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 a vertical surface. Tray couplers are provided for coupling trays together. The brackets include an L-shaped support member and a hinge arm pivotally attached to the support member. The hinge arm portion of the bracket may be rotated downwards for loading of a cable tray therein and then rotated upwards and latched to the base members to lock the cable tray in place. Ninety-degree bend and T-shaped cable tray sections are also provided. Adjacent cable tray sections may be joined with couplers to create a cable raceway or support assembly in which the cable tray provides support for any electrical, communication, or data cables installed therein.

Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/471,151 filed Jun. 20, 2006 now U.S. Pat. No. 7,304,204 the entire contents of which are incorporated herein by reference. 

   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 
   Cable raceways are used for supporting high or low voltage cables in residences and commercial buildings. One such cable raceway system was proposed in U.S. patent application Ser. No. 11/471,151, which shares common ownership and inventorship with the present invention and has been incorporated herein by reference thereto. The cable raceway system of the parent application included a cable tray that was supported from an overhead support that included a pivoting hinge arm. The hinge arm was capable of being released thereby allowing downward rotation of the hinge arm and the cable tray to permit inspection of any cables within the cable tray or the addition of additional cables if desired. 
   The cable raceway system of U.S. patent application Ser. No. 11/471,151 thereby provided a system for eliminating the bending or sagging of cables or bundles of cables. Bending or sagging 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. 
   The current invention provides enhancements over the cable raceway of the parent application, including a mechanism for supporting the cable raceway from a vertical surface such as a wall and an improved coupler for securing various cable tray portions together. Additionally there are provided 90-degree bends and T-raceway portions for added functionality in constructing cable raceway systems. The cable support assembly of the present invention includes a hinged arm that can be pivoted downward to enable easy lowering of the cable tray, when desired, to facilitate inspection, repair, or installation of additional cables. 
   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 of various configurations and brackets for securing the cable trays to a vertical surface. Tray couplers are provided for coupling tray sections together. The L-shaped brackets include a vertical arm, a horizontal arm, and a hinge arm pivotally attached at one end to the horizontal arm. The releasable hinge arm is adapted to hold a cable tray and can be closed in the up position on the bracket or released and rotated downwards. A series of hinge arms may be mounted to support several cable trays and adjacent cable trays joined together with a coupler to form a cable raceway system. A 90-degree bend cable tray and a T-shaped cable tray are provided for enhanced flexibility in forming a cable raceway. The resultant cable raceway or cable support assembly provides support for any electrical, communication, or data cables installed therein. 
   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 releasable hinge arms that allow insertion of the cable trays after the brackets have been secured to the wall.   (3) The cable brackets include a closing mechanism that enables the cable tray sections to be securely held in the up position after the cable tray sections are loaded within the brackets.   (4) The closing mechanism facilitates easy release of the cable tray sections for inspection or repair of existing cables or easy installation of additional cables.   (5) The closing mechanism is releasable, thereby enabling lowering of one side of the cable tray when released. As a result the cable tray sections continue to support the cables in the lowered position. This provides enhanced protection of the cables or cable bundles over prior art cable trays in which the cable trays must be snapped off or completely removed and leave the cables supported only by the hangers.       

