Cable support and method

A J-hook cable support includes a semicircular saddle, a stem at one side of the saddle, and a tip at the other side of the saddle. The stem includes protruding tabs able to engage snap-on brackets in order to engage structural parts, or to couple multiple cable supports together. The stem may have two pairs of tabs at different heights along the stem away from the saddle. The tabs may be bent pieces of the metal of the stem, bent toward the back of the stem, away from the cable-receiving area defined by the saddle. The snap-on brackets may include one or more pairs of notches for engaging the tabs of one or more of the cable supports. A wire retainer may be used to close off the cable-receiving area, with the wire coupled to both the tip and the stem.

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The invention relates in general to cable supports and methods.

2. Description of the Related Art

U.S. Pat. No. 5,740,994 describes a variety of J-hook cable supports that are usable with high performance communications cable, as well as other types of cables. Such cable supports allow cables to be supported without constrictions on the cables, and without damage to the cables. Cable supports of this sort are available from ERICO, Inc., of Solon, Ohio, USA.

Despite the benefits of J-hook cable supports previously available from ERICO, Inc., improvements in this area are possible.

SUMMARY OF THE INVENTION

According to an aspect of the invention, a cable support provides larger cable bend radii than prior supports.

According to another aspect of the invention, a cable support has a removable wire retainer that can be easily installed or removed in the field, and that can be used to open or close access to a cable-receiving area of the cable support.

According to yet another aspect of the invention, a cable support has tabs for receiving any of a variety of snap-on brackets. The snap-on brackets may include a tree bracket (for coupling multiple cable supports together), a straight bracket, and a right-angle bracket.

According to still another aspect of the invention, a cable support includes: a cable-receiving saddle; a stem emerging from one side of the saddle; and a tip emerging from the other side of the saddle. The cable support includes one or more of the following features: tabs on stem for receiving a snap-on bracket; wherein the snap-on bracket is a tree bracket for coupling multiple supports together; wherein the snap-on bracket is a straight bracket; wherein the snap-on bracket is an angle bracket; wherein a clip, clamp, hanger, or the like is permanently or temporarily coupled to the snap-on bracket; wherein the tabs each have a relatively narrow neck and a relatively broad body; wherein the tabs include two pairs of tabs; wherein the tabs are bent sheet metal tabs; wherein the brackets include notches for receiving the stem tabs; wherein the support is made of sheet metal; a wire retainer for selectively closing off a cable-receiving area of the cable support; wherein the stem has a pair of notches for receiving bent ends of the wire retainer; wherein the tip has protrusions for securing the wire retainer; wherein the protrusions include loops with holes for receiving the wire retainer therein; wherein the cable support has a J shape; wherein the saddle has a width of at least 2 inches; wherein the saddle includes a central portion with a width of at least 0.6 inches; wherein the central portion is flat except for curvature of the saddle; wherein the saddle also includes angled portions attached to sides of the central portion, wherein the angled portions curve away from the central portion; wherein the saddle further includes flanges attached to distal sides of the angled portions that are opposite proximate sides of the angled portions that are attached to the central portion; wherein the flanges are angled relative to the central portion; wherein the flanges are angled at about 50 degrees relative to the central portion; wherein the flanges are angled at about 45 degrees relative to the central portion; wherein the flanges each include two parts or portions that are angled relative to one another; wherein a depth of a cross section shape the saddle is at least 0.34 inches; wherein a depth of a cross section shape the saddle is at least 0.4 inches; wherein a depth of a cross section shape the saddle is at least 0.5 inches; wherein a depth of a cross section shape the saddle is at least 0.4 inches, with the diameter of the saddle being at least 2 inches; wherein a depth of a cross section shape the saddle is at least 0.5 inches, with the diameter of the saddle being at least 3 inches; wherein the saddle is semicircular; wherein the saddle has a composite bend radius of at least 2 inches; wherein the saddle has a composite bend radius of at least 2.5 inches; wherein the saddle has a composite bend radius of at least 3 inches wherein the saddle, the tip, and the stem are all parts of a single piece; wherein the cable support is made of steel; wherein the cable support is made of spring steel.

