Abstract:
A system for arranging a plurality of conductors includes a guide assembly having a plurality of passage guides. Each of the plurality of passage guides are constructed to guide the passage of a conduit through the guide assembly. The guide assembly is securable to a substrate and constructed to organize individual conduits passing therethrough. The individual conduits communicate any one of a fluid, an electrical power, a hydraulic fluid, or the like through the guide assembly.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application is continuation-in-part of and claims priority of U.S. Ser. No. 10/908,414 filed May 11, 2005, the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to guide assemblies and, more particularly, to a guide assembly having multiple passage guides connected thereto.  
         [0003]     During construction of residential and commercial facilities, it is often required to pass conductors through the structure of the facility. Such conductors include power cables, water lines, phone cables, and television signal cables. Additionally, with the proliferation of “smart buildings” it has become more desirable and cost efficient to pass computer cables as well as entertainment and security cables within wall, floor, and ceiling cavities. Such systems are often referred to as structured wiring systems and often include a bundled array of phone, computer, co-axial, and speaker cables.  
         [0004]     Often, the devices associated with a specific system share a common point of origin. For simplicity, only one such system will be described. In buildings equipped with radiant heat systems, a plurality of radiant heating loops are connected to a manifold and extend about the building. The simplest of radiant heating loops have a first end connected to a hot water inlet, extend about the area to be heated, and have a second end connected to a return manifold thereby forming a “loop”. A heating fluid, such as water, is heated by a heat source, such as a water heater or boiler, and is pumped through the heating loop. Such radiant heating loops are frequently located in close proximity to a finish floor of the area to be heated. The heating loops can be positioned beneath a subfloor or sandwiched between a subfloor or substrate, and a finish floor.  
         [0005]     To maximize the usable space of a structure, the heating loops often extend generally transverse to the floor surfaces in close proximity to a wall surface. Such an orientation minimizes the space obstructed by the heating tubes. Often, an elbow is employed to facilitate this generally transverse directional change. For radiant heat systems, each end of a loop must be threaded through an elbow. A single loop heating system requires an elbow to be passed over each end of the heating tube. Each elbow must then be securely fastened to a sub-surface to allow a finish floor to be formed thereabout. Individually securing each elbow is a time consuming and tedious process and often delays the construction process. Although there are known elbow constructions that allow the conduit to pass radially into the elbow, these elbows only support individual conductors. That is, often multiple elbows must be individually secured and individual conductors passed therethrough or thereinto. Additionally, depending on the finish floor system formed about the heating tubes, inadvertent movement of the individual elbows can result in damage or displacement of the conductor passed therethrough during formation of the finish floor.  
         [0006]     Radiant floor heating has gained increased acceptance as the preferred heating method for spaces built on grade or in basements. The radiant tubes are often attached to a supporting structure and a concrete floor is often poured thereover. The process of finishing a concrete floor often employs the application of a power trowel. The power trowel includes a plurality of individual floats attached to an engine. Operation of the engine rotates the floats and as the power trowel is moved across the surface of the floor, the floats provide a relatively smooth and flat finish of the floor. An operator of the power trowel must be particular careful during finishing of the floor near the array of individual elbows that have been passed thereinto. Although the concrete is generally stiff enough to support the weight of the power trowel and an operator thereof, inadvertent contact between the power trowel and the elbows can result in displacement of the elbows from their secured location. Such an event produces a relatively unsightly finished alignment of the individual elbows and/or a blemish in the finish of the floor. Worse yet, if the floats of the power trowel contact the radiant tube or other conductor passed through the elbow, the float could sever the conductor or minimally form a leak in fluid communicating conductors.  
         [0007]     It would therefore be desirable to have a system and method capable of quickly and efficiently guiding and securing a plurality of conductors in such applications.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0008]     The present invention provides a system and method that solves the aforementioned drawbacks. Specifically, a system for arranging a plurality of conductors includes a guide body having a plurality of passage guides connected thereto. Each of the plurality of passage guides is constructed to direct the passage of an individual conductor therethrough. The guide body is securable to a substrate and constructed to organize the individual conductors connected thereto. The individual conductors communicate any one of a fluid, an electrical power, a hydraulic fluid, or the like through the guide body.  
