Abstract:
A connector for securing a pipe or conduit to a pipe support where the pipe support has at least one channel and two rails that run parallel to the channel and where the connector has an upper pipe connector portion having a platform and a fastening means for securing the pipe to the platform; a middle portion that provides a gap between the upper portion and a lower pipe support connecting portion and where the lower pipe support connecting portion has at least two legs that are integrally formed with the upper pipe connector portion and the two feet at a bottom portion of the legs has two channels formed by the feet and legs whereby the rails of the pipe support are inserted into and secured within the channels.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to pipe supports and to pipe block connecting apparatus that are designed and used to secure pipe to the pipe supports. More particularly, the invention relates to an easily usable connecting apparatus designed to simplify affixing the connecting apparatus to a pipe support block and to then simplify affixing a pipe to the connecting apparatus, thus by way of the connecting apparatus affixing the pipe to the pipe support block. 
         [0003]    2. Description of the Prior Art 
         [0004]    The present invention deals with products in the field of construction, and specifically in the area of configuration and organization of pipe. Even more specifically the invention deals with a product and method of securing piping as it runs across a roof top. However, the product can be used for affixing pipe to supports and pipe configuration anywhere it may be required. 
         [0005]    Typically when a commercial building is constructed it tends to have a flat roof. The reasons for this are numerous, including the fact that many items are installed on the roof top. Included in these installations there generally are a large number of pipes or conduit. These pipes may carry electricity, oil, gas, water, air, etc. and generally it is required that these pipes be elevated up and off the roofing surface. Again, the reasons for this requirement are numerous but typically the reasons involve safety issues. For example, if the pipe or conduit carries electrical cables it is imperative that these be elevated up and off the roof surface in case the roof surface has standing water. Obviously it could be possible for the water to find a hole or leak in the conduit and this could in turn lead to shorts in the electrical system or in a worst case scenario even complete failure in the system. 
         [0006]    Historically the methods or products required for this elevation has not been codified or set out by any rule making body. Thus, engineers and architects typically do not specify what products to use and installers then will generally use whatever is most cost efficient and available on the job. Contractors will use whatever remaining 4×4s exist on the site, combined with metal strapping that is run up and over the conduit and then simply screwed in place. The wooden 4×4s are typically cut to size, the pipes are set across the blocks, or sleepers, and then the pipes are strapped down using metal strapping and screws. 
         [0007]    There are numerous problems and issues that result when using these products with this method and procedure. First, the wooden blocks are not uniform in height. Because the installers use scraps from the job site there are usually differences in the block height. This can cause stress points and thus may cause issues with the pipe or conduit. Secondly, the blocks rot and decay. Because it is just wood it is of course susceptible to the elements and the blocks tend to weather, rot and eventually fall apart. Again, this causes stress points and compromises the conduit or piping. Next, it is extremely time consuming and inefficient. The block is heavy and usually is not uniform in size. In order to cut the block to size the installer must have the proper saw to cut to length. Next, to secure the pipe to the block the installer must have metal strapping and screws. The strapping must be measured to fit each pipe, cut to size, folded over the pipe and then screwed into the wooden block. Additionally, when the wood begins to rot the screws tend to pull free, again compromising the connection to the block. Finally, using the wooden blocks and strapping is aesthetically unappealing. 
         [0008]    In order to resolve these issues a number of companies created and produce a variety of products to replace the wooden block. However, most products currently available are a large footprint of plastic or rubber that utilizes a metal channel, or strut. Then a hanger or some other device is used to secure the pipe to the block. It has recently been discovered that when these products are used with solar panels electrolysis, deterioration, corrosion and decay occurs and destroys the metal clamps and metal channels. Electrolysis is a process by which an electric current is passed through a substance to effect a chemical change. The chemical change is often oxidation or reduction. Electrolysis, deterioration and corrosion all cause the block to conduit connection to be compromised. 
         [0009]    In a typical solar configuration solar panels are placed on the roof and conduit then runs from the panels, across the roof and into an inverter. The pipe supports are used across the roof surface to elevate the conduit throughout the run to the inverter. However, the power running through the lines is direct current (DC). It has recently been discovered that the DC power, combined with outside moisture is causing electrolysis and corrosion to occur at the connection points between the metal channel and the metal struts and the metal is decaying and failing, thus compromising the connection point and again causing a weakness in the structure will compromise the conduit. 
       OBJECTS AND SUMMARY OF THE INVENTION 
       [0010]    In view of the foregoing it is an object of the present invention to provide a pipe support block and a connecting apparatus that will securely fasten a pipe to the pipe support block, that is easily, quickly and efficiently installable. Ideally this locking connector is made entirely of plastic, ABS, AES, nylon or any other non-metallic material to avoid the occurrence of electrolysis and corrosion. However, it may also be made or metallic materials for use in other fields or applications where the occurrence of electrolysis and corrosion is not an issue. 
