the above-indicated T-bar cable hanger is quickly and cheaply adapted for inverted (hanging—vertical stud) T applications. This is done by punching out the reverse dimple to create a hole sufficiently large that the stud may freely pass through it. A male/female elongate standoff spacer is provided for double (or triple, etc.) decking of the bars. Then, a bar is threaded upwardly onto a depending vertical stud, at the threaded hole in one of the above-indicted arms. The standoff spacer is then threaded onto the stud below the bar. This is repeated for as many decks of bars as is desired. The cables are banded to the bars. 
     In accordance with third and fourth embodiments, separate bands for the cables are not employed. Instead, integral metal arms support the cables. In the third embodiment, additional metal arms extend from a short channel having the above-indicated overlapping arms one of which is threaded. In the fourth embodiment, a return-bent sheet metal strip is internally threaded on one side to receive the stud. The other side of the return-bent strip is provided with the dimple (as is the flange of the third embodiment indicated above). The return-bent element extends in U-shaped configuration such that cables (one or several) nest therein and are supported thereby. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric exploded view of the first embodiment, the bands and cables being unshown; 
     FIG. 2 corresponds to FIG. 1 but is an assembly view showing the bands and cables in phantom, and showing the stud stop pushed out by forceful threading; 
     FIG. 3 is a section on line  3 — 3  of FIG. 1 but showing the stud threaded into contact with the reverse dimple, and showing (in section) the overlapped arms before excessive torque is applied; 
     FIG. 4 is a section on line  4 — 4  of FIG. 2, showing bending and binding that result from application of excessive torque; 
     FIG. 5 is a section on line  5 — 5  of FIG. 4; 
     FIG. 6 is an isometric view, largely exploded, of the second embodiment; 
     FIG. 7 is a side elevation of the second embodiment when fully assembled, but with cables unshown; 
     FIG. 8 is a section on line  8 — 8  of FIG. 6; 
     FIG. 9 is an isometric view of the third embodiment, showing in phantom two cables held by bent arms; 
     FIG. 10 is an isometric view showing the third embodiment from the other side; 
     FIG. 11 is a section on line  11 — 11  of FIG. 9; 
     FIG. 12 is an isometric view of the fourth embodiment; and 
     FIG. 13 is a section on line  13 — 13  of FIG. 12, and showing cables held by bent sheet metal. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the first embodiment, a heavy duty T-bar cable hanger assembly, this is shown in FIGS. 1 through 5. The overlapped arms are also shown in isometric FIG. 6, top bar. 
     A threaded steel stud  10  is welded at one end to a wall (bulkhead)  11  of a ship or other construction (for example, a building). Typically, wall  11  is substantially vertical, and the stud, which is perpendicular to the wall, extends substantially horizontally. 
     An elongate cable-supporting bar  12  is threaded onto stud  10  so as to be supported thereby; the stud and bar combine to form a T-shape. Bar  12  has a channel-shaped body  13 . 
     It is conventional for bar  12  to be threaded onto stud  10  for a desired number of turns and until bar  12  is horizontal as illustrated. It is not known what orientation bar  12  will be in when it first seats; thus, one benefit of the present invention is to permit bar  10  to be turned-after first seating-until the bar is not only horizontal but is tightly associated with the stud. 
     Without limitation, it is pointed out that the bar  12  nay have a length ranging from (for example) 1.5 inches to 7.5 inches. A typical width of the bar is about 1 inch. The bar is formed of strong but bendable sheet steel, either carbon steel or stainless steel. 
     Description of the Method of Manufacture 
     It is a feature of the invention that the T-bar cable hanger may be, and very preferably is, made out of a single piece of sheet steel, on a punch-press. Without limitation, a specific example is now given of how this is preferably accomplished. The particular example relates to the 7.5 inches long cable-supporting bar  12 . 
     There is punched out of sheet steel stock a flat blank, not shown, that is an elongate rectangle 7.5 inches long and approximately 1⅝th inches wide. The end corners of the rectangle are cut off at approximately 45 degrees. The blank is not free, being held to a metal strip that moves through the press. 
     Provided at the central region of the blank, and lying in the same plane, are an outer arm and an inner arm. The arms are preferably exactly registered with each other; each has a dimension longitudinally of the blank of approximately 1.5 inches. Each arm projects outwardly approximately ⅞ inch. 
     While the entire blank, including the arms, is in the same plane, holes are punched in the arms and, furthermore, sheet metal surrounding each hole is bent outwardly. 
