Abstract:
A cable tray apparatus for use with a ladder-type cable tray having a pair of parallel spaced apart rails interconnected by a plurality of rungs is disclosed. The cable tray apparatus includes an elongate flexible spine member selectively bendable into a number of different configurations, and a plurality of spaced apart hangers attached to the elongate spine member along the length thereof, each of the plurality of hangers defining a partially enclosed area configured and dimensioned to receive at least one cable therein, wherein each of the plurality of hangers includes a support bracket integrally formed therewith for removably attaching the hanger to at least one of the pair of spaced apart rails of the ladder-type cable tray. The present disclosure also relates to methods of using the cable tray subassemblies disclosed herein in conjunction with ladder-type cable trays.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   The present application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 60/361,437 filed on Mar. 4, 2002, the entire contents of which are incorporated herein by reference. 

   BACKGROUND 
   1. Technical Field 
   The present disclosure relates to a cable tray apparatus and, more particularly, to a cable tray apparatus for attachment to separate structural members, for example, a ladder-type cable tray. The present disclosure also relates to methods of using the cable tray subassemblies disclosed herein in conjunction with separate structural members, such as ladder-type cable trays. 
   2. Background of Related Art 
   Conventional ladder-type cable trays generally include a pair of spaced apart parallel and/or concentric side rails and a series of spaced apart rungs typically extending transversely between the rails for cradling cables, wiring, tubes and the like, such as for computer networks, telecommunications and the like. Ladder-type cable trays normally are suspended from ceilings on rods. In computer network installations, ladder-type cable trays are used for routing network cables along the ceiling of a dedicated room to upright components known as racks. 
   A typical ladder-type cable-tray in accordance with the general state of the art is disclosed in U.S. Pat. No. 6,313,405 to Rinderer, the entire content of which is incorporated herein by reference. As seen in present  FIG. 1 , a ladder-type cable tray, in accordance with Rinderer, is generally illustrated as ( 20 ) and includes first and second generally parallel side rails ( 22 ) and a plurality of spaced apart rungs ( 26 ) secured to and extending generally transversely between the side rails ( 22 ). Moreover, as seen in present  FIG. 2 , an arcuate section of cable tray, in accordance with Rinderer, is generally designated ( 21 ) which includes a pair of curved concentric spaced apart side rails ( 24 ,  25 ) connected by rungs, each also designated ( 26 ). 
   Current applications demand greater numbers of cable runs be installed to satisfy the ever-increasing need to interconnect computer and telecommunication systems, etc. Some existing cable tray and rack systems while structurally sound cannot meet the need of routing the increased volume of cable required. 
   Accordingly, a need exists for a cable tray apparatus which increases the capacity of existing or new cable management installations, reduces the incidents of sag along the cable run and which provides a relatively smooth curve transition from one existing cable tray section to the next. In addition, a need exists for a cable tray apparatus which can be retrofitted to existing cable tray systems and which is relatively inexpensive and easy to install. 
   SUMMARY 
   According to one aspect of the present disclosure, a cable tray apparatus for use with a ladder-type cable tray having a pair of parallel spaced apart rails interconnected by a plurality of rungs is disclosed. The cable tray apparatus includes an elongate flexible spine member selectively bendable into a number of different configurations, and a plurality of spaced apart hangers attached to the elongate spine member along the length thereof, each of the plurality of hangers defining a partially enclosed area configured and dimensioned to receive at least one cable therein, wherein each of the plurality of hangers includes a support bracket integrally formed therewith for removably attaching the hanger to at least one of the pair of spaced apart rails of the ladder-type cable tray. 
   The elongate flexible spine member is bendable by hand in at least one of a vertical and a horizontal direction. The plurality hangers are arrayed along the elongate flexible spine member to define a pathway to support and direct cables. 
   Each hanger includes a cable support member integrally attached to the elongate flexible spine member and a pair of spokes integrally formed at either end of the cable support member. Each spoke is substantially U-shaped including a riser portion integrally connected to the end of the cable support member and a return portion integrally connected to the end of the riser portion. 
   It is envisioned that the support bracket is integrally connected, one each, to each free end of the return portion. 