         [0011]    It is another object of the present invention to provide a connector, either of non-metallic or metallic material that is easily installable to a block product that utilizes either an all plastic channel or a metal channel. 
         [0012]    It is still another object of the present invention to provide a connector that can use differing means to secure the pipe to the fastener. 
         [0013]    The present invention achieves these objects and other objects that become evident from the following detailed description of the preferred embodiments of the invention by providing an improved pipe block connector that is easily mountable to both a pipe support and to a pipe or conduit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is an elevated view of a first embodiment of the block connector of the present invention showing the progression of connection, beginning prior to insertion into the block, during and finally after insertion into the block pipe support. 
           [0015]      FIG. 2  is an elevated view of the first embodiment of the block connector with U-shaped feet utilizing an attached zip tie, or cable tie through a side hole specifically designed to receive and lock the zip tie into place; 
           [0016]      FIG. 3  is an elevated view of the first embodiment of the block connector with shoulders and U-shaped feet utilizing an attached zip tie, or cable tie through side hole specifically designed to receive and lock the zip tie into place; 
           [0017]      FIG. 3(   b ) is an elevated view of the first embodiment of the block connector with shoulders and U-shaped feet utilizing an attached zip tie, or cable tie through side hole specifically designed to receive and lock the zip tie into place, with a piece of pipe attached; 
           [0018]      FIG. 4  is an elevated side view of a second embodiment of the block connector without the shoulders and with U-shaped feet utilizing a zip tie through two holes where one hole is configured to receive an end of the zip tie such that the end will not slide through the hole and the other hole has an internal zip tie ratcheting configuration designed to receive and lock the zip tie other end into place; 
           [0019]      FIG. 5  is an elevated view of a third embodiment of the block connector where the connector simply has a hole on each side of the connector and in this configuration the connector has no shoulders and U-shaped feet; further a zip tie is inserted through the two opposing side holes and is then arranged such that it will lock using its own locking mechanism; 
           [0020]      FIG. 6  is an elevated view of the third embodiment of the block connector with shoulders, U-shaped feet and a zip tie through the two side holes; 
           [0021]      FIG. 7  is a side view of the third embodiment of the block connector with U-shaped feet and with the zip tie run through and connected; 
           [0022]      FIG. 8  is a side view of the first embodiment of the block connector with U-shaped feet after connection to the block, utilizing a zip tie that is permanently affixed to the connector; 
           [0023]      FIG. 9  is a side view of the third embodiment of the connector with U-shaped feet and with a pipe connected; 
           [0024]      FIG. 10  is an elevated view of the third embodiment without shoulders, U-shaped feet and with a pipe connected; 
           [0025]      FIG. 11  is an elevated view of the third embodiment with shoulders, with U-shaped feet and with a pipe connected; 
           [0026]      FIG. 12  is a side view of the third embodiment with U-shaped feet when connected to the pipe support with a pipe connected as well; 
           [0027]      FIG. 13  is a side view of the third embodiment but with V-channel feet; 
           [0028]      FIG. 14  is a side view of the third embodiment with the V-channel feet and a pipe connected; 
           [0029]      FIG. 15  is a side view of the first embodiment with the V-channel feet connected to the pipe block; 
           [0030]      FIG. 16  is a side view of the third embodiment with the V-channel feet connected to the pipe block and a pipe attached thereto; 
           [0031]      FIG. 17  is a bottom view of the connector with square corners; 
           [0032]      FIG. 18  is a bottom view of the connector with 45 degree corners; 
           [0033]      FIG. 19  is a side view of the third embodiment with sloped feet; 
           [0034]      FIG. 20  is a side view of the fourth embodiment with pipe connected to the connector; 
           [0035]      FIG. 21  is a side view of the fourth embodiment when the connector is connected to the pipe support and with a pipe connected. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0036]    The invention will now be described in detail with reference to the attached drawings. As described above in the summary there is a need for a pipe support block that contains no metallic substance. Therefore, the present invention utilizes a non-metallic block  10  made of nylon, plastic, ABS/AES or other non-metallic materials as shown in  FIG. 1 . This block is described more completely in U.S. Pat. No. 8,181,916 B2. The block is basically square in size and can be of varying height, width and length. The block features a dual channel configuration. The first channel  11  is usually of a standard ⅜ bolt size whereas the second connector channel  12  is of the typical strut size that is approximately 1.5 inches wide by 1 inch deep. However, it is noted that these measurements are not restrictive and that they may be of any other configuration. The present invention deals primarily with a block connector apparatus  20  designed to easily lock into the connector channel  12 . 