According to a further aspect of the invention, a cable support includes: a cable-receiving saddle; a stem emerging from one side of the saddle; and a tip emerging from the other side of the saddle. The stem includes tabs for receiving a snap-on bracket.

According to a still further aspect of the invention, a cable support includes: a cable-receiving saddle; a stem emerging from one side of the saddle; a tip emerging from the other side of the saddle; and a wire retainer used to selectively closing off a cable-receiving area of the cable support that is above the saddle and between the tip and the stem. The wire retainer passes around edges of the tip when used to close the cable-receiving area.

According to another aspect of the invention, a cable support includes: a cable-receiving saddle; a stem emerging from one side of the saddle; and a tip emerging from the other side of the saddle. The saddle is semicircular. The saddle has a composite bend radius of at least 2 inches. The saddle, the tip, and the stem are all monolithic parts of a single sheet metal piece.

According to still another aspect of the invention, a method of securing one or more cables includes: providing a cable support that includes: a cable-receiving saddle, a stem emerging from one side of the saddle, and a tip emerging from the other side of the saddle; installing a wire retainer through loops of the tip that have respective holes therein; placing the one or more cables in a cable-receiving area on the saddle; and securing the cables in the wire-receiving area using the wire retainer.

DETAILED DESCRIPTION

A J-hook cable support includes a semicircular saddle, a stem at one side of the saddle, and a tip at the other side of the saddle. The stem includes protruding tabs able to engage snap-on brackets in order to engage structural parts, or to couple multiple cable supports together. The stem may have two pairs of tabs at different heights along the stem away from the saddle. The tabs may be bent pieces of the metal of the stem, bent toward the back of the stem, away from the cable-receiving area defined by the saddle. The snap-on brackets may include one or more pairs of notches for engaging the tabs of one or more of the cable supports. Among the possible types of snap-on brackets are a tree installation bracket, which allows multiple cable supports to be coupled back-to-back and/or vertically, to form a tree of cable supports; a variety of mounting brackets for mounting cable supports to structure, such as by engaging various types of purlins; and various angle brackets for connecting one or more cable supports to structure using a fastener, such as by use of a nail, a screw, or a rivet. A wire retainer may be used to close off the cable-receiving area, with the wire coupled to both the tip and the stem.

Referring initially toFIGS. 1 and 2, a J-hook or J-shape cable support10includes a cable-receiving saddle12. The saddle12is shown as a semicircular saddle, but it will be appreciated that the saddle12alternatively may have a different shape, for example having a combination of flat portions and curves. The saddle12has a curved inner surface14that is bulged toward the longitudinal middle of the saddle12. The surface14has a flat central portion16, with substantially no curvature in a direction along the axis of the saddle12. On either side of the central portion16are angled portions18and20that angle away from the central portion16. Distal flanges22and24emanate from the angled portions18and20, angled further away from the central portion16. The overall shape provided by the portions16,18, and20, and the flanges22and24, is a bulging shape, with the angled portions18and20and the flanges22and24providing a flared shape away from the central portion16.

The central portion16of the surface may have a width of at least 0.6 inches (15.2 mm), although it will be appreciated that the central portion16may have other widths. The central portion16may be substantially flat, although it will be appreciated that the central portion16may alternatively have some curvature.

The angled portions18and20may have a curvature of about 3 inches (76 mm), curving way from the central portion16. It will be appreciated that the angled portions18and20may have other curvatures, however.

The flanges22and24may be flat or curved. The flanges22and24may each have a single flat or curved surface, or may alternatively include multiple surfaces angled relative to one another. The flanges22and24may be angled away from the angled portions18and20, such that the flanges22and24do not contact cables when the cables are ordinarily resting in the saddle12.

The saddle12may have a width of at least 2 inches (50.8 mm), although it will be appreciated that the saddle12may alternately have other widths. The configuration of the saddle inner surface14may provide the cables or other objects in contact with it with a radius of curvature of at least 2 inches (5 cm), or alternatively at least 2.5 inches (6.3 cm). The saddle inner surface14helps in maintaining a minimum radius of curvature for cables in the cable support10supported by the saddle12. The radius of the curved inner surface16may be selected to maintain a minimum radius required for installations of Category 6, Category 6A, Category 7, or higher Category cable. It will be appreciated that other suitable radii of curvature may be selected, for instance to conform with other minimum cable radii of curvature.