   According to one embodiment, each support bracket includes a portion configured and adapted to extend below an upper surface of the rail of the ladder-type cable tray and a portion configured and adapted to be supported on top of the rail of the ladder-type cable tray. Each support bracket includes a guide member having a first leg portion integrally formed with and coaxially extending from the distal end of the return portion, a second leg portion spaced from and parallel with the first leg portion, and an interconnecting member integrally connected to and extending between the first and second leg portions. Each support bracket further includes a mounting bracket integrally connected to the distal end of the second leg portion. Each mounting bracket includes a support leg integrally formed at the distal end of the second leg portion, wherein the support leg is oriented in a direction orthogonal with respect to the support bracket, and a guide leg integrally formed at the distal end of the support leg, wherein the guide leg is oriented in a direction substantially parallel with return portion. 
   According to another embodiment, the support brackets enable the cable tray apparatus to be snap-fit onto the ladder-type cable tray. Each of the support brackets includes an arm integrally connected to the distal end of the return portion, the arm extending in an orthogonal direction away from the elongate spine member and in a direction substantially parallel to the cable support member, a leg integrally connected to the distal end of the arm, the leg extending in a direction orthogonal to the cable support member and parallel with the return portion, and a locking member integrally connected to the distal end of the leg, the locking member having a portion extending in a direction toward the elongate spine member. It is envisioned that a plurality of tethers extending between and releasably connected, one each, to the locking members of the plurality of hangers can be provided. Preferably, each locking member is a hook. 
   According to another aspect of the present disclosure, the cable tray apparatus can include an elongate spine member, and a plurality of spaced apart hangers attached to the elongate spine member along the length thereof, each of the plurality of hangers defining a partially enclosed area configured and dimensioned to receive at least one cable therein. Each of the plurality of hangers includes a cable support member having a first end and a second end, the cable support member being oriented in a direction which is substantially orthogonal to the elongate spine member, a spoke connected to each of the first end and second end of the cable support member to define a channel into which runs of cable are to be laid, each spoke includes a pair of riser portions integrally connected, one each, to the first end and the second end of the cable support member, the pair of risers oriented in a direction which is orthogonal to the cable support member and the spine member, and a pair of return portions integrally connected, one each, to the free end of each of the pair of riser portions, the pair of return portions being oriented in a direction which is substantially parallel to the pair of riser portions, and a pair of support brackets integrally connected, one each, to the free end of the pair of return portions for removably attaching each of the plurality of hangers to at least one of the pair of spaced apart rails of the ladder-type cable tray. 
   The present disclosure also relates to methods of using the cable tray subassemblies disclosed herein in conjunction with ladder-type cable trays. 
   According to one aspect of the present disclosure, a method of installing a series of cable tray subassemblies to a ladder-type cable tray having a pair of spaced apart rails interconnected by a plurality of rungs, wherein the method includes the steps of providing a plurality of cable tray subassemblies. Each cable tray apparatus includes an elongate flexible spine member selectively bendable into a number of different configurations, a plurality of spaced apart hangers attached to the elongate spine member along the length thereof, each of the plurality of hangers defining a partially enclosed area configured and dimensioned to receive at least one cable therein, wherein each of the plurality of hangers includes a support bracket integrally formed therewith for removably attaching each hanger to the pair of spaced apart rails of the ladder-type cable tray. The method further includes the step of mounting the plurality of cable tray subassemblies along the length of the ladder-type cable tray such that the support brackets are removably supported by the rails of the ladder-type cable tray. 
   According to a further aspect of the present disclosure, there is disclosed a cable tray apparatus for mounting to an existing cable tray structure. According to the present aspect, the cable tray apparatus includes a plurality of hangers configured and adapted to define a partially enclosed area for receiving at least one cable therein, wherein each of the plurality of hangers includes at least one mounting structure configured and dimensioned to maintain the plurality of hangers removably mounted atop the existing cable tray structure, and a connecting element configured and dimensioned to interconnect each of the plurality of hangers to one another. 