     The outwardly-bent sheet metal surrounding the hole in the outer arm is generally frustoconical; it is not threaded. The outwardly-bent sheet metal surrounding the hole in the inner arm is generally cylindrical. 
     The size relationships are caused to be such that, after the arms are bent and overlapped as described below, the cylindrical outward-bent sheet metal extends upwardly into the frustum of a cone. 
     The cylindrical sheet metal surrounding the hole in the inner arm is threaded at a later stage in the manufacturing process, as indicated below. It is sized and adapted to threadedly receive the threaded stud  10 . 
     In the present specific example the hole in the outwardly-bent sheet metal cylinder in the inner arm is approximately ⅜ inch in diameter. 
     Proceeding further with a description of the steps that occur while the blank is in the same plane in the punch-press, two slots are formed in spaced relationship from each other and parallel to each other, each extending perpendicularly to the longitudinal axis of the blank. Each slot is approximately ¾ inch long and ⅛ inch wide. Pressing operations are then performed on the metal, which becomes the stud stop, between the slots. Such metal between the slots is pressed so as to be offset substantially from the main body of the sheet metal blank. There are crease lines that extend parallel to the blank; the metal between the crease lines is somewhat outwardly arcuate. 
     In addition, a dimple is formed in the under side of the stud stop, and this creates the above-indicated reverse dimple that extends outwardly and is subsequently engaged by an end of the stud. 
     Side flanges are bent upwardly from side regions of the flat blank so as to be perpendicular to the main body of the blank (this being the web of the channel-shaped body). In the present specific example, each side flange is approximately ⅜ inch high so that the web between the side flanges is approximately 1 inch wide. 
     The arms are bent and folded into parallel and overlapping relationship to each other, parallel to the web, with the outwardly-bent sheet metal cylinder extending upwardly into the hole defined within the outwardly-bent frustum of a cone. 
     The outwardly-bent cylinder is then tapped to form a thread that will threadedly receive the stud  10 . 
     Accordingly, the cable-supporting bar  12  had been rapidly and strongly and cheaply made, in a punch-press, from a single piece of sheet metal, namely a unitary sheet metal blank punched from sheet metal stock. 
     Summary of the Construction of the Bar  12 , Using Reference Numbers 
     The arms shown in FIG. 6 (which relates primarily to the second embodiment) are exactly the sane as the arms, of the first embodiment. Thus, the arm portions shown in FIG. 6 correspond exactly to the arm portions shown in FIG.  3 . In these figures, and others, the outer arm is numbered  14  and the inner arm is numbered  15 . 
     These arms are bent (folded) and overlapped as shown. They are not significantly connected to each other except through the channel flanges and web with which they are integral. By “significantly” is meant in such a way as to prevent movement of the arms relative to each other. Thus, for example, the arms are preferably not welded to each other. 
     The outwardly-bent frustum of a cone, surrounding the hole in outer arm  14 , is numbered  17 . The outwardly-bent cylinder, surrounding the hole in inner arm  15 , is numbered  19 . Cylinder  19  penetrates frustum  17 , as shown in the drawings. There is close nesting, with consequent high-strength two-ply defining of the threaded hole. 
     The described slots are shown at  21 , 22  in FIGS. 1 and 3, prior to excessive torquing. Such slots define the stud stop  23 . The crease lines at the longitudinal side edges of stud stop  23  are numbered  24  in FIGS. 1 and 3. 
     Numbers  26  and  27  indicate, respectively, the dimple and reverse dimple (FIGS.  1  and  3 ). 
     Description of Operation, and Further Description of Construction of the First Embodiment of the Invention 
     Let it be assumed that the described cable-supporting bar  12  is threaded properly onto the stud  10  that has been welded to bulkhead  11  (FIG.  1 ). The person mounting the bar on the stud merely threads the integral threaded cylinder  19  onto stud  10  by rotating the bar. Rotation is continued until the end of the stud engages reverse dimple  27 , which is protuberant toward bulkhead  11 . 
     As soon as the stud end seats on the reverse dimple, the installer rotates the bar  12  for an additional turn or partial turn, until the bar is horizontal as shown. Furthermore, the pressure thus exerted between reverse dimple and stud creates a tightening action, somewhat in the nature of a lock washer, that prevents the bar from rotating on the stud unless the bar is intentionally turned. 