         [0009]     Therefore, in accordance with one aspect of the present invention, a method of positioning a conduit array is disclosed. The method includes the step of securing a guide block to a substrate and securing a first conduit to the block such that the first conduit extends in crossing directions from the guide block. The process also includes securing a second conduit to the guide block such that the second conduit extends in directions generally similar to the first conduit.  
         [0010]     According to another aspect of the invention, a guide assembly having a body and a plurality of channels formed therein is disclosed. The body has a first portion which extends in a first direction and a second portion that extends in a crossing direction relative to the first portion. The plurality of channels formed in the body extend across the first portion and the second portion and each channel is constructed to receive a conductor conduit therein.  
         [0011]     According to a further aspect of the present invention, a guide system having a guide body and a cover is disclosed. The guide body has a plurality of passages formed therein and each passage extends between a first end and a second end of the guide body. The first end of each passage extends in a first direction which is across a second direction of the second end. The cover is connectable to the guide body and has a profile that generally matches at least a portion of a profile of the guide body. A plurality of recesses is formed in the cover and spaced apart a width of each of the plurality of passages. Each recess is constructed to allow uninterrupted passage of a conductor conduit from an associated passage of the plurality of passages of the guide body.  
         [0012]     Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.  
         [0014]     In the drawings:  
         [0015]      FIG. 1  is a perspective view of one embodiment of a guide assembly according to the present invention secured in a substrate.  
         [0016]      FIG. 2  is a perspective view of the guide assembly shown in  FIG. 1 .  
         [0017]      FIG. 3  is a cross-sectional view of the guide assembly along line  3 - 3  of  FIG. 2 .  
         [0018]      FIG. 4  is a perspective view of another embodiment of a guide assembly according to the present invention.  
         [0019]      FIG. 5  is a perspective view of a further embodiment of the guide assembly according to the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]      FIG. 1  shows one embodiment of a guide assembly  10  according to the present invention. Guide assembly  10  includes a plurality of retainers, or passage guides  12  formed therethrough. Each passage guide  12  includes a first end  14  that extends in a first direction, indicated by arrow  16 , and a second end  18  that extends in a second direction, indicated by arrow  20 . First direction  16  is oriented to generally align with a floor system  22  and second direction  20  extends outwardly therefrom. Although first direction  16  and second direction  20  are shown as generally transverse to one another, other crossing orientations are envisioned and within the scope of the appending claims. First ends  14  are generally aligned to share a common plane preferably below a finish surface  24  of floor system  22 . In one preferred embodiment, the second ends  18  are arranged in two sets. A first set  26  of second ends  18  are generally aligned with, but offset from, a second set  28  of second ends  18 . First set  26  and second set  28  of second ends  18  preferably extend along a wall  30  with the first set  26  being further from wall  30  than second set  28 .  
         [0021]     The plurality of passage guides  12  extend through a body  32  of guide assembly  10  such that each passage extends through body  32  between first end  14  and second end  18 . First ends  14  and second ends  18  extend from a first surface  34  and a second surface  36  of body  32 , respectively. During installation, first surface  34  is constructed to be positioned within floor system  22  and second surface  36  is oriented to be generally flush or extend above finish surface  24  of floor system  22 .  
         [0022]     Prior to forming floor system  22  about guide assembly  10 , either a plurality of conductors  38  are passed through the plurality of passage guides  12  or the passage guides  12  are connected to conduit means to allow passage of some medium therethrough. Each conductor  38  is isolated from other conductors of the plurality conductors as it passes through an associated passage guide  12  of guide assembly  10 . The plurality of conductors  38  are any of a radiant heating tube  40 , an electrical cable  42 , a computer cable, a potable water tube, a structured wiring cable, a computer cable, a phone cable, or any other conductor that is desired to be passed through floor system  22 . A first end  44  of each conductor  38  extends from first end  14  of a respective passage guide  12  and passes through floor system  22 . First end  44  of each conductor  38  can exit floor system  22  at a location remote from guide assembly  10  or loop through floor system  22  and return to guide assembly  10  and exit floor system  22  thereat. That is, where conductor  38  is a radiant heating tube  40  connected to a heat source with an intended return site located proximate guide assembly  10 , radiant heat tube  40  could enter and exit floor system  22  via guide assembly  10 . Comparatively, if conductor  38  is an electrical cable  42  desired to feed a device such as an outlet, electrical cable  42  does not need to exit floor system  22  at guide assembly  10 . Similarly, if a return site for radiant heat tube  40  is remote from guide assembly  10 , a supplemental guide assembly can be positioned at the desired exit of radiant heat tube  40  and/or electrical cable  42  from floor system  22 .  