   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 perspective view of the preferred embodiment of a bracket that forms a portion of a cable support assembly according to the present invention. 
       FIG. 2  is an upper perspective view of an L-shaped frame of the bracket depicted in  FIG. 1 . 
       FIG. 3  is a lower perspective view of the top portion of the frame depicted in  FIG. 2 . 
       FIG. 4  is an end view of the top portion of the frame depicted in  FIG. 2 . 
       FIG. 5  is a sectional view of the top portion of the frame taken along line  5 - 5  of  FIG. 4 . 
       FIG. 6  is a top view of the top portion of the frame depicted in  FIG. 2 . 
       FIG. 7  is a sectional view of the top portion of the frame taken along line  7 - 7  of  FIG. 6 . 
       FIG. 8  is a top perspective view of a bottom portion of the frame depicted in FIG.  1 . 
       FIG. 9  is a side view of the bottom portion of the frame depicted in  FIG. 8 . 
       FIG. 10  is a lower perspective view of the bottom portion of the frame depicted in  FIG. 8   
       FIG. 11  is an end view of the bottom portion of the frame depicted in  FIG. 8 . 
       FIG. 11A  is a side view depicting the bottom portion in alignment with the top portion to be inserted therein to form the frame member of  FIG. 2 . 
       FIG. 11B  is a side view depicting the bottom portion fully inserted and locked within the channel of the top portion thereby forming the frame member of  FIG. 2 . 
       FIG. 12  is a side view of a preferred embodiment of a bracket according to the present invention with the hinge arm in the up and closed position and forward leg of the leg pairs cut away to show details of the pins. 
       FIG. 13  is a side view of the bracket of  FIG. 12  with the hinge arm released and pivoted downward. 
       FIG. 14  is a side view of the bracket of  FIG. 12  with the hinge arm pivoted downward and a cable tray loaded into the hinge arm. 
       FIG. 15  is a side view of the bracket of  FIG. 12  with the hinge arm in the up and closed position with a cable tray portion held therein. 
       FIG. 16  is a perspective view of the preferred embodiment of a T-shaped cable tray portion according to the present invention. 
       FIG. 17  is a top view of the T-shaped cable tray portion of  FIG. 16 . 
       FIG. 18  is a perspective view of the preferred embodiment of a 90-degree bend cable tray portion according to the present invention. 
       FIG. 19  is a top view of the 90-degree bend cable tray portion of  FIG. 18 . 
       FIG. 20  is an end view of a preferred embodiment of a coupler according to the present invention. 
       FIG. 21  is a side view of the coupler of  FIG. 20 . 
       FIG. 22  is a top view of the coupler of  FIG. 20 . 
       FIG. 23  is an end view of the coupler with a cable tray installed therein. 
       FIG. 24  is a front view of a preferred embodiment of an end cap according to the present invention. 
       FIG. 25  is a sectional view of the end cap taken along line  25 - 25  of  FIG. 4 . 
       FIG. 26  is an exploded perspective view of a portion of a cable support assembly according to the present invention. 
       FIG. 27  is a perspective view of a preferred embodiment of a cable support assembly or cable raceway according to the present invention. 
       FIG. 28  is an end view of a preferred embodiment of a cable tray according to the present invention. 
       FIG. 29  is a top view of the cable tray of  FIG. 28 . 
       FIG. 30  is a side view of the end portion of the cable tray taken along line  30 - 30  of  FIG. 29 . 
   

   INDEX TO REFERENCE NUMERALS IN DRAWINGS 
   
     
       
             
             
             
           
         
             
                 
                 
             
           
           
             
                 
               30 
               cable support assembly or cable raceway 
             
             
                 
               32 
               bracket 
             
             
                 
               34 
               cable tray 
             
             
                 
               36 
               coupler 
             
             
                 
               38 
               end cap 
             
             
                 
               40 
               frame member 
             
             
                 
               42 
               hinge arm 
             
             
                 
               44 
               top portion of frame member 
             
             
                 
               46 
               bottom portion of frame member 
             
             
                 
               48 
               vertical arm of top portion 
             
             
                 
               50 
               horizontal arm of top portion 
             
             
                 
               51 
               planar mounting surface 
             
             
                 
               52 
               brace 
             
             
                 
               54 
               lower edge of top portion 
             
             
                 
               56 
               guide 
             
             
                 
               58 
               channel 
             
             
                 
               60 
               aperture 
             
             
                 
               62 
               open area of top portion 
             
             
                 
               64 
               flat edge 
             
             
                 
               66 
               opening 
             
             
                 
               67 
               flat top surface of bottom portion 
             
             
                 