The inner surface14of the saddle12defines the bottom of a cable-receiving area26of the cable support10. Cables are placed in the cable-receiving area26, and rest on the inner surface14. The flanges22and24provide rounded edges for contact with cables resting on the saddle12, or being pulled over the saddle12.

A stem30extends vertically from one end of the saddle12. The stem30includes a vertically upward continuation of the saddle surface14, with continuations of the flat central portion16, the angled portions18and20, and the flanges22and24. This provides the stem30with the same cable-friendly surface (no corners or sharp edges) as the saddle12. These corresponding continuations are designated by reference numbers36-44in theFIGS. 1 and 2.

Referring now in addition toFIG. 3, the stem30has tabs52,54,56, and58. The tabs52and56protrude from in the stem angled portion38, and the tabs54and58protrude from the angled portion40. As explained in greater detail below, the tabs52-58are used to couple the stem30to one or more snap-on brackets, to couple multiple cable supports10together and/or to couple the cable support10to a structure member or surface. The tabs52and54constitute a first tab set60, and the tabs56and58constitute a second tab set62. The tab sets60and62are at different heights above saddle12, with the first tab set60closer to a free end64of the stem30than the second tab set62.

The tabs52-58each have narrow neck65that broadens out into a broader body66. On one side of the body66of each of the tabs52-58there is a sloped edge surface68. The sloped edge surfaces68face toward the center of the stem30, the portion of the stem30between the tab sets60and62. On the other side of each tab body66(facing away from the portion of the stem30between the tab sets60and62) there is a curved edge surface69that leads to a step70at the neck65.

The tabs52-58may be bent portions of the sheet metal of the stem30. The tabs52-58protrude rearward from the stem30, from a back side71of the stem30, away from the side that is continuous with the inner surface14of the saddle12. The tabs52-58may thus leave corresponding holes72,74,76, and78in the angled portions38and40.

The stem30may also have other holes for receiving fasteners. In the illustrated embodiment the fastener holes include a rivet hole80, a nail hole82, and a thread form screw hole84. The fastener holes80-84may be used to mechanically couple the stem30to structure and/or to other cable supports. The fastener holes80-84are centered in the stem central portion36, in a vertical line, at different heights above the saddle12. It will be appreciated that different numbers of number, type, and/or configuration of fastener holes may be utilized instead.

The stem30includes a pair of notches86and87in the stem flanges42and44. The notches86and87are used for receiving and securing a wire retainer88, as explained below.

A tip90of the support10extends from the saddle12, on the side opposite from the stem30. The tip90may be substantially parallel to the stem30. Alternatively the tip90may be angled slightly away from the stem30, in order to facilitate placing cables in the cable-receiving area26.

The tip90, like the stem30includes a vertically upward continuation of the saddle surface14, with continuations of the flat central portion16, the angled portions18and20, and the flanges22and24. This provides the stem30with the same cable-friendly surface (no corners or sharp edges) as the saddle12. These corresponding continuations are designated by reference numbers96-104in theFIGS. 1 and 2.

The tip90includes a flangeless portion108near its free end110, where the flanges102and104do not extend. The tip90includes a pair of loops114and116for receiving and retaining the wire retainer88. The loops114and116are tabs that are bent out from the tip angled portions98and100, away from the cable-receiving area26. The loops114and116have central circular holes118and120for receiving a round cross-section object. The holes118and120are closed holes, such that an object inserted in the holes118and120along the axes of the holes cannot be removed except by sliding it out along the axes

The cable support10may be made of a suitable metal, such as a suitable spring steel. The various parts of the cable support10may be formed by suitable processes, such as stamping and bending.

The wire retainer88has a rectangular shape, with a central portion130, a pair of legs132and134, and a pair of bent ends136and138. The legs132and134are substantially parallel to one another, and are at substantially right angles to the central portion130. The bent ends136and138are bent inward at distal ends of the legs132and134, farthest from the central portion130. The bent ends136and138are bent inward toward a centerline of the wire retainer88. The retainer88may be made from a single piece of wire, bent to form the various parts130-138.