         [0023]     A second end  45  of each conductor  38  extends from second end  18  of a respective passage guide  12  for connection with an associated system. That is, second end  45  of radiant heat tube  40  extends from second end  18  of guide assembly  10  for connection to a heating system whereas second end  45  of electrical cable  42  extends from second end  18  of guide assembly  10  for connection to an electrical device or an electrical panel. Once the desired conductors  38  have been passed through guide assembly  10 , floor system  22  is formed thereabout. For concrete flooring systems  46 , first ends  44  of plurality of conductors  38  are secured about a length  48  of the conductor  38  to a reinforcing material  50  associated with the concrete flooring system  46 . A plurality of ties  52  secure conductors  38  to reinforcing material  50  in a desired location such that conductors  38  remain in the desired location during the process of forming floor system  22  thereabout. Alternatively, conductors  38  could be secured directly to a subfloor, substrate, or graded surface.  
         [0024]     Understandably, floor system  22 , being a concrete floor system, is merely an exemplary application of guide assembly  10 . That is, guide assembly  10  is equally applicable with other flooring systems such as wood/tile/carpet flooring systems. Additionally, the orientation of guide assembly  10  to floor system  22  is also exemplary. That is, as shown in  FIG. 1 , second ends  18  of guide assembly  10  extend upwardly from finish floor  24 . Where passage of conductors  38  through a first floor flooring system is desired, guide assembly  10  is rotatable 180 degrees to allow the conductors that are passed therethrough to extend into a joist cavity below the first floor flooring system. As such, guide assembly  10  is applicable to multiple levels of a building structure and provides an efficient and convenient method of passing multiple conductors into and out of any flooring system.  
         [0025]      FIG. 2  shows guide assembly  10  removed from flooring system  22 . Body  32  of guide assembly  10  includes a base  54  extending therefrom. Base  54  is constructed to secure guide assembly  10  to a substrate. Base  54  includes a plurality of openings  56  formed therethrough. A plurality of fasteners  58  pass through openings  56  and secure guide assembly  10  to a substrate. As shown in  FIG. 2 , fasteners  58  are constructed to engage a gravel base disposed beneath a concrete floor system. Understandably, fasteners  58  could be any suitable fastener such as a nail or screw and constructed to secure guide assembly  10  to a sub-floor system of any material. Alternatively, body  32  could include a plurality of fastener openings or tabs connected thereto such that body  32  could be secured to a surface. In another alternate embodiment, the base  54  may be equipped with tabs to engage joists or studs.  
         [0026]     Body  32  of guide assembly  10  includes a groove  60  formed in a first lateral end  62  thereof and a rib  64  extending from a second lateral end  66  thereof. Groove  60  and rib  64  each have a triangular cross-sectional shape such that rib  64  slidingly engages a corresponding groove  60  formed in another guide assembly  10 . Such a construction allows the connection of a plurality of guide assemblies  10  when more passage guides  12  are desired. Understandably, this dove-tailed engagement between rib  64  and a corresponding groove  60  of another guide assembly  10  is merely exemplary. That is, other configurations such as a circular cross-section or other unique cross-sectional shapes are envisioned and within the scope the claims. Alternatively, lateral ends  62 ,  66  could have substantially similar cross-sectional shapes. For such a construction, guide assembly  10  would include a connector constructed to engage a respective end of adjacent guide assemblies thereby connecting the adjacent guide assemblies. Similarly, rather than the sliding engagement between multiple guide assemblies, other connection means are envisioned such as mechanical connectors or a snap-fitting engagement between adjacent guide assemblies.  
