Abstract:
A cable support assembly for routing electrical, communication, or data cables throughout a building. The cable support assembly includes cable trays and brackets for securing the cable trays to an overhead structure. Tray couplers are provided for coupling tray sections together. The brackets include a base portion and an integral downward-depending band. The brackets are first secured to the overhead structure to establish a desired path for the cables. A cable tray is then slid end-wise through the secured brackets and is cradled by the downward-depending bands. Adjacent cable trays are joined with couplers to create a cable support assembly in which the cable tray provides support for any electrical, communication, or data cables installed therein. The base portion of the brackets includes a cuttable portion that can be cut to split the base portion and thereby enable the brackets to be used for supporting cables in a retrofit situation.

Description:
FIELD OF THE INVENTION 
   This invention relates to cable supports and specifically to a cable support assembly or cable raceway that supports electrical cables in such a manner that the bend radius of individual cables is minimized. 
   BACKGROUND OF THE INVENTION 
   The installation of electrical cables in buildings is typically accomplished by drilling holes in wooden support elements such as joists or studs or using existing holes in metal support elements and routing the cables through the holes. Routing electrical cables in this manner causes each cable to be supported by the narrow thickness of the support element and will lead to sagging of cables in the open spaces between the support elements. Unfortunately, for the installation of low voltage cables such as communication or database cables, sagging can disturb the conductors within the cables. Bending and twisting of conductors can adversely affect the data transmission rate, which becomes very critical in cables having higher transmission rates, such as Category 5 telecommunications cables. 
   Various methods proposed for the support of low voltage electrical cables include the use of hangers for supporting the cables and cable pans or raceways. 
   What is needed is a simple cable support assembly in which the cable tray provides the support for the installed cables. The cable support assembly should also allow easy lowering of the cable tray, when desired, to facilitate inspection, repair, or installation of additional cables. The cable support assembly should be capable of supporting cables or cable bundles in a new installation or in a retrofit situation to support cables that have been previously installed. 
   SUMMARY OF THE INVENTION 
   The invention is a cable support assembly for routing electrical, communication, or data cables throughout a building. The cable support assembly includes cable trays and brackets for securing the cable trays to an overhead structure. Tray couplers are provided for coupling tray sections together. The brackets include a base portion and an integral downward-depending band. The brackets are first secured to the overhead structure to establish a desired path for the cables. A cable tray is then slid end-wise through the secured brackets and is cradled by the downward-depending bands. Adjacent cable trays are joined with couplers to create a cable support assembly in which the cable tray provides support for any electrical, communication, or data cables installed therein. The base portion of the brackets includes a cuttable portion that can be cut to split the base portion and thereby enable the brackets to be used for supporting cables in a retrofit situation. 
   OBJECTS AND ADVANTAGES 
   Several advantages are achieved with the cable support assembly of the present invention, including:
         (1) The hanger brackets of the cable support assembly are located exterior of the cable tray, thereby ensuring that the cables or cable bundles are supported by the cable tray and not by the hangers, thereby eliminating any possibility of cable sag which could be detrimental to the data transfer capabilities of the installed cables.   (2) The cable brackets of the present invention provide an easy method of creating a cable raceway within a building structure.   (3) The cable brackets include a cuttable portion to enable separation and spreading of the base portion to enable installing the brackets in a retrofit situation around previously suspended cables.   (4) The brackets include an integral seat to enable rapid positioning of the brackets with respect to an overhead support.       