               68 
               stop 
             
             
                 
               69 
               beveled front edge of top portion 
             
             
                 
               70 
               tab 
             
             
                 
               72 
               end of bottom portion 
             
             
                 
               74 
               pair of legs 
             
             
                 
               76 
               pin 
             
             
                 
               76A 
               inner pin 
             
             
                 
               76B 
               outer pin 
             
             
                 
               78 
               upper edge of bottom portion 
             
             
                 
               80 
               wing 
             
             
                 
               82 
               pivot end of hinge arm 
             
             
                 
               84 
               closing end of hinge arm 
             
             
                 
               86 
               hook on closing end of hinge arm 
             
             
                 
               88 
               opening 
             
             
                 
               90 
               outer end of bracket 
             
             
                 
               92 
               outer leg of hinge arm 
             
             
                 
               98 
               vertical surface 
             
             
                 
               100 
               fastening arrangement 
             
             
                 
               102 
               fastener 
             
             
                 
               104 
               bottom wall of cable tray 
             
             
                 
               106 
               sidewall of cable tray 
             
             
                 
               108 
               end of cable tray 
             
             
                 
               110 
               beveled edge of cable tray 
             
             
                 
               112 
               top edge of cable tray 
             
             
                 
               114 
               T-shaped cable tray member 
             
             
                 
               116 
               first cable tray portion 
             
             
                 
               118 
               second cable tray portion 
             
             
                 
               120 
               sidewall 
             
             
                 
               122 
               bottom wall 
             
             
                 
               124 
               90-degree cable tray member 
             
             
                 
               126 
               first cable tray portion 
             
             
                 
               128 
               second cable tray portion 
             
             
                 
               130 
               third cable tray portion 
             
             
                 
               132 
               sidewall 
             
             
                 
               134 
               bottom wall 
             
             
                 
               136 
               bottom wall of coupler 
             
             
                 
               138 
               sidewall of coupler 
             
             
                 
               140 
               top lip of coupler 
             
             
                 
               142 
               inner lip 
             
             
                 
               144 
               separator tab 
             
             
                 
               146 
               end wall of end cap 
             
             
                 
               148 
               outer edge of end cap 
             
             
                 
               150 
               peripheral wall 
             
             
                 
               152 
               post 
             
             
                 
               θ 1   
               angle of sidewall with respect to the top edge 
             
             
                 
