Scalable cable hanger

A cable hanger assembly comprises a unitary skeletal frame comprising (i) a base that comprises a first base surface and a second base surface that are separated by a channel that is open at a proximate channel end and closed at a distal channel end, (ii) a first sidewall extending from a distal end of the first base surface to the distal channel end, (iii) a second sidewall extending from a distal end of the second base surface to the distal channel end, and (iv) where at least one of the first and second base surfaces includes a slot open on its respective proximate slot end. A removable and replaceable strap or supplemental hanger assembly may be engaged with the slot and hangs from the slot.

BACKGROUND OF THE INVENTION

1. Technical Field

This disclosure relates generally to cable hangers, and in particular to a scalable cable hanger assembly for use with solar panel mounting systems.

2. Background Information

Cable hangers are known for suspending cables (e.g., power and data) from a messenger wire or other support in a utility scale solar power plant. As utility scale solar power plants have increased in scope there is a greater need to handle the increased number of cables that are suspended from the racking or tracker systems. In addition, since each utility scale solar power plant is different, the hanger needs are different. There is a need for an improved cable hanger that is scalable.

SUMMARY OF THE DISCLOSURE

According to an aspect of the disclosure, a cable hanger assembly comprises a unitary skeletal frame comprising a base that comprises a first base surface and a second base surface that are separated by a channel that is open at a proximate channel end and closed at a distal channel end, a first sidewall extending from a distal end of the first base surface to the distal channel end, a second sidewall extending from a distal end of the second base surface to the distal channel end, and where at least one of the first and second base surfaces includes a slot open on its respective proximate slot end.

The first sidewall may include a finger projection extending in the direction of the distal channel end, where the finger projection includes a finger distal end that is separated from the first sidewall and forms a cable receptacle area with the first sidewall.

The second sidewall may include a second finger projection extending in the direction of the distal channel end, where the second finger projection includes a second finger distal end that is separated from the second sidewall and forms a second cable receptacle area with the second sidewall.

At least one of the first and second sidewalls may include an outwardly facing furcated member.

The unitary skeletal frame may comprise polypropylene.

The unitary skeletal frame may comprise polypropylene with an ultraviolet additive.

The unitary skeletal frame may comprise plastic.

The unitary skeletal frame may comprise metal.

The slot may be a T-slot.

The slot may be a dovetail slot.

The cable hanger assembly may further comprise a unitary supplemental hanger assembly that comprises a shaft, a slot nut located at a distal shaft end of the shaft, and a plurality of cable holding projections extending from the shaft.

The cable holding projections may include a J-hook.

The cable holding projections may include a plurality of J-hooks in spaced relationship.

The unitary skeletal frame may further comprise a second slot located in one of the first or second base surfaces; and a strap having a first longitudinal end and a second longitudinal end, where the first longitudinal end includes a first slot nut that engages with the first slot and the second longitudinal end includes a second slot nut that engages with the second slot, such that the strap forms a cable carrying receptacle suspended from the unitary skeletal frame.

The strap may be polypropylene.

The strap may comprise polypropylene with an ultraviolet additive.

The strap may be plastic.

The strap may be metal.

The hanger may be configured and arranged as a truss structure comprising a plurality of webs.

The cable hanger assembly may include a removable and replaceable supplemental hanger assembly that is engaged with the slot and suspended from the slot.

DETAILED DESCRIPTION

FIG.1illustrates a perspective view of a skeletal frame10of a cable hanger assembly.FIG.2illustrates a front view of the skeletal frame10illustrated inFIG.1. Referring toFIGS.1and2, the skeletal frame10includes a base12that comprises a first base surface14and a second base surface16, which are separated by a channel18open at a proximate channel end20and closed at a distal channel end22. The frame10also includes a first sidewall24extending from a distal end26of the first base surface14to the distal channel end22. The first sidewall24includes a first finger projection28extending in the direction of the distal channel end22, where the finger projection28includes a finger distal end30that is separated from the first sidewall24to form a cable receptacle area32in cooperation with the first sidewall. In this embodiment the first finger projection28is L- or J-shaped, but it is contemplated that the finger projection may take on various shapes to form a suitable cable receptacle area with the first sidewall. The frame may be configured as a truss with the plurality of webs supporting the first and second bases14,16and the first and second sidewalls24,34.