   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front elevation view of the preferred embodiment of a bracket according to the present invention. 
       FIG. 2  is a side view of the bracket taken along line  2 - 2  of  FIG. 1 . 
       FIG. 3  is a top view of the bracket of  FIG. 1 . 
       FIG. 4  is a bottom view of the bracket of  FIG. 1 . 
       FIG. 5  is a front elevation view of a second embodiment of a bracket according to the present invention. 
       FIG. 6  is a side view of the bracket taken along line  6 - 6  of  FIG. 5 . 
       FIG. 7  is a top view of the bracket of  FIG. 5 . 
       FIG. 8  is a top view of the preferred embodiment of a cable tray according to the present invention. 
       FIG. 9  is an end view of the cable tray taken along line  9 - 9  of  FIG. 8 . 
       FIG. 10  is a front elevation view of the preferred embodiment of a coupler according to the present invention. 
       FIG. 11  is a top view of the coupler taken along line  11 - 11  of  FIG. 10 . 
       FIG. 12  is a sectional view of the coupler taken along line  12 - 12  of  FIG. 10 . 
       FIG. 13  is a plan view of the preferred embodiment of an end cap according to the present invention. 
       FIG. 14  is a sectional view of the end cap taken along line  14 - 14  of  FIG. 13 . 
       FIG. 15  is a front view of the preferred embodiment of a bracket of  FIG. 1  but with the base portion cut at the cuttable portion and the resulting halves of the base portion separated to enable entry of cables in a retrofit situation. 
       FIG. 16  is an end view of the latch bracket assembly of  FIG. 15  with a cable tray inserted in the bracket. 
       FIG. 17  is an end view of a coupling secured to a cable tray according to the present invention. 
       FIG. 18  is a sectional view of the end cap of  FIG. 13  secured to the cable tray of  FIG. 9 . 
       FIG. 19  is a top view of a portion of a cable support assembly according to the present invention. 
       FIG. 20  is top view of a portion of a cable support assembly with electrical cables inserted within the cable tray. 
       FIG. 21  is a front elevation view of a third embodiment of a bracket according to the present invention. 
       FIG. 22  is a side view of the bracket taken along line  22 - 22  of  FIG. 21 . 
       FIG. 23  is a bottom view of the bracket of  FIG. 21 . 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 INDEX TO REFERENCE NUMERALS IN DRAWINGS 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                  30 
                 cable support assembly 
               
               
                   
                  32 
                 bracket, preferred embodiment 
               
               
                   
                  34 
                 cable tray 
               
               
                   
                  36 
                 base portion 
               
               
                   
                  36A 
                 first half of split base portion 
               
               
                   
                  36B 
                 second half of split base portion 
               
               
                   
                  38 
                 downward-depending band 
               
               
                   
                  40 
                 building structure 
               
               
                   
                  42 
                 fastener 
               
               
                   
                  44 
                 end portion 
               
               
                   
                  46 
                 second end of hinge arm 
               
               
                   
                  50 
                 first side of bracket 
               
               
                   
                  52 
                 second side of bracket 
               
               
                   
                  54 
                 tooth 
               
               
                   
                  56 
                 upper planar edge 
               
               
                   
                  58 
                 seat 
               
               
                   
                  59 
                 ear 
               
               
                   
                  60 
                 attachment arrangement 
               
               
                   
                  62 
                 aperture in ear 
               
               
                   
                  64 
                 slot in base portion 
               
               
                   
                  66 
                 cuttable portion 
               
               
                   
                  68 
                 central opening of bracket 
               
               
                   
                  82 
                 first leg of hinge arm 
               
               
                   
                  84 
                 second leg of hinge arm 
               
               
                   
                  86 
                 third leg of hinge arm 
               
               
                   
                  88 
                 bottom wall of cable tray 
               
               
                   
                  90 
                 sidewall of cable tray 
               
               
                   
                  92 
                 end of cable tray 
               
               
                   
                  94 
                 interior channel 
               
               
                   
                  96 
                 coupler 
               
               
                   
                  98 
                 bottom wall of coupler 
               
               
                   
                 100 
                 sidewall of coupler 
               
               
                   
                 102 
                 top lip 
               
               
                   
                 104 
                 inner lip 
               
               
                   
                 106 
                 separator tab 
               
               
                   
                 108 
                 end cap 
               
               
                   
                 110 
                 end wall 
               
               
                   
                 112 
                 outer edge 
               
               
                   
                 114 
                 peripheral wall 
               
               
                   
                 116 
                 post 
               
               
                   
                 117 
                 large entryway 
               
               
                   
                 118 
                 joist 
               
               
                   
                 120 
                 communications cable 
               
               
                   
                 122 
                 bracket, second embodiment 
               
               
                   
                 124 
                 base portion 
               
               
                   
                 126 
                 band portion 
               
               
                   
                 128 
                 planar first edge 
               
               
                   
                 130 
                 second edge 
               
               
                   
                 132 
                 upper planar edge 
               
               
                   
                 134 
                 seat 
               
               
                   
                 140 
                 bracket, third embodiment 
               
               
                   
                 142 
                 base portion 
               
               
                   
                 144 
                 first side of base portion 
               
               
                   
                 146 
                 second side of base portion 
               
               
                   
                 148 
                 integral flange 
               
               
                   
                 150 
                 attachment arrangement 
               
               
                   
                 152 
                 aperture 
               
               
                   
                 154 
                 fastener 
               
               
                   
                 156 
                 seat 
               
               
                   
                 158 
                 band portion 
               
               
                   
                 160 
                 central opening 
               
               
                   
                 d 1   
                 distance between post and peripheral wall of end cap 
               
               
                   
                 d 2   
                 thickness of bottom wall and sidewall of cable tray 
               
               
                   