   The connecting element is an elongate bendable spine member extending across each of the plurality of hangers. Each of the plurality of hangers includes a cable support member oriented in a direction which is substantially orthogonal to the direction of the elongate bendable spine member. Each of the plurality of hangers includes a spoke extending from each end of the cable support member, wherein each spoke is oriented in a direction orthogonal to the elongate spine and the cable support member. Each spoke includes a mounting structure configured and dimensioned to selectively and releasably connect the cable tray apparatus atop a portion of the existing cable tray structure. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with a general description of the embodiments given above, and the detailed description of the embodiments given below serve to explain the principles of the disclosure. 
       FIG. 1  is a perspective view of a straight section of cable tray in accordance with a prior art embodiment; 
       FIG. 2  is a perspective view of a curved section of cable tray in accordance with the prior art embodiment; 
       FIG. 3  is an exploded perspective view of a cable tray apparatus in accordance with the present disclosure with a prior art ladder-type cable tray shown in phantom; 
       FIG. 4  is an enlarged perspective view of area “A” of  FIG. 3  illustrating the support bracket for the cable tray apparatus in accordance with the present disclosure; 
       FIG. 5  is a front elevational view of the cable tray apparatus as shown in  FIG. 3  mounted on to a ladder-type cable tray; 
       FIG. 6  is a top plan view of a typical prior art ladder-type cable tray run having a plurality of cable tray subassemblies, in accordance with the present disclosure, mounted thereto; 
       FIG. 7  is a side elevational view of a typical prior art ladder-type cable tray run having a plurality of cable tray subassemblies, in accordance with the present disclosure, mounted thereto; and 
       FIG. 8  is a front elevational view of an alternative embodiment of a cable tray apparatus in accordance with the present disclosure. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   As seen in  FIG. 1 , a prior art ladder-type cable tray is generally designated as  20  and includes first and second generally parallel side rails  22  and a plurality of spaced apart rungs  26  secured to and extending generally transversely between the side rails  22 . In addition, as seen in  FIG. 2 , a prior art arcuate section of cable tray is generally designated as  21  and includes a pair of curved concentric spaced apart side rails  24 ,  25  connected by rungs, each also designated  26 . 
   Preferred embodiments of the presently disclosed cable tray apparatus will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. Referring now in specific detail to  FIGS. 3-8 , and initially to  FIGS. 3-7 , one embodiment of a cable tray apparatus, in accordance with the present disclosure, is shown generally as  100 . Cable tray apparatus  100  includes a plurality of spaced apart hangers  102  and a flexible spine  104 , integral with and interconnecting each of the plurality of hangers  102 . Each hanger  102  includes a cable support member  106  and a pair of U-shaped spokes  108  integrally formed at either end of cable support member  106 . 
   Each U-shaped spoke  108  includes a riser portion  110  integrally formed at an end of cable support member  106  and a return portion  112  integrally formed with riser portion  110  via turnaround portion  114 . Each U-shaped spoke  108  is oriented such that riser portion  110  and return portion  112  are substantially in the same plane as cable support member  106  and wherein each U-shaped spoke  108  is oriented substantially upward. As such, U-shaped spokes  108  define a channel or canyon  116  into which runs of cable (not shown) are to be laid. 
   Each spoke  108  includes a cable tray apparatus support bracket  118 . Each support bracket  118  includes a substantially U-shaped guide member  120  having a first leg  122  integrally formed with and co-axially extending from the distal end of return portion  112  of U-shaped spoke  108  and a second leg  124  integrally formed with first leg  122  via cross member  126 . Preferably, each cross member  126  is oriented substantially orthogonal to the plane defined by riser portion  110  and return portion  112  of spoke  108 . 
   Each cable tray apparatus support bracket  118  further includes a mounting bracket  128  integrally formed at the end of second leg  124  of guide member  120 . Each mounting bracket  128  includes a support leg  130  integrally formed at the end of second leg  124  and a guide leg  132  integrally formed at the end of support leg  130 . It is contemplated that each support leg  130  is oriented substantially parallel to cable support member  106  and directed toward flexible spine  104  while each guide leg  132  is oriented substantially parallel to riser portion  110  and return portion  112 . Support legs  130  permit cable tray apparatus  100  to rest atop rails  50  of an underlying and previously installed ladder-type cable tray  52 . 