         [0027]     Conductor  38  passes uninterruptedly through passage guides  12  such that first end  44  of conductor  38  extends in first direction  16  along base  54  generally parallel to a floor surface. Second end  45  of conductor  38  extends from second end  18  of passage guide  12  in direction  20  and across first direction  16 . Such a construction provides a guide assembly that is robust and resistant to movement during formation of a finish floor system thereabout. Additionally, guide assembly  10  provides an aesthetically pleasing arrangement of conductors  38  as the conductors exit the floor system.  
         [0028]     First ends  14  of passage guides  12  share a common plane, indicated by line  68 , generally parallel to a floor surface. Such a construction ensures that conductors  38  passed from first ends  14  of guide assembly  10  are a relatively uniform depth in a floor system. For heating type systems, this ensures relatively uniform heating of the floor surface. A first set  70  of first ends  14  are a first distance  72  from first surface  34  of body  32 . A second set  74  of first ends  14  are a second distance  76  from first surface  34  of body  32 . Such an orientation allows a user to readily distinguish interconnected conductors. That is, for radiant heating loops, each inlet conductor could extend from a passage guide  12  of first set  70  of first ends  14  and a return associated therewith could pass through an adjacent first end  14  of second set  74  of passage guides  12 . Such a construction is particularly helpful when multiple users are installing multiple loops. That is, each user can independently determine which passage of the plurality of passage guides  12  is required for a return associated with another users heating loop by visual inspection of the guide assembly. Such a construction becomes particularly helpful when multiple guide assemblies are connected and multiple conductors are simultaneously being passed therethrough.  
         [0029]      FIG. 3  shows a cross-sectional view of guide assembly  10  along line  3 - 3  of  FIG. 2 . As shown in  FIG. 3 , second ends  18  of guide assembly  10  extend from body  32  outwardly from floor surface  24 . Conductors  38  pass through passage guides  12  of guide assembly  10  and enter/exit floor system  22  thereat. Second ends  18  of passage guides  12  extend above second surface  36  of body  32  and prevent inadvertent contact with conductors  38  passed therethrough. Alternatively, second surface  36  could be constructed to extend above floor surface  24  to prevent contact of floor finishing tools with second ends  18  of passage guides  12  as conductors  38  passing therethrough. First set  26  of second ends  18  of passage guides  12  is a distance  78  from first surface  34  of body  32  and second set  28  of second ends  18  of passage guides  12  is another distance  80  from first surface  34 . Such a construction allows a user to quickly identify associated conductors after a floor system has been installed. That is, for radiant heating loops, a feed conductor is passed through a passage guide  12  of first set  26  and the associated return is passed through an adjacent passage guide  12  of the second set  28 . Understandably, only one of first ends  14  and second ends  18  need be constructed for operative association of conductor loops passed therethrough. Additionally, by offsetting first and second sets  26 ,  28  of second ends  18 , guide assembly  10  provides a compact and visually appealing organization of the plurality of conductors  38  passed therethrough.  
         [0030]     Although guide assembly  10  is shown in  FIGS. 1-3  as having six passage guides  12  formed therethrough, understandably other numbers of passages are envisioned and within the scope of the claims. That is, guide assembly  10  could be constructed to have any number of passage guides formed therethrough. Additionally, it is understood and within the scope of the claims to provide a guide system having a first guide assembly having a number of passage guides formed therethrough and a second guide assembly having the same or a different number of passage guides formed therethrough. The first and second guide assemblies are connectable to provide a guide system having an application specific number of passage guides. Such a system is highly versatile and limits waste by providing a guide assembly that provides a desired number of passage guides.  
         [0031]      FIG. 4  shows an alternate embodiment of a guide assembly  100  according to the present invention. Guide assembly  100  includes a plurality of retainers or passage guides  102  removably connectable thereto. Passage guides  102  are generically referred to as elbows and have a first end  104  that extends in a first direction, indicated by arrow  106 , and a second end  108  that extends in a second direction, indicated by arrow  110 . A body  112  is attached to a base  114  and extends therefrom. A first set of clips  116  are attached to body  112  and a second set of clips  118  are attached to base  114  remote from body  112 . Passage guides  102  individually engage an associated clip pair  120  of first set of clips  116  and second set of clips  118 . Such a construction allows guide assembly  100  to include no more than a desired number of passage guides  102 .  