         [0037]      FIG. 1  is an elevated view of the invention showing the installation steps to securely place a block connector  20  into channel  12 . As can be seen in  FIG. 1 , connector channel  12  is basically square in design with an open, channel, or slotted top. Unique to the channel or slot is a short extending rail  13  that runs the entire length of the block  10 . This rail  13  is important as it provides a basis to which a standard metal hanger may connect. However, it also provides a solid connection rail for the present invention. In fact, in the present invention the connection portion of the block connector  20  extends further along the rail with a matingly locking section, thus providing a more solid connection and base for block connector  20 . 
         [0038]    In a first embodiment the block connector  20  is inserted into channel  12 , is twisted and then locks in place, as is shown in  FIG. 1 . This locking occurs as a result of the unique design of block connector  20 , more fully described below. In this first embodiment, shown in  FIGS. 2 ,  3  and  3 ( b ), the block connector  20  is designed with an upper saddle, or platform  21 . This saddle  21  provides a seat for a pipe  30  to rest therein. This saddle  21  can be either affixed to the lower portion  40  of the block connector  20  or it can be formed integrally with lower portion  40  of the block connector  20 . In the preferred embodiment the platform  21  runs perpendicular to channel  12 , however, it can run either perpendicular to channel  12  or parallel with channel  12 . 
         [0039]    First will be described the connecting means by which the pipe is attached or secured to the block connector  20 . In the first embodiment, shown in  FIGS. 2 ,  3 ,  8 ,  15 , the saddle  21  runs perpendicular to the channel  12 . Also in this embodiment the block connector  20  can be either bordered on both sides by shoulders  23 ,  24 , as shown in  FIGS. 3 and 3(   b ), or it can have no shoulders, as shown in  FIG. 2 . This saddle can vary in size depending on the diameter of the pipe and could also simply be a flat surface. In the shouldered design of  FIG. 3 , on one of these shoulders there is a strap  25  that is permanently affixed to shoulder  23 . This strap  25  can be similar to a zip tie, cable tie or any other strapping mechanism that has a means for securing it to a second end. In this embodiment there is a slot  26  extending through shoulder  24 . This slot  26  has an inner channel that accepts the zip tie strap  25  such that strap  25  is brought up and over pipe  30  and then strap  25  is inserted through slot  26 . Strap  25  is then pulled down through slot  26  to secure pipe  30  to block connector  20 . Strap  25  and slot  26  interact with each other just as a zip tie or cable tie would interact. These ties can be made of nylon, plastic, metal, a combination of these or any other flexible yet break resistant material. Obviously this same orientation and configuration can be made in the embodiment shown in  FIG. 2  where there are no shoulders, but simply a saddle. 
         [0040]    In a second embodiment the connector can again either have or not have shoulders  23 ,  24 .  FIG. 4  shows this embodiment configuration without shoulders. In this second embodiment with shoulders, shoulders  23 ,  24  would have two slots  28 ,  29  with only one slot configured to receive and lock a standard zip tie strap into place. The second slot  28  would be just a simple, clean slot with an opening large enough to receive a standard zip tie  27  but smaller than the locking mechanism end of the zip tie  27  in order to prevent the tie from sliding entirely through the hole, thus securing the tie in place. In this configuration the zip tie  27  is fed through the second slot  28  such that the locking end of the zip tie  27  abuts against the lower portion of shoulder  23 , thus preventing the zip tie  27  from passing entirely through the slot. The free end is then wrapped up and over pipe  30  and is then inserted down and through slot  26 . It is then pulled down to securely affix pipe  30  to block connector  20 . This could also be configured as shown in  FIG. 4  where the platform has no shoulders but still has the holes therethrough. 
         [0041]    Alternatively, an even simpler configuration is possible in a third embodiment where shoulders  23 ,  24 , or plain saddle, have two open slots. In this embodiment again a standard zip tie  27  could be utilized. As shown in  FIGS. 5 ,  6 ,  7 ,  9 ,  10 ,  11 ,  12 ,  13 ,  14 , and  16  zip tie  27  is inserted up and through first clean slot  28 , it is then brought up and over pipe  30 , fed down through second clean slot  29 , once through clean slot  29  it is brought back up along the side of shoulder  23  and continues to be brought up to the top of pipe  30 . The opposite locking end strap portion extends up along the side of shoulder  24  and over the top of pipe  30  where it is then matingly joined with the opposite end of zip tie  27 . The zip tie  27  is pulled taught and thus the pipe is securely fastened on top of block connector  20 . These figures show the basic embodiments with slight variation, particularly with or without shoulders, and with a V-shaped or U-shaped channel in a foot portion, described below. 