The frame10also includes a second sidewall34extending from a distal end36of the second base surface16to the distal channel end22. The second sidewall34includes a second finger projection38extending in the direction of the distal channel end22. The second finger projection38includes a finger distal end40that is separated from the second sidewall34to form a second cable receptacle area42in cooperation with the second sidewall34. In this embodiment, the second finger projection38may also be L- or J-shaped, but again it is contemplated that the finger projection may take on various shapes to form the cable receptable area42.

At least one of the first and second base surfaces14,16includes a slot open on its respective proximate slot end20. In this embodiment, the first base surface14includes slots44,46, and the second base surface1614includes slots48,50. Each of these slots is open on its respective proximate slot end20side. The slots may be configured in various shapes. For example, one or more of the slots may be configured as a T-slot, a dovetail slot, et cetera. In addition, the hanger may have no slots, one slot or a plurality of slots.

The frame10may be constructed of a number of different materials depending upon a number of factors, including the operating environment and load requirements on the hanger. In one embodiment, the skeletal frame10may be a unitary structure that comprises polypropylene, polypropylene with an ultraviolet additive or other types of plastic. The frame may also comprise metal, e.g., shape retention wire. While an exemplary embodiment of the frame is a unitary structure, one skilled in the art will recognize that the frame may be a non-unitary structure.

Referring still toFIG.1, at least one of the first and second sidewalls24,34includes an outwardly facing furcated member, such as for example outwardly facing furcated members52,54. In this exemplary embodiment the furcated members52,54included opposing sloped sidewalls56-59and receptacle frames60,62that form cable receptacle areas64,66. The receptacle frames60,62may be shaped as a partial sphere, oblate spheroid, U-shaped, W-shaped, J-shaped, et cetera, such that the cable receptacle areas64,66can hold a conductive cable or a data cable wire. In the exemplary embodiment ofFIG.1, the area/volume formed by the receptacle frames60,62is large enough to accept a cable that will pass through the cable receptacle areas64,66and the sloped sidewalls56-59facilitate insertion of the cable in the cable receptacle areas64,66. The opposing sloped sidewalls56-59and receptacle frames60,62may have sufficient flexibility so the base of the sidewalls move outwardly when the force of a cable being inserted acts on the sidewalls and then return to their nominal position such that the cable may not be removed from the receptacle without the sidewalls56-59flexing outwardly.

The frame10may be hung from a messenger wire (not shown) that runs through the channel18to support the frame at the distal channel end22. Once the frame is hung from the messenger wire, conductive and/or data cables may be inserted for support by the hanger. For example, power cables may be inserted into the first and second cable receptacle areas32,42and data cables may be inserted into the cable receptacle areas64,66.

FIG.3is a front view of a strap80that may be engaged to the skeletal frame10ofFIGS.1and2. The strap80includes a first longitudinal end82and a second longitudinal end84and a strap support surface85extending there between. The first longitudinal end82includes a first slot nut86that engages with a first slot of the frame10(FIGS.1and2) and the second longitudinal end84includes a second slot nut88that engages with a second slot of the frame, such that the strap forms a cable carrying receptacle when suspended from the unitary skeletal frame. The strap may be formed from the same material as the frame or from a dissimilar material. In one embodiment, the strap80is substantially U-shaped as shown inFIG.3and formed from polypropylene with a UV additive.

FIG.4is a top view of the strap80illustrated inFIG.3. The first slot nut86includes a front pair of flexible tabs90,91and a rear pair of flexible tabs92,93. Similarly, the second slot nut88includes flexible tabs96-99. The first and second slot nuts86,88include front and back pairs of flexible tabs to make installation of the strap80on the frame10(FIGS.1-2) easier. The flexible tabs include abutment surfaces, such as for example, the flexible tabs96,97that include abutment surfaces102,104respectively, which shall be discussed below.