   As best seen in  FIG. 5 , each hanger  108  preferably has a length wherein U-shaped guide members  120  are located on the outside of rails  50  and wherein guide legs  132  rest along the inside of rails  50  via support legs  130  directed substantially toward flexible spine  104 . In the alternative, it is contemplated that each hanger  108  can have a length wherein U-shaped guide members  120  are located on the inside of rails  50  and guide legs  132  rest on the outside of rails  50  via support legs  130  directed substantially away from flexible spine  104 . 
   Preferably, each support leg  130  has a length sufficient such that U-shaped guide members  120  and guide legs  132  rest on either side of rails  50  (see FIG.  5 ). In this manner, U-shaped guide members  120  and guide legs  132  cooperate with one another to inhibit the transverse movement of cable tray apparatus  100  relative to the underlying cable tray  52 . Moreover, in accordance with the present disclosure, each hanger  102  is spaced from one another a distance which is less than the distance between adjacent rungs  54  of the underlying cable tray  52 . 
   In use, cable tray apparatus  100  is placed atop rails  50  of an existing ladder-type cable tray system  52  and is provided with a plurality of hangers  102  which are more closely spaced to one another than the rungs  54  of the underlying cable tray  52 . As such, the data transmission cables (not shown), placed within channel  116  of cable tray apparatus  100 , will be supported at more points along its length, thereby reducing the potential adverse effects of cable sag on the transmission of data through the cable. 
   Preferably, cable tray apparatus  100  is formed of wire stock material having sufficient strength to support a plurality of cables thereon. Alternatively, cable tray apparatus  100  may be formed of any suitable material which is configured and dimensioned to support a plurality of cables thereon. 
   As seen in  FIG. 6 , a typical layout for a cable run having to navigate a 90° turn using a prior art ladder-type cable tray  52  is shown having a cable tray apparatus  100 , in accordance with the present disclosure, supported thereon. In the past, runs of cable which were laid atop ladder-type cable tray  52  had to bend around a sharp corned “C 1 ”. While corner “C 1 ” may not have caused problems with the use of copper core cables, corner “C 1 ” may result in data transmission losses with some of today&#39;s more sensitive cable products, i.e., the cracking or fracturing of the glass filament of a fiberoptic type cable, thus resulting in an interruption or a termination of data transmission therethrough. Moreover, the relatively large distance between adjacent rungs  54  along ladder-type cable tray  52  is reduced by the placement of cable tray apparatus  100 , having relatively closely spaced adjacent hangers  102 , on top of rails  50 . 
   As seen in  FIG. 7 , another typical layout for cable run having to navigate either up or down a level using a prior art ladder-type cable tray  52  is shown having a cable tray apparatus  100 , in accordance with the present disclosure, supported thereon. In the past, runs of cable laid atop ladder-type cable tray  52  had to bend around sharp internal corners “C 2 ” and/or sharp external corners “C 3 ”. Once again, while corners “C 2 ” and/or “C 3 ” may not have caused problems with the use of copper core cables, corners “C 2  and C 3 ”, may now result in data transmission losses with some of today&#39;s more sensitive cable products. For example, the cracking or fracturing of a fiberoptic type cable which is laid on ladder-type cable tray  52  might occur. However, by placing cable tray apparatus  100  atop ladder-type cable tray  52 , corners “C 2  and C 3 ” are smoothed out thereby reducing the likelihood of cable damage. For example, the tendency of the glass filament of a fiberoptic type cable to crack or fracture at or near corners “C 2  and/or C 3 ”. 
   As seen in  FIG. 5 , riser portion  110  and return portion  112  of U-shaped spokes  108  can have any length. In this manner the height of U-shaped spokes  108  can be varied or selected as needed. For example, if fewer cables are to be run then U-shaped spokes  108  having a reduced height is sufficient, however, if more cables are to be run then U-shaped spokes having an increased height would be necessary. 
   It is further envisioned that the individual lengths of riser portion  110  and return portion  112  of U-shaped spokes  108  can be varied with respect to one another so that a height “H” (between cable support members  106  of cable tray apparatus  100  and rungs  54  of ladder-type cable tray  52 ) can be adjusted or selected as needed. Accordingly, the existing cables (not shown) installed can remain supported by rungs  54  of ladder-type cable tray  52  while additional cable runs (not shown) can be concomitantly supported by cable support members  106  of cable tray apparatus  100 . In this manner, in an existing cable tray installation, using ladder-type cable trays, cable tray apparatus  100  can be retrofit to the ladder-type cable trays in order to run cables substantially concomitantly along the existing runs of cables. 