When the retainer88is installed, the retainer central portion130is held in place by the loops114and116of the tip90. The retainer legs132and134extend around edges142and144of the tip angled portions98and100. The bent ends136and138of the retainer88fit into and are retained by the notches86and87in the stem30.

FIGS. 4-13illustrate a pair of processes for installing the wire retainer88on the stem30and the tip90, to secure cables, wires, conduits, or other objects within in the cable-receiving area26.FIGS. 4-6show how the wire retainer88may be installed into the loops114and116. First the bent end138is inserted into the hole118of the loop114, and from there into the hole120of the loop116(FIG. 4). Then the retainer88is turned, with the leg134inserted through the holes118and120(FIG. 5). Another rotation of the retainer88allows the retainer central portion130to be inserted through the holes118and120(FIG. 6). The retainer88is thus secured within the loops114and116. As shown inFIG. 7, the retainer88is free to rotate about its central portion130, and may be allowed to hang down, outside of the cable-receiving area26. This allows unfettered access to the cable-receiving area26, for instance to allow entry, exit, or repositioning of cables or other objects.

As shown inFIGS. 8-10, the retainer88may be used to close the cable-receiving area26. First the retainer88is rotated upward, as illustrated inFIG. 8. As the rotation is continued, the retainer legs132and134are pulled apart, to enable the legs132and134and the bent ends136and138to clear the stem flanges42and44(FIG. 9).FIG. 10shows the wire retainer88is in the fully installed position, with the bent ends136and138in the stem flange notches86and87. The stem30is wider than the unstressed configuration of the wire retainer88. This means that some elastic deformation of the retainer legs132and134occurs to install the retainer88on the stem30. When installed, the legs132and134exert an inward resilient force against the sides of the stem30. This resilient force aids in keeping the bent ends136and138in the notches86and87.

FIGS. 11-13illustrate an alternate process for installing the wire retainer88. The wire retainer88slides or is placed over the flangeless portion108of the tip90(FIG. 11). At this step the legs132and134of the retainer88may be in contact with the tip edges142and144in the tip flangeless portion108.

FIG. 12illustrates the next step in the installation process, in which the legs132and134are bent apart to clear the stem flanges42and44.FIG. 13shows the retainer88fully installed, with the retainer bent ends136and138in the stem flange notches86and87. The loops114and116serve to keep the retainer88from sliding off the top of the tip90, even though the retainer88is not inserted into the holes118and120of the loops114and116. The tip flanges102and104prevent the wire retainer88from sliding down the tip90.

The installation method ofFIGS. 3-9allows the retainer88to be coupled to the tip90even while not preventing access to the cable-receiving area26. The method of11-13requires fewer steps and less space, and allows for easier removal of the retainer88.

FIGS. 14-16show a tree mounting bracket150used for coupling together a pair of the cable supports10(FIG. 1). The mounting bracket150has a generally rectangular shape, with four notches152,154,156, and158for receiving and securing pairs of stem tabs52,54,56, and58(FIG. 2) of two different cable supports10, in order to secure the cable supports10together. The notches152-158are in two sets, located at different distances along the bracket150. Tabs162,164,166, and168extend at an angle to the body170of the mounting bracket150, adjacent to the respective notches152-158. The tabs162-168are located adjacent to the notches152-158, at the ends of the notches152-158closest to the center of the mounting bracket150. The tabs162-168aid in maintaining the stem tabs52-58in the notches152-158.

The bracket body170has a central channel172, and a pair of angled portions174and176. The angled portions174and176may be configured to have substantially the same angle between them as the stem angled portions38and40(FIG. 1). The central channel172provides structural support for the bracket150.

The bracket150may be made from spring steel or another suitable material. The bracket150may be formed using suitable processes, such as stamping.