FIG.5is a front view of a plurality of straps, including the strap80(FIG.4) mounted to the skeletal fame10. In this embodiment the first slot nut86of the strap80is inserted into the slot48of the frame, and the second slot nut88of the strap is inserted into the frame slot50. Referring toFIGS.4and5, the slot nuts86,88are inserted into their respective slots48,50by pushing the rear pair of flexible tabs98,99(FIG.4) into and through the slot50. The nut88cannot be pushed entirely through the slot50because abutment surfaces102,104(FIG.4) of the front pair of flexible tabs96,97abut against the second base surface16limiting the travel of the tab88within the slot50. SeeFIG.4. When the nut88is pushed far enough into the slot50such that the abutment surfaces102,104(FIG.4) abut against the second base surface16, the rear pair of flexible tabs98,99are outside the slot50and the rear tabs98,99flex slightly outwardly so the rear tabs cannot pass back through the slot50without the rear tabs being pinched inward enough so the rear tabs can enter the slot. Similarly, the tab88may be removed by pinching the front tabs96,97inward so the front tabs can enter and pass through the slot50. This provides a relatively easy and quick way to attach the strap(s) to the frame. The tab86may be installed and detached from the frame in a similar manner.

FIG.6is a perspective view of front tabs96,97within a hanger slot50and the position of the front tabs.

FIG.7is a front view of a supplemental hanger130that may be hung from the skeletal frame10(FIGS.1and2). The supplemental hanger130includes a central frame132with a slot nut134located at a distal shaft end136of the central frame132and a plurality of cable holding projections138extending from the central frame. The cable holding projections138may be configured as one or more J-hooks in spaced relationship along the central frame132. The embodiment ofFIG.7illustrates a plurality of J-hooks extending from the central frame. AlthoughFIG.7illustrates all the cable holding projections138as J-hooks of the same size, it is contemplated that the cable holding projections138may also be different sizes as well as different shapes.

FIG.8is a top view of the supplemental hanger130illustrated inFIG.7. Similar to the slot nuts82,84of the strap80illustrated inFIGS.3-6, the slot nut134of the supplemental hanger130includes a front pair of flexible tabs142,143and a rear pair of flexible tabs144,145. It is contemplated that the cable holding projections can be one or more of a number of different shapes suitable for supporting cables, including cables of different sizes. The

FIG.9is a front view of a plurality of supplemental hangers, including the supplemental hanger130(FIG.7) mounted to the skeletal fame10. In this embodiment the slot nut134of the supplemental hanger130is inserted into the slot50of the frame10. The slot nut134is inserted into the slot50by pushing the rear pair of flexible tabs144,145(FIG.8) into and through the slot50. The nut134cannot be pushed entirely through the slot50because abutment surfaces148,150(FIG.8) of the front pair of flexible tabs142,143abut against the second base surface16limiting the travel of the tab134within the slot50. When the nut is pushed far enough into the slot such that the abutment surfaces148,150of the flexible tabs142,143abut against the second base surface16, the rear flexible tabs144,145are outside slot50and the rear tabs flex slightly outwardly. This prevents the rear tabs144,145from passing pass back through the slot50without the rear tabs144,145being pinched inward enough so the rear tabs can enter the slot. Similarly, the tab134may be removed by pinching the front tabs142,143inward so the front tabs can enter and pass through the slot50. This provides relatively easy and quick way to attached the supplemental hanger(s) to the frame.

The scalable hanger arrangement disclosed herein allows for various configurations. For example, for some solar panel tracker systems the skeletal frame10alone may be sufficient, but in larger solar panel tracker system embodiments such asFIG.5or9may be required to handle all the cables. The skeletal frame10may be larger than the embodiment illustrated toFIGS.1-2to handle more cable, and/or to allow for more secondary hanger components such as for example the strap80(FIGS.3-5) or the supplemental hanger130(FIG.7). It is contemplated that the hanger may have more than two finger projections to establish additional cable receptacle area, or no fingers at all. Similarly for the furcated members, there can zero, one, two or more furcated members on the hanger.