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 27  there is shown a preferred embodiment of a cable support assembly  30 , which includes a plurality of brackets  32  and one or more elongated cable trays  34 . The cable support assembly  30  can further include a coupler  36  for securing cable trays  34  together at their ends and an end cap  38  for terminating the end of a cable tray  34 . 
   With reference to  FIG. 1  there is shown a preferred embodiment of a bracket  32  according to the present invention. The bracket  32  includes an L-shaped frame member  40  and a hinge arm  42 . 
   Referring to  FIG. 2 , the frame member  40  includes a top portion  44  and a bottom portion  46 . The top portion  44  and bottom portion  46  are preferably each molded of plastic in one piece. 
   Referring to  FIGS. 3-7  there are shown various views of an especially preferred embodiment of the top portion  44  of the bracket. As shown in  FIG. 3 , the top portion  44  includes a vertical arm  48  and a horizontal arm  50 . The outer side of the vertical arm  48  includes a planar mounting surface  51  thereon. An integral brace  52  extends between the vertical arm  48  and the horizontal arm  50  thereby providing strength and stiffening the top portion  44 . The top portion  44  further includes a lower edge  54 , guides  56  extending inwards horizontally from the lower edge  54 , and a channel  58  between the guides  56  and the horizontal arm  50  at the lower end of the top portion  44 . 
   As shown in  FIG. 4 , a plurality of apertures  60  is provided within the vertical arm  48  of the top portion  44 . The apertures  60  are provided in both a large and small diameter to accommodate large and small fasteners as will be described herein. 
   As shown in  FIG. 5 , open areas  62  are provided along the lower edge  54  of the top portion  44  and a flat edge  64  is provided in an opening  66  if the horizontal arm  50 . As shown in  FIGS. 6 and 7 , the guides  56  and the horizontal arm  50  define the channel  58 . 
   Referring to  FIGS. 8-11  there is shown various views of an especially preferred embodiment of the bottom portion  46  of the bracket. As shown in  FIGS. 8 and 9 , the bottom portion  46  includes a flat top surface  67 , stops  68 , a beveled front edges  69 , and one or more tabs  70  extending from the top surface  67 . The function of the tabs  70  will be to lock the bottom portion  46  within the channel  58  (see  FIGS. 11A and 11B ) of the top portion when it is inserted therein. 
   With reference to  FIGS. 10 and 11 , the bottom portion  46  further includes two ends  72  and two pairs of legs  74  extending downward from each end  72 . A pin  76  extends between each pair of legs  74  at each end  72  of the bottom portion  46 . The bottom portion  46  further includes an upper edge  78  and wings  80  extending outward at the upper edge  78 . Although the pins  76  are depicted as being circular in cross-sectional shape, they could be hexagonal, octagonal, or similar shapes and perform equally as well. 
   With reference to  FIG. 11A  there is shown the lower part of the top portion  44  of the bracket and the bottom portion  46  in alignment with the channel  58  of the top portion to be slid therein. The beveled front edges  69  enable the bottom portion  46  to easily enter the channel  58 . The guides  56  of the top portion  44  guide the wings  80  of the bottom portion  46  into the channel  58 . As shown in  FIG. 11B , after the bottom portion  46  is fully inserted into the channel  58  of the top portion  44 , the tab  70  snaps into opening  66  and engages the flat edge  64 . The bottom portion  46  of the bracket is then held securely to the top portion  44  with the bottom portion  46  locked within the channel  58  by the tab  70  and the stop  68 . 
   Referring to  FIG. 12  there is shown the preferred embodiment of the bracket  32  after the bottom portion  46  and top portion  44  are locked together to form an integral frame member  40  and the hinge arm  42  has been secured to the pins  76 A,  76 B. The hinge arm  42  is shown in the up and closed position. The hinge arm  42  includes a pivot end  82  and a closing end  84 . The pivot end  82  is shaped into a hook shape and is snapped around the inner pin  76 A, which is termed the inner pin as it will be oriented toward the inner side of the bracket  32  when it is mounted to a vertical surface (not shown). The closing end  84  of the hinge arm  42  includes a hook  86 . The hinge arm  42  is preferably molded in one piece of flexible plastic therefore imparting flexibility to the pivot end  82  and enabling it to be snapped over inner pin  76 A. The hinge arm  42  can therefore pivot around inner pin  76 A. An opening  88  is provided on the outer end  90  of the bracket  32  between the outer pin  76 B and the top portion  