         [0032]     Associated clip pairs  120  engage respective passage guides  102  and secure the position of the passage guide during formation of a floor surface thereabout. Alternatively, it is further understood and within the scope of the claims to construct clip pairs  120  to directly engage a conductor connected to guide assembly  100 . That is, each conductor could be attached to guide assembly  100  without passage guides  102 . Base  114  includes a plurality of openings  122  formed therethrough. Openings  122  are constructed to allow a fastener  124  to pass therethrough. Fasteners  124  secure guide assembly  100  to a subsurface of the floor formed thereabout. Alternatively, it is understood and within the scope of the claims to form openings  122  through body  112 .  
         [0033]     Body  112  includes a groove  126  formed therein and a rib  128  extending therefrom. Groove  126  and rib  128  cooperate to allow guide assembly  100  to be securely connected to additional guide assemblies  100 . Such a construction provides a guide assembly that is highly versatile and has only a desired number of passage guides or conductors connected thereto. Similar to passage guides  12  of guide assembly  10 , passage guides  102  of guide assembly  100  are constructed to allow any one of a plurality of different types of conductors to pass therethrough. That is, passage guides  102  are constructed to allow uninterrupted guided passage of radiant heat tubes, potable water tubes, electrical cables, computer cables, structured wiring cable bundles, or the like, through guide assembly  100 . Such a guide system provides a highly versatile, relatively rugged, and visually appealing orientation of the plurality of individual conductors directed by guide assembly  100 .  
         [0034]     The guide assemblies  10 ,  100  provide a compact and versatile guide assembly. The guide assemblies include a plurality of passage guides and are quickly and efficiently attachable to additional guide assemblies. Such a construction provides a multi-passage guide system that can be quickly adapted to provide a desired number of passage guides. Additionally, the structure of guide assemblies  10 ,  100  allows the guide assembly to be quickly and securely attached to a sub-floor surface thereby preventing movement of the guide assembly during formation of a floor thereabout. Guide assemblies  10 ,  100  provide a compact and esthetically pleasing organization for a plurality of conductors desired to pass through a floor system.  
         [0035]      FIG. 5  shows another embodiment of a guide assembly  150  according to the present invention. Guide assembly  150  includes a guide block  152  and an optional cover  154  exploded therefrom. Guide block  152  includes a plurality of grooves or passages  156  which extend therethrough. Passages  156  extend in a first direction, indicated by arrow  158 , and a second direction, indicated by arrow  160 . Guide block  152  also includes a plurality of first openings  162 . Each opening  162  is constructed to pass a fastener therethrough for securing the guide block to a substrate during installation. Guide block  152  also includes a plurality of second openings  164  constructed to secure cover  154  thereto. Understandably, depending on the type of fastener used to secure cover  154  to guide block  152  and the type of fastener used to secure guide block  152  to the substrate, openings  162 ,  164  may pass completely or partially through guide block  152 . That is, openings  162 ,  164  can be constructed to slidably engage a fastener such as a nail, spike, or tie, or threadingly engage a screw fastener.  
         [0036]     Each passage  156  is constructed to receive a pair of conductor conduits  166 . Understandably, during installation, conductor conduit  166  can be arranged such that a first conductor conduit  168  is a delivery conduit and a second conductor conduit  170  is a return conduit such that each pair of conductors forms a service loop. Each pair of conductor conduits  166  is received in a respective passage such that the conductor conduits  166  do not interfere with the engagement of cover  154  with guide block  152 . Alternatively, guide block  152  could be constructed to snap-fittingly receive and secure conductor conduits  166 . Conductor conduits  166  can be any of radiant heat tubes, potable water tubes, electrical cables, computer cables, structured wiring cable bundles, or the like.  