                 W1 
                 width of base portion 
               
               
                   
                 W2 
                 width of band portion 
               
               
                   
                 θ 
                 angle of cable tray sidewalls with respect to bottom wall 
               
               
                   
                   
               
             
          
         
       
     
   

   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 16  there is shown a preferred embodiment of a cable support assembly  30 , which includes a bracket  32  and an elongated cable tray  34 . The bracket  32  includes a base portion  36  and a downward-depending band  38 . The bracket  32  is shown in  FIG. 16  secured to a building structure  40  by fasteners  42 . 
   Referring to  FIGS. 1-4 , the base portion  36  includes two end portions  44  with the downward-depending band  38  integrally attached to each end portion  44 . The bracket  32  includes a first  50  and second side  52 . A tooth  54  extends outwards from the first side  50  of the bracket  32  and includes an upper planar edge  56  that includes a seat  58  thereon. The end portions  44  of the bracket  32  have ears  59  extending inwards therefrom and an attachment arrangement  60  for securing the bracket to a building structure (not shown). The attachment arrangement  60  includes apertures  62  in the ears  59  and fasteners  42  associated with one or more of the apertures  62 . The base portion  36  of the bracket  32  includes a slot  64  therein that defines a cuttable portion  66  to enable separation and spreading of the base portion  36  to enable installing the bracket in a retrofit situation around previously suspended cables. If preferred, the base portion  36  may be placed against a support with the seat  58  fit flush against a rafter or joist, in which case fasteners can be driven into the rafter or joist though both the ears  59 . The bracket  32  includes a central opening  68  defined by the base portion  36  and band  38 . 
   With reference to  FIGS. 8-9 , the elongated cable tray  34  includes a bottom wall  88 , two sidewalls  90 , and two ends  92 . The sidewalls  90  are preferably at an angle θ of between 95 and 110 degrees with respect to the bottom wall  88 . The bottom wall  88  and sidewalls  90  of the cable tray  34  define an interior channel  94  capable of receiving and supporting therein electrical, communication, or data cables or cable bundles (not shown). The cable tray  34  is provided in lengths, as measured between the two ends  92 , preferably between 4 and 15 feet. 
   With reference to  FIGS. 10-12 , the cable support assembly includes a coupler  96  for connecting two of the cable trays together. The coupler  96  includes a bottom wall  98 , two sidewalls  100 , top lip  102  extending inwardly from the sidewalls  100 , and an inner lip  104  extending downward from the top lip  102 . A separator tab  106  extends upward from the bottom wall  98  of the coupler  96 . The separator tab  106  will function to limit the distance a cable tray may be inserted in the coupler  96 . 
   Referring to  FIGS. 13-14 , the cable support assembly of the present invention includes an end cap  108  for closing the open end of the cable tray. The end cap  108  includes an end wall  110  having an outer edge  112  and a peripheral wall  114  extending orthogonally from the outer edge  112 . One or more posts  116  extend orthogonally from the end wall  110  proximate the peripheral wall  114 . The posts  116  extend as far as does the peripheral wall  114  from the end wall  110 . 
   With reference to  FIG. 16 , to operate the current invention, brackets  32  are secured to an overhead building structure  40  such as a joist or rafter. At least two brackets  32  (one shown) are secured to the overhead structure to support each cable tray  34 . Each bracket is secured to the building structure using the attachment arrangement  60 , including fasteners  42  driven through ears  59  into the building structure  40 . Once the brackets  32  are mounted to the building structure  40 , a cable tray  34  is slid lengthwise through the central opening  68 . 
   As shown in  FIG. 17 , a coupler  96  is used for securing together two cable trays at their ends. The coupler  96  shown in  FIG. 17  has been slid upon the end  92  of a cable tray  34 . The bottom wall  98  and two sidewalls  100  of the coupler  96  are of a slightly larger dimension than the bottom wall  88  and sidewalls  90  of the cable tray  34  and an end  92  of a cable tray  34  will therefore nest within the coupler  96  and be frictionally held thereto. Two cable trays  34  may therefore be connected together by sliding an end  92  of each cable tray  34  into one of the couplers  96 . Top lip  102  and inner lip  104  of coupler  96  hold cable tray  34  therein and prevent it from sliding out of the coupler  96  and also limit vertical and horizontal movement of the cable tray  34  with respect to the coupler  96 . Coupling the two ends of the cable trays in this manner maintains the bottom walls of the two separate cable trays substantially even and therefore causes no bending or sagging of cables or cable bundles (not shown) when they are laid therein. 