44  of the frame member  40 . The opening  88  is also shown in  FIGS. 8 and 10 . Referring again to  FIG. 12 , the closing end  84  can be snapped onto the outer pin  76 B at the outer end  90  of the bracket  32  to close the hinge arm  42  in the up position. The hinge arm  42 , being constructed of flexible plastic, can be easily snapped onto the outer pin  76 B to close the hinge arm  42  in the up position. Conversely, the outer leg  92  of the hinge arm  42  can be pushed upward and slightly inward until to release the hinge arm  42  from the outer pin  76 B thereby allowing the hinge arm  42  to pivot downwards as the pivot end  82  pivots around the inner pin  76 A (see  FIG. 13 ). When the hinge arm  42  is in the up and closed position as shown in  FIG. 12 , a cable tray (see  FIG. 15 ) will create a force downwards on the hinge arm  42  thereby holding it in the closed position. 
   With reference to  FIG. 13 , the bracket  32  is depicted with the hinge arm  42  pivoted downward and in the open position. With the hinge arm  42  open, a cable tray (not shown) can be fit within the hinge arm  42  of the bracket  32 . Although the hinge arm  42  can be rotated to the open position to accept a cable tray (not shown), it is not necessary to do so as there is sufficient open area in a closed bracket  32  (see  FIG. 12 ) that a cable tray may be inserted endwise into the opening between the hinge arm  42  and the frame member  40 . 
   Referring to  FIG. 14 , the bracket  32  is shown with a cable tray  34  loaded into the open hinge arm  42 . The bracket  32  is shown being secured to a vertical surface  98  by a fastening arrangement  100  that includes fasteners  102  and the apertures  60  in the vertical arm  48  of the frame member  40 . 
   With reference to  FIGS. 28-30 , the cable tray  34  is substantially U-shaped and includes a bottom wall  104  and two sidewalls  106 . The ends  108  of each cable tray  34  included beveled edges  110  on each sidewall  106  that are beveled at an angle of θ 1  with respect to the top edge  112  of the sidewalls  106 . Preferably angle θ 1  is between 15 and 45 degrees. The cable tray  34  includes an outer profile substantially matching the inner profile of the hinge arm (not shown). The cable tray  34  is preferably molded in one piece of plastic and preferably includes a length of 6 feet or greater. The sidewalls  106  are sufficiently flexible to be depressed inwards with slight force. Therefore, when loaded into a hinge arm  42  in the open position as shown in  FIG. 14 , the hinge arm  42  and cable tray  34  combined may be pressed inward after which the hinge arm  42  may be rotated upward and the closing end  84  of the hinge arm  42  closed on the pin  76  of the frame member  40  to secure the hinge arm  42  in the closed position as shown in  FIG. 15 . the weight of the hinge arm  42  and the cable tray  34  holds the hinge arm in the up or closed position. 
   With reference to  FIGS. 16 and 17 , the cable support assembly of the present invention may further include a T-shaped cable tray member  114 . The T-shaped cable tray member  114  includes a straight first cable tray portion  116  and a second cable tray portion  118  branching perpendicular from the first cable tray portion  116 . The T-shaped cable tray member  114  includes sidewalls  120  and a bottom wall  122 . The T-shaped cable tray member  114  can be placed between two linear cable trays to provide a side-branching cable tray for routing cables in another direction if necessary for the particular application. The T-shaped cable tray member  114  is preferably molded of plastic in one piece. 
   Referring to  FIGS. 18 and 19 , the cable support assembly of the present invention may further include a 90-degree cable tray member  124 . The 90-degree cable tray member  124  includes a straight first cable tray portion  126 , a second cable tray portion  128  branching from the first cable tray portion at a 45-degree angle and a third cable tray portion  130  branching from the first cable tray portion  126  at a 45-degree angle. The 90-degree cable tray member  124  is used at the end of a straight section of cable trays to change the routing of the cables 90 degrees. The 90-degree cable tray member  124  includes sidewalls  132  and a bottom wall  134 . The 90-degree cable tray member  114  is preferably molded of plastic in one piece. 
   With reference to  FIGS. 20-23 , the cable support assembly of the present invention may further include one or more couplers  36  for connecting two cable trays together at the ends or for connecting a cable tray to a T-shaped cable tray member or to a 90-degree cable tray member. The coupler  36  includes a bottom wall  136 , two sidewalls  138 , a top lip  140  extending inwardly from each the sidewall  138 , and an inner lip  142  extending downward and inward from the top lip  140  toward each sidewall  138 . The coupler  36  further includes a separator tab  144  extending upwards into the tray from the bottom wall  136 . The separator tab  144  limits the distance a cable tray (see  FIG. 23 ) may be inserted into the coupler  36 . 