         [0037]     Cover  154  includes a plurality of openings  172  constructed to receive a fastener (not shown) which secures the cover to guide block  152 . Understandably, openings  172  could be constructed to pass completely through cover  154  to receive the fastener or simply be depressions for positioning the fasteners. Alternatively, cover  154  could be constructed to snap-fittingly engage guide block  152  such that cover  154  can be secured to the guide block without requiring separate fasteners. A first portion  174  of cover  154  includes a plurality of recesses  176  and a plurality of tabs  178  formed thereat. Recesses  176  are constructed to allow uninterrupted passage of conductor conduits  166  through cover  154  when the cover is connected to guide block  152 . Tabs  178  are constructed to generally align cover  154  with guide block  152  and extend over a respective partition  180  between adjacent passages of guide block  152 . Openings  172  formed in a tab  178  of cover  154  are constructed to align with an opening  164  formed in a partition  180  and secure the first portion of  174  of cover  154  to guide block  152 . When cover  154  is secured to guide block  152 , plurality of passages  156  are generally isolated from one another.  
         [0038]     A profile  182  of cover  154  substantially matches a portion  184  of a profile  186  of the guide block  152  such that cover  152  snuggly engages guide block  152  and thereby secures conductor conduits  166  within respective passages  156  of guide block  152 . Understandably, although guide block  152  and cover  152  are shown to form twelve passages  156  which smoothly transition conductor conduits  166  from first direction  158  to second direction  160 , the number of passages  156  can be selected to satisfy a particular application. For example, if a specific application only requires four passages, guide assembly  150  may be provided with four passages or can be cut in the field to satisfy the particular application. Alternatively, if more than twelve passages are required, a guide block assembly having more than twelve passages may be provided or multiple guide block assemblies can be connected together to provide the desired number of guided passages. As such, guide assembly  150  is as functionally dynamic as guide assemblies  10  and  100 .  
         [0039]     Therefore, one embodiment of the present invention includes a guide assembly that has a body having a first surface and a second surface, wherein the first surface is arranged in a first direction and the second surface is arranged in a second direction that extends outwardly from the first direction. The guide assembly also includes a number of passage guides extending through the body, each passage guide having an inlet generally aligned with the first surface of the body and an outlet generally aligned with the second surface. The passage guides are constructed to allow the passage of a plurality of conduits or conductors therethrough between the first surface to the second surface.  
         [0040]     Another embodiment of the present invention includes a guide system that has a first body, a second body connected to the first body, and a plurality of tubes. The tubes are connected to at least one of the first and second bodies and each tube has a first end facing a first common direction and a second end facing a second common direction, wherein the two directions are other than parallel.  
         [0041]     A further embodiment of the present invention includes a method of securing a conduit array that includes the step of securing a guide block to a substrate and securing a first conduit to the block such that the first conduit extends in crossing directions from the guide block. The process also includes securing a second conduit to the guide block such that the second conduit extends in directions generally similar to the first conduit.  
         [0042]     Yet another embodiment of the present invention includes a guide assembly having a body with first and second portions, wherein the second portion extends from the first portion. A first set of retainers is attached to the first portion of the body in and a second set of retainers is attached to the second portion of the body and is generally aligned with the first set of retainers. The retainers are constructed to retain a plurality of conduits therein.  
         [0043]     Another embodiment of the present invention includes a guide assembly having a body and a plurality of channels formed therein. The body has a first portion which extends in a first direction and a second portion that extends in a crossing direction relative to the first portion. The plurality of channels formed in the body extend across the first portion and the second portion and each channel is constructed to receive a conductor conduit therein.  
         [0044]     A further embodiment of the present invention includes guide system having a guide body and a cover. The guide body has a plurality of passages formed therein and each passage extends between a first end and a second end of the guide body. The first end of each passage extends in a first direction which is across a second direction of the second end. The cover is connectable to the guide body and has a profile that generally matches at least a portion of a profile of the guide body. A plurality of recesses is formed in the cover and spaced apart a width of each of the plurality of passages. Each recess is constructed to allow uninterrupted passage of a conductor conduit from an associated passage of the plurality of passages of the guide body.  
         [0045]     The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.