     Let it next be assumed that, as often occurs, the installer does not stop at the right time but instead continues rotating-often with a large amount of muscle applied. What happens then is that the reverse dimple is depressed and, furthermore, stud stop  23  is pushed by the stud in a direction away from the bulkhead. If carried to extreme, the stud stop  23  is pushed through the plane of web  30  of the channel-shaped bar  12  and is bent to the side of the bar remote from the bulkhead  11 , as shown in FIG.  2 . The stud stop nay be caused to extend away from the plane of web  30  as far “below” the web (away from the bulkhead) as it was originally “above” the web (toward the bulkhead). The reverse dimple is inverted-turned inside out (FIG.  2 ). 
     Let it next be assumed that there is a more extreme condition, such that the rotation is continued even after the stud stop  23  is pushed by the stud as far as the stud stop will go. This would normally strip the threads  32  of the outwardly-bent sheet metal cylinder  19 , thereby destroying the integrity of the connection between stud and the cable-supporting bar  12 . However, because of a further aspect of the invention the connection will be maintained even under such extreme conditions. What happens is that the additional turning of the bar  12  causes inner arm  15  to bend away from web  30 . When the inner arm thus bends, it lifts the outer arm  14  (FIG.  4 ). This causes the holes in the outer and inner arms to no longer be fully registered with each other, but instead to become more and more out of registry with each other. In other words, there is a binding action created, the strength of the binding action increasing in accordance with the magnitude of the turning action. 
     Even if the original threads  32  strip, this binding action is such that additional threads can be cut in response to the binding and turning. 
     It follows that in substantially all events short of actual breaking of the stud  10 , the stud and cable-supporting bar  12  will remain assembled with each other regardless of excessive torquing performed by the operator who installs the bar on the stud. 
     (It is also emphasized that even a direct pulling force, unrelated to turning or installation, is resisted by the overlapping arms  14 , 15  so that there is a very strong action securing the cable-supporting bar to the stud and thus to the bulkhead  11 .) 
     The electrical cables  33  (FIG. 2) are then readily installed onto the bar  12  by use of synthetic resin (or other) bands  34 . These bands are extended through the slots  21 , 22  in web  30 , so that these slots have a double function. The bands are secured by suitable buckle or fastening arrangements (not shown) known in the art. 
     The inner portions of the bands extend between channel flanges  28 , 29 , and thus are held in position by the flanges as well as by the edges defining the slots. As shown, the bands extend around the ends of the web. The channel flanges thus not only add strength, but aid in mounting the bands. 
     If at any time it is desired to remove the cables and bar, the cables are first dismounted, following which the bar  12  is removed by merely rotating it in the opposite direction from which it was installed. It has been found that the bar will normally rotate off the stud even after the above-described binding action has occurred. 
     Description of the Second Embodiment of the Invention, Namely, a T-bar Cable Hanger for Inverted T applications 
     Referring to FIGS. 6 through 8, a (frequently) long threaded stud  38  is welded at its upper end to an overhead  38   a  in a ship, or to a ceiling in a building, etc. Then, a cable-supporting bar that corresponds exactly to the one described relative to the previous embodiment, with one salient exception, is provided. Such bar is numbered  12   a  and has the reverse-dimple  27  and surrounding region punched out (or drilled out) to such a diameter as to just provide clearance for the associated stud  38 , there being no threading. Thus, stated otherwise, a clearance hole  39  is formed by the punching-out that permits free movement of stud  38  therethrough without any threading action, but lateral support is provided by the circular edge of the hole. The cable-supporting bar  12   a  is used in conjunction with one or two other parts. The first is an elongate male/female standoff spacer  41  (FIG.  6 ). The other is a common nut  42 . The spacer and nut are sized and threaded correspondingly to stud  38 . 
     In the operation of the present embodiment, a first cable-supporting bar  12   a  is moved up around the lower end of stud  38 , with the stud passing freely (but with no slop) through the indicated clearance hole  39 —such clearance hole being uppermost when the bar  12   a  is oriented as illustrated in FIGS. 6 and 7. Such upward movement is continued until the lower end of stud  38  reaches the internally threaded hole in the outwardly-bent cylindrical portion  19 . 
     Then, the bar  12   a  is rotated about the vertical axis to thread it upwardly onto the lower end portion of the stud  38 . After a desired amount of such threading, creating a strong connection, the internally-threaded tubular upper portion  43  of the standoff spacer  41  is threaded upwardly onto the lower end of stud  38  and is tightly seated against the outwardly-bent frustum region  17  surrounding the hole in outer arm  14 . This firmly holds the bar  12   a  in a desired angular position. 