   With reference to  FIG. 26  there is shown a cable tray  34  having a coupler  36  inserted on its end  108  in order to attach another cable tray (not shown) thereto. The bottom wall  136  and two sidewalls  138  of the coupler  36  are of a slightly larger dimension than the bottom wall  104  and sidewalls  106  of the cable tray  34 . Two of the cable trays  34  are capable of being connected together by sliding an end  108  of each of the cable trays  34  into one of the couplers  36 . The beveled edges  110  of the cable tray  34  enable the cable tray ends  108  to easily enter the coupler  36 . Each cable tray  34  advances into the coupler  36  until the bottom wall  104  of the cable tray  34  butts against the separator tab  144  of the coupler  36 . As shown in  FIG. 23 , after a cable tray  34  is inserted into the coupler  36  the inner lip  142  bears against the sidewall  106  of the cable tray  34  and holds the cable tray  34  tightly within the coupler  36 . 
   With reference to  FIGS. 24 and 25 , the cable support assembly of the present invention may include one or more end caps  38  for closing the open end of a cable tray or a connected chain of cable trays. The end cap  38  includes an end wall  146  having an outer edge  148 , a peripheral wall  150  extending orthogonally from the outer edge  148  of the end wall  146 , and one or more posts  152  extending orthogonally from the end wall  146  proximate the peripheral wall  150 . As shown in  FIG. 26 , an end cap  38  may be slid onto an end  108  of a cable tray  34  to close off the end. The tight tolerance between the posts  152  and the peripheral wall  150  enables a tight frictional fit of the end cap  38  to the cable tray  34  when it is applied thereon. Preferably, the bottom wall  104  and the sidewalls  106  of the cable tray  34  include a thickness and the distance between the post  152  and the peripheral wall  150  of the end cap  38  are no more than 0.010 inch larger than the thickness of the bottom wall  104  and sidewalls  106  of the cable tray  34 . 
   Referring to  FIG. 26 , the cable support assembly  30  includes one or more brackets  32 , cable trays  34 , couplers  36 , and end caps  38 . Although not shown in  FIG. 26 , the cable support assembly  30  may further include the T-shaped cable tray  114  of  FIG. 16  or the 90-degree cable tray  124  of  FIG. 18 . The elongated cable trays  34  are preferably at least 6 feet in length. 
   To operate the present invention, brackets  32  are first mounted by the fastening arrangement  100  to a vertical surface or support  98  at the desired location for routing cables. After the brackets  32  are mounted in the desired location, either the cable trays  34  can be inserted endwise into the brackets  32  with the hinge arm  42  closed or the cable trays  34  may be placed in the open hinge arms  42  and the hinge arms  42  pivoted upwards and the closing ends  84  of the hinge arms closed in the up position. All variations of the cable tray are connected at their ends  108  to an adjacent cable tray end  108  using a coupler  36 . The beveled edges  110  of the cable tray ends  108  enable easy initial insertion of the cable trays  34  and also enable a tight fit of the cable tray  34  within the coupler  36  as the top lips  140  of the coupler  36  are forced upward by the beveled edges  110  and the sidewalls  106  of the cable trays  34 . End caps  38  are used to close off an end  108  of the cable tray  34 . The close tolerance between the posts  152  and the peripheral wall  150  of the end cap  38  lock the end cap  38  onto the end of the cable tray  34 . 
   With reference to  FIG. 27  there is shown a portion of the preferred embodiment of an installed cable support assembly or cable raceway  30  according to the present invention. The brackets  32  secure the cable raceway  30  to a wall  98  or similar vertical support. The releasable hinge arms  42  may be rotated downward in order to perform inspection of cables (not shown) or to enable easy installation of additional cables as needed. The hinge arms  42  are simply pivoted upward and snapped and closed into the frame member  40  after inspection or installation of additional cables is complete. Conversely, if preferred, additional cables may be threaded through the cable raceway while the hinge arms  42  remain in the upward closed position. The brace  52  portion of the bracket strengthens the bracket so that it can better bear the load of the cable tray after it has been loaded with cables. 
   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.