   Referring now to  FIG. 8 , an alternative embodiment of a cable tray apparatus is generally shown as  200 . Cable tray apparatus  200  includes a plurality of spaced apart hangers  202  and a flexible spine  204 , integral with and interconnecting each of the plurality of hangers  202 . Each hanger  202  includes a cable support member  206  and a pair of U-shaped spokes  208  integrally formed at either end of cable support member  206 . 
   Each U-shaped spoke  208  includes a riser portion  210  integrally formed at an end of cable support member  206  and a return portion  212  integrally formed with riser portion  210  via turnaround portion  214 . Each U-shaped spoke  208  is oriented such that riser portion  210  and return portion  212  are substantially in the same plane as cable support member  206  and wherein each U-shaped spoke  208  is oriented substantially upward. As such, U-shaped spokes  208  define a channel or canyon  216  into which runs of cable (not shown) are to be laid. 
   Each spoke  208  includes a cable tray apparatus support bracket  218  configured and adapted to enable cable tray apparatus  200  to be snap-fit onto the existing ladder-type cable tray. Each support bracket  218  includes an arm  220  integrally formed at a distal end of return portion  212 . Each arm  220  is oriented in a direction which is orthogonal to return portion  212  and substantially parallel to cable support member  206 . Each support bracket  218  further includes a leg  222  integrally formed at a distal end of a respective arm  220 . Each leg  222  is oriented in a direction which is substantially parallel return portion  212 . Support bracket  218  further includes a locking member  224  integrally formed at a distal end of each leg  222  and extending substantially toward flexible spine  204 . 
   Preferably, each hanger  202  has a length such that each return portion  212  of U-shaped spoke  208  terminates short of the outer edge of rails  50  of ladder-type cable tray  52 . In this manner, arms  220  define the supporting surface against which rails  50  will rest. Preferably, arms  220  extend a distance sufficient for legs  222  to contact the surface of rails  50 . In addition, legs  222  preferably have a length substantially equal to the height of rails  50 . In this manner, when cable tray apparatus  200  is placed atop ladder-type cable tray  52 , cable tray apparatus  200  will snap fit around rails  52 . 
   It is contemplated that each locking member  224  has a hook shape. In this manner, additional data transmission cables or in the alternative power transmission cables can be run along side the ladder-type cable tray. Preferably, each locking member  224  includes a portion  224   a  which extends below the outer edge of rails  50  of ladder-type cable tray  52 . 
   Preferably, cable tray apparatus  200  is formed of wire stock material having sufficient strength to support a plurality of cables thereon. Alternatively, cable tray apparatus  200  may be formed of any suitable material which is configured and dimensioned to support a plurality of cables thereon. Preferably, cable tray apparatus  200  is formed from a material having a shape memory, such as spring steel. In this manner, when installing cable tray apparatus  200  on to ladder-type cable tray  52 , return portions  212  can be temporarily deformed to create an opening larger than the outer edge of rails  50  so that locking members  224  slip over rails  50  at which time return portions  212  can be released and allowed to snap back into their original shape, thus locking onto ladder-type cable tray  52 . 
   In the present embodiment, it is envisioned that a tether  246  can be provided which hooks onto and extends between locking member  224  of a particular hanger  208  or in between adjacent hangers  208 . Tether  246  is intended to inhibit an outward deflection of return portions  212  relative to one another, which outward deflection may cause arms  220  to slip off of rails  50 . 
   Similar to cable tray apparatus  100  shown in  FIGS. 3-7 , it is envisioned that the individual lengths of riser portion  210  and return portion  212  of U-shaped spokes  208  can be varied with respect to one another so that a height “H” (between cable support members  206  of cable tray apparatus  200  and rungs  54  of ladder-type cable tray  52 ) can be adjusted or selected as needed. In this manner, the existing cables (not shown) can remain supported by rungs  54  of ladder-type cable tray  52  while additional cables (not shown) can be concomitantly supported by cable support members  206  of cable tray apparatus  200 . 
   While the present disclosure has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the disclosure. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and the spirit of the present disclosure.