     Cables  45  are then mounted on the upper side of the bar  12   a  by means of associated bands  46  corresponding to bands  34  previously referred to. This can be done on one or both sides of the stud, namely the right side as shown in FIG. 6 (where cables are illustrated) and the left side therein (where cables are not now illustrated but where they can be present). The flanges  28 , 29  help support the cables. 
     Then, assuming it is desired to hang more cables, an additional (lower) bar  12   a  is moved upwardly around the downwardly projecting lower male end of standoff spacer  41 , this being numbered  47 . During the first part of the upward movement, the male end  47  moves freely (with no slop) through the clearance hole  39 ; thereafter it is necessary to rotate the bar  12   a  about a horizontal axis in order to thread the male end  47  into the internally threaded hole in the outwardly-bent cylinder  19 . 
     Additional cables (not shown) are then banded to the bar. This procedure is repeated relative to a desired number of bars, there being two bars illustrated in FIGS. 6 and 7. Below the lowermost bar is mounted the nut  42 . 
     The several bars  12   a  are caused to be parallel to each other as illustrated, and resist undesired rotation. 
     It is pointed out that the clearance hole  39 , that is to say the metal surrounding the clearance hole, acts as a guide and torque-resisting means which strengthens the association between the stud and the bar. 
     Instead of using the standoff spacers  41 , it is possible to provide all of the bars on a single elongate stud, and then provide a nut below each bar to serve as a locking means. In each case, the nut is tightened against the bottom surface of the outwardly-bent sheet metal  17 . 
     Description of the Third Embodiment of the Invention, Employing Integral Metal Arms Instead of Separate Bands 
     Referring to FIGS. 9-11, there is illustrated at  12   b  a short cable-supporting bar which corresponds somewhat to the bar  12  with the important exception that there is (in the illustrated form) no stud stop  23 . Instead, the reverse dimple (indicated at  51  in FIG. 11) is formed in the web  30   b  of the short channel, there being no slots. The channel flanges are shown at  128   b , 29   b.    
     Offset elongate arms  52 , 53  extend outwardly from the ends of the channel web  30   b . These arms are bent by the installer so as to bend around the cables in place of the previously described bands  34  and  46 . 
     In the operation of the third embodiment, a threaded stud  54  is welded onto a vertical (normally) wall or bulkhead, and the threaded outwardly-bent sheet metal cylinder is threaded onto the end of such stud. Threading is continued until the reverse dimple  51  is engaged by the stud end. Further threading is then effected in order to tighten the connection and achieve the desired orientation of the bar. Cables  55  are thus supported by the arms  52 , 53  which are wrapped around them. 
     When the torquing is excessive, so that the reverse dimple  51  is fully collapsed and bent to a region where it can no longer bend further, additional (undesired) threading causes the overlapping arms (shown at  14   b , 15   b ) to start to unfold and create the above-described binding action. Thus, the cable hanger has great strength against excessive torque during mounting, and also against pulling forces applied from external sources. 
     Description of the Fourth Embodiment of the Invention 
     In accordance with the fourth embodiment, an elongate strip of sheet metal, is provided, in a punch press, with a hole around which sheet metal is outwardly bent in generally cylindrical relationship, to form cylinder  57 . Th is cylinder is tapped so as to form internal thread  58 . 
     Also in the press, a reverse dimple  59  is formed in such location that it will be directly opposite the internally-threaded cylinder when an end portion of the blank is return-bent into the U-shaped (hairpin-shaped) configuration  60  shown at the upper-right in FIG.  13 . 
     The remainder of the blank is bent into a much larger U-shaped configuration  61  so as to receive one or more (for example two or three) cables  62  one on top of another. 
     In operation, a stud  63  is welded to a bulkhead  64  and projects horizontally therefrom. The described cable hanger is threaded onto the stud until the reverse dimple  59  is engaged and partially collapsed. Thus, there is a tight relationship between the stud and the cable hanger, and the large U-shaped portion  61  of the cable hanger is caused to be in the desired orientation which is normally the one illustrated. Cables  62  are then mounted in U-shaped portion  61 . 
     The upper-outer end of the large U-shaped cable-receiving portion  61  is vertically split, as shown, in order to facilitate bending thereof around the cable so as to lock them in place. 
     The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.