FIGS. 17 and 18show use of brackets150to couple together the stems30of multiple cable supports10. The bottom stem tabs56and58of one cable support10engage the top notches152and154and the top tabs162and164of the bracket150. The top stem tabs52and54of another cable support10engage the bottom notches156and158and the top tabs166and168of the bracket150. Inserting the stem tabs52-58into the notches152-158causes the curved edge69of each of the stem tabs52-58to come into contact with one of the tabs162-168. The contact resiliently deforms the tabs162-168, causing the tabs162-168to press the stem tabs52-58against the opposite ends of the notches152-158. This aids in retaining the stem tabs52-58in the bracket notches152-158, with the sloped edge surfaces68of the stem tabs also discouraging dislodgement of the tabs52-58from the bracket notches152-158.

FIG. 19shows a straight mounting bracket200that may be coupled to the cable support10(FIG. 1), to couple the cable support10to structure either directly or by use of any of a variety of clips or clamps. The mounting bracket200has a pair of notches202and204that have respective angled tabs206and208adjoining them. The notches202and204and the tabs206and208may function in a manner similar to the tabs152-158and the tabs162-168of the mounting bracket150(FIG. 14). That is, the notches202and204and the tabs206and208may be used to engage stem tabs52and54(FIG. 2) of the cable support10, to secure the mounting bracket200to the cable support10.

The mounting bracket200has a bracket body210with a flat central portion212, and angled portions214and216angled away from the central portion212. The angled portions214and216may be configured to have the same angle between them as the stem angled portions38and40(FIG. 1). The central portion212has a hole220therein. The hole220may be used to receive a rivet, threaded fastener, or other fastener, usable to secure the bracket200to a structural member or to a mounting clip or clamp.

FIGS. 20-25show configurations where the mounting bracket200is coupled to various configurations of purlin or flange clips by use of rivets.FIG. 26shows the mounting bracket200coupled by a rivet to a pipe or rod clamp for engaging a circular cross section object.FIGS. 27 and 28show the mounting bracket200coupled by a rivet or bolt to beam or purlin clamps for engaging a flange of a beam or purlin.FIGS. 29 and 30show the mounting bracket200to hangers for coupling to a rod or wire used for hanging items.

FIGS. 31 and 32show one example of how the mounting bracket200coupled to the cable support10. In the illustrated example the mounting bracket200is used to couple a beam or purlin clamp230to the cable support10.

FIG. 33shows an angle bracket240that can be coupled to the cable support10(FIG. 1). The bracket240has a bracket body242that has a similar cross-section shape to that of the bracket body210of the bracket200(FIG. 18), with a flat central portion244and angled portions248and250.

The bracket body242has a substantially right-angle bend251bisecting it along its length. It will be appreciated that the bracket240may alternatively have a bend of a different extent. On one side of the bend251the bracket240has a pair of notches252and254that have respective angled tabs256and258adjoining them. The notches252and254and the tabs256and258may be substantially identical in configuration and function to the notches202and204and the tabs206and208(FIG. 19) of the bracket200. One the other side of the bend251the bracket240has a hole260. The hole260may be used to receive a rivet, threaded fastener, or other fastener, usable to secure the bracket200to a structural member or to a mounting clip or clamp.FIGS. 34 and 35show alternate configurations of the bracket240with larger diameter holes260′ and260″, respectively.

FIGS. 36-38show the bracket240coupled to various types of clips, for engaging purlin edges or other structures.FIGS. 39 and 40show the mounting bracket240coupled by rivet(s) or bolt(s) to beam or purlin clamps for engaging a flange of a beam or purlin.

FIGS. 41 and 42show one example of use of the right-angle mounting bracket240. The illustrated example shows the mounting bracket240used to couple a beam or purlin clamp270to the cable support10.

FIGS. 43 and 44illustrate how the various brackets can be combined to secure several cable supports10. A pair of angle brackets240are used to couple a pair of cable supports10to a threaded rod280. Tree brackets150couple together additional cable supports10to the cable supports coupled to the angle brackets240. Through the use of the brackets150and240eight cable supports10of various sizes are coupled to a single support structure, the threaded rod280.