         [0042]    Block connector  20  is uniquely designed to connect and lock in place to block  10 .  FIGS. 1 ,  2  and  3  show differing views of the first embodiment where the strap  25  is directly connected to shoulder  23 , or saddle and where the block connector  20  is oriented so that the pipe  30  lays perpendicular to channel  12 . Although this description is set out utilizing the first embodiment with the permanently connected strap it is anticipated that this same configuration and design can be used with any strap configuration as set out hereinabove. 
         [0043]      FIGS. 2 ,  3  and  3 ( b ) show the block connector  20  when separated from the block  10 . The block connector  20  of this embodiment includes the upper portion  22  as described above with the permanently affixed strapping, a middle portion  40  and lower portion  50 . It is envisioned that the pipe can be affixed to the block connector  20  either prior to or after affixing block connector  20  to the block  10 . 
         [0044]    Middle portion  40  is necessary as it provides a firm base for affixing the block connector to the block. Additionally, middle portion  40  provides the required space to either attach zip tie  27  or zip strap  25 . Middle portion  40  is either permanently affixed to upper portion  22  and lower portion  50  or it is a singley formed piece of material. That is, upper portion, middle portion and lower portion are made of one, uniform piece of material. 
         [0045]    Lower portion  50  includes two flexible legs  51 ,  52 . These legs are preferably mirror images of each other and perform the same functions on opposite sides so the description set out hereinbelow applies to both legs equally. The legs  51 ,  52  extend downward from the middle portion  40  and have an inner side that is slanted and an outer side that is basically perpendicular to middle portion  40 . However, the inner side could also be perpendicular to middle portion  40 . At the bottom of both legs are feet  55 ,  56 . The feet extend outward from legs  51 ,  52  and the turn upward. As seen in  FIG. 7  the upward portion and the downward leg form U-channels  53 ,  54  or alternatively, they could form V-channels. Various views of the U-shaped channels can be seen in  FIGS. 1 through 12  and various views of the V-shaped channels can be seen in  FIGS. 13 through 16 . Additionally, each foot can have bevel portions  57 ,  58  that are located at opposite ends of feet  55 ,  56 , as can be seen in  FIG. 19 . This unique design provides for easy installability and lockability of the block connector  20  to the pipe block  10 . This configuration is only shown in  FIG. 19  but can be incorporated into any of the configurations. The method of installing is described next. 
         [0046]    First, the distance from the front of the foot to the back of the foot cannot exceed the width of the connector channel  12 . This is so the connector, when turned sideways, will fit into the channel  12 .  FIG. 1  shows the user inserting connector  20  into the channel  12  until the middle portion  40  is resting on the top of the block. Then, the connector is rotated in the direction of the beveled corners  57 ,  58  and snap locks in place, as described below.  FIGS. 8 ,  12 ,  15  and  16  show the connector  20  after it is twisted into the locked position. The beveled sides  57 ,  58  of the connector  20  allow rails  13  to connect easily with the top of the feet on opposite sides and then further allows rails  13  to gradually tighten up until rail  13  reaches the lock point  59  on the top of the feet. After reaching lock point  59  rails  13  slip into V or U-channels  53 ,  54 , thus locking the connector  20  to the block  10 . In addition, feet  55 ,  56  are somewhat flexible in a vertical direction so that when rails  13  contact the bevel and finally the upper portion of the feet the feet will tend to flex downward, allowing rails  13  to continue back until they each reach the lock point  59 . When they pass lock point  59  both feet will reflex back into their original position, thus securely locking the connector to the block. It is also noted that when used with a plastic block the rails  13  are also somewhat flexible and so rails will also flex in order to receive the connector therein. 
         [0047]    It is to be understood that the order of connection does not matter. That is, the user may first connect to pipe to the connector  20  and then connect the connector  20  to the block  10  or alternatively, the user may first connect the connector  20  to the block  10  and then connect the pipe  30  to the connector  20 . 
         [0048]    Still another embodiment is shown in  FIGS. 20 and 21 . This embodiment is similar to the previously described embodiments but the configuration is such that it is a push and snap lock mechanism. As can be seen from the  FIGS. 20 and 21  the legs are designed in a flexible V shape such that they are simply driven down into the channel  12  by forcing them past rails  13 . In this manner both the connector legs and the block both flex somewhat so that the connector is snapped into place. Once past the rail and in the channel the legs snap back to their original position, as do rails  13  such that rails  13  are inserted into the V or U-channels, thus securing the connector to the block. The top pipe connector embodiments are the same as previously described. 
         [0049]    Although the invention has been described with reference to the preferred embodiments illustrated in the attached drawing figures it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. 
         [0050]    Having thus described the various embodiments of the invention, what is claimed as new and desired to be protected by letters patent includes the following.