   With reference to  FIG. 18 , an end cap  108  may be used to terminate a cable tray  34 . The end cap  108  is simply slid onto an end of the cable tray  34 . The cable tray  34  is typically molded or extruded of plastic with the bottom wall  88  and the sidewalls  90  of the cable tray  34  of a given thickness. The end cap  108  is configured such that the distance between the post  116  and the peripheral wall  114  (see distance d 1  in  FIG. 13 ) are no more than 0.010 inch larger than the thickness (see thickness d 2  in  FIG. 9 ) of the bottom wall  88  and sidewalls  90  of the cable tray  34 . Sliding the end cap  108  onto the cable tray  34  therefore enables a frictional fit of the end cap  108  to the cable tray  34  with the cable tray  34  frictionally held between the posts  116  and peripheral wall  114  of the end cap  108 . 
   The cable support assembly of the present invention can be used to support cables in a retrofit situation. A retrofit is that situation in which the cables have already been affixed to the overhead structure by ring-type hangers. With reference to  FIG. 3 , to use the bracket  32  to support existing cables, tin snips or a similar cutter (not shown) can be used to snip through the cuttable portion  66  of the base portion  36 . 
   With reference to  FIG. 15 , after the base portion  36  is split in a retrofit situation, the resulting two halves  36 A,  36 B of the base portion can be lifted upwards and outwards thereby creating a large entryway  117  into the central opening  68  of the bracket  32 . The bracket  32  can then be lifted upwards over the existing cables (not shown) with the large entryway  117  allowing the cables to slip within the central opening  68  of the bracket  32 . As the bracket is typically molded of a resilient plastic, the two halves  36 A,  36 B of the base portion will spring back essentially to their original orientation thereby closing the two halves  36 A,  36 B of the base portion. Fasteners (not shown) can then be driven through ears  59  and into a structure (not shown) to secure the bracket  32  thereto. Cable trays  34  can then be slid lengthwise into the central openings  68  of two adjacent brackets  32  in linear alignment and two or more cable trays joined together to form a cable support assembly in the same manner as described above for a new installation. 
   Although they could be constructed of metal or other materials, it is preferred that the components of the cable support assembly of the present invention, including the bracket, the end cap, the coupler, and the elongated cable tray are each formed in one piece of plastic. The bracket, the end cap, and the coupler are preferably molded of plastic and the cable tray can be molded or extruded of plastic. 
   With reference to  FIG. 19 , the top view of a portion of a cable support assembly  30  is shown according to the present invention. The cable support assembly  30  includes cable trays  34 , brackets  32  secured to joists  118 , a coupler  96  securing together two cable trays  34 , and an end cap  108  capping one end of a cable tray. 
     FIG. 20  depicts a close up view of the left hand portion of  FIG. 19  and with communications cables  120  laid therein and supported by the bottom wall  88  of the cable tray  34 . The advantage of the cable support assembly  30  of the present invention is that the cables  120  are supported by the cable tray  34  and not by the hangers or brackets  32 . Supported as shown, the delicate communication cables  120  are not subjected to sagging or bending as a result of being supported primarily by the hangers or brackets, as in prior art cable support systems. 
   A second embodiment of a bracket  122  according to the present invention is depicted in  FIGS. 5-7 . The bracket  122  includes a base portion  124  of a first width (W 1 ) and a band portion  126  of a second width (W 2 ). The band portion  126  and base portion  124  share a planar first edge  128  but the band portion  126  is wider than the base portion  124  and extends outwards from the second edge  130  of the base portion  124 . An upper planar edge  132  provides a seat  134  for use in positioning the bracket  122  against an overhead support (not shown). A slot  64  and cuttable portion  66  are provided in the base portion  124  to enable cutting of the base portion  124  for a retrofit situation. 
   A third embodiment of a bracket  140  according to the present invention is depicted in  FIGS. 21-23 . The bracket  140  includes a base portion  142  having two sides  144  and  146  and an integral flange  148  extending upwards along the first side  144  of the base portion  142 . An attachment arrangement  150  for securing the bracket  140  to a building structure includes apertures  152  in the flange  148  and fasteners  154  that can be driven through the flange  148  and into the building structure (not shown). A seat  156  is provided at the juncture of the flange  148  and the base portion  142  for positioning the bracket  140  on an overhead structure. The bracket  140  includes a band portion  158  that extends downwardly from the base portion  142  and creates a central opening  160  therein for receipt of a cable tray in the manner described above for the preferred embodiment. 
   Although the description above contains many specific descriptions, materials, and dimensions, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.