FIGS. 45-47show a cable support310with a 1 inch (25.4 mm) diameter on its saddle312. The saddle central portion316is flat (except for the semicircular shape of the saddle312), and has a width of 0.6 inches (15.2 mm). The saddle angled portions318and320have a curvature of 3 inches (76.2 mm). The combined width of the central portion316and the angled portions318and320(the distance between the distal end of the angled portion318and the distal end of the angled portion320) is 1.551 inches (39.39 mm). The flanges322and324are at an angle of 50 degrees relative to the plane of the central portion316. The overall width of the saddle312, the distance from the distal end of the flange322to the distal end of the other flange324is 2 inches (50.8 mm). The depth of the saddle312, the perpendicular distance from the ends of the flanges322and324to the plane of the central portion316, is 0.34 inches (8.5 mm).

A stem330extends to a height of 3.3 inches (83.8 mm) above the saddle312. A tip340extends to a height of 1.06 inches (26.9 mm) above the saddle312.

FIGS. 48-50show a cable support360with a 2 inch (50.8 mm) diameter on its saddle362. The saddle central portion366is flat (except for the semicircular shape of the saddle362), and has a width of 0.6 inches (15.2 mm). The saddle angled portions368and370have a curvature of 3 inches (76.2 mm). The combined width of the central portion366and the angled portions368and370(the distance between the distal end of the angled portion368and the distal end of the angled portion370) is 1.57 inches (39.8 mm). The flanges372and374are two part flanges, having respective proximal portions376and377emerging from the angled portions368and370, and having respective distal portions378and379. The proximal portions376and377each are at an angle of45degrees relative to the plane of the central portion366. The distal portions378and379are at angles of 45 degrees relative to their respective proximal portions376and377. This makes the distal portions378and379substantially perpendicular to the central portion366. The overall width of the saddle362, the distance from the distal end of the flange372to the distal end of the other flange374is 2 inches (50.8 mm). The depth of the saddle362, the perpendicular distance from the ends of the distal flange portions378and379to the plane of the central portion366, is 0.4 inches (10.2 mm). A stem380extends to a height of 3.39 inches (86.1 mm) above the saddle362. A tip390extends to a height of 1.6 inches (40.6 mm) above the saddle362.

FIGS. 51-53show a cable support410with a 3 inch (76.2 mm) diameter on its saddle412. The saddle central portion416is flat (except for the semicircular shape of the saddle412), and has a width of 0.6 inches (15.2 mm). The saddle angled portions418and420have a curvature of 3 inches (76.2 mm). The combined width of the central portion366and the angled portions418and420(the distance between the distal end of the angled portion418and the distal end of the angled portion420) is 1.57 inches (39.8 mm). The flanges422and424are two part flanges, having respective proximal portions426and427emerging from the angled portions428and420, and having respective distal portions428and429. The proximal portions426and427each are at an angle of 45 degrees relative to the plane of the central portion416. The distal portions428and429are at angles of45degrees relative to their respective proximal portions426and427. This makes the distal portions428and429substantially perpendicular to the central portion416. The overall width of the saddle412, the distance from the distal end of the flange422to the distal end of the other flange424is 2 inches (50.8 mm). The depth of the saddle412, the perpendicular distance from the ends of the distal flange portions428and429to the plane of the central portion416, is 0.5 inches (12.7 mm). Larger-diameter saddles may utilize a similar cross-sectional configuration.

A stem430extends to a height of 4.62 inches (117.3 mm) above the saddle412. A tip440extends to a height of 2.29 inches (58.2 mm) above the saddle412.

The dimensions described above may result in improved properties for the various cable supports. In particular, the various depths and shapes for the cable supports may make the cable supports easier to form. The depths and cross-section shapes for the saddles may provide greater strength in pull tests, for example, than has been achieved in prior j-shape cable supports. The shapes also aid in preventing unwanted saddle deflection when the supports are under load.

It will be appreciated that the dimensions shown in the specific embodiments shown inFIGS. 45-53are particular to those specific embodiments. Other suitable dimensions and configurations may also be used.

It will also be appreciated that the various cable support systems described herein provide a multitude of advantages over the various systems in use. Some of these advantages have been discussed above. In addition, the coupling of cable supports together without the need to use threaded fasteners provides a significant time saving in installation. The employment of spring steel cable supports having the various configurations described herein allows large loads to be supported, such as by trees of multiple cable supports coupled together as described above, both in back-to-back coupling and top-to-bottom coupling. The ability to couple various brackets to the cable support increases its versatility in coupling to various types of building structure.