Abstract:
A system for fastening an electrical cable to a wall stud or structural member. The system includes a rectilinear frame with first and second ends and a predetermined length. A leg is communicatively connected to the frame at the first end, the leg being for coupling contact with the wall stud, the leg having an aperture disposed at a predetermined location thereon. The system further includes a fastener such as a nail and a screw, the fastener being adapted for driving into the wall stud through the leg aperture. A lock member is connected to the frame at a predetermined location, the lock member having a mating notch. A flexible arm is connected to the frame at the second end, the arm having a curvilinear configuration defining a substantially cylindrical passage with open ends adapted to receive the electrical cable in use, the arm having a free end with a mating notch which is releasibly couplable to the mating notch of the lock member.

Description:
BACKGROUND  
       [0001]     1. Field  
         [0002]     The present invention relates, generally, to fasteners, clamps and holders, and methods of manufacture and use therefor. More particularly, the invention relates to a device for engaging a cable and fastening it to a structural member such as a wall stud. A method of use for the fastener device and a method of making the fastener are also disclosed The fastener and methods of this invention are particularly useful for electrical wiring of commercial buildings. The techniques of the invention can also be used in other fields such as electrical wiring of residential buildings, low voltage wiring, wiring of various craft, plumbing and the like.  
         [0003]     2. Background Information  
         [0004]     Existing technology, in general, includes apparatus and/or methods for fastening wires. This technology is believed to have significant limitations and shortcomings, including but not limited to difficulties of installation and problems with placement of electrical wires in too close proximity to structural members.  
         [0005]     Existing members are difficult to use and install. Some fasteners are very small. This makes them difficult to pick up and to firmly grasp, especially when holding the fastener at the time of nailing or screwing to a structural member, such as a wall stud. This can also require that the held cable is placed directly on or in very close proximity to the stud. Placement of the cable on or near the stud exposes the cable to damage when sheet rock or other wall material, or other mechanical structures (such as other wiring, plumbing, or HVAC elements) are attached to the stud. Sheet rock in particular is a problem because fasteners, typically screws, are driven into the studs without the installer being able to visually appreciate the stud and any wiring fixed thereto. Also, installers tend to work extremely fast and often without great care. Screws which puncture wires can cause complete failure of electrical systems or can degrade their performance. Diagnosing problems of this nature is particularly problematic because the damage is covered up by the wall.  
         [0006]     Some fasteners must engage the cable to be held at the same time the fastener is being secured to the stud. This slows down the securement process. This can be a costly problem in large building projects.  
         [0007]     Some fasteners cannot disengage cable when necessary for alignment, adjustment, or troubleshooting.  
         [0008]     For these and other reasons, a need exists for the present invention.  
         [0009]     All U.S. patents and patent applications, and all other published documents mentioned anywhere in this application are hereby incorporated by reference in their entirety.  
       BRIEF SUMMARY  
       [0010]     The present invention provides an apparatus or device for engaging or clamping and fastening or holding articles such as cables and methods of use and manufacture therefor, which is practical, reliable, accurate and efficient, and which is believed to fulfil a need and to constitute an improvement over the background technology.  
         [0011]     The fastener and methods of this invention are particularly useful for electrical wiring of commercial buildings. The techniques of the invention can also be used in other fields such as electrical wiring of residential buildings, low voltage wiring (such as telephone, computer network, audiovisual, and the like) wiring of various craft (such as motor vehicles, watercraft, and aircraft), plumbing and the like.  
         [0012]     In one aspect, the invention provides a device comprising: 
        a. a frame,     b. a leg communicatively connected to the frame, the leg being for coupling contact with an external base object;     c. an arm connected to the frame, the arm defining a passage in which an article is disposed.        
 
         [0016]     In another aspect, the invention provides a cable fastening device comprising: 
        a. a frame with first and second ends,     b. a leg communicatively connected to the frame at the first end, the leg being for coupling contact with an external base object;     c. a lock member connected to the frame at a predetermined location; and     d. a flexible arm connected to the frame at the second end, the arm having a rectilinear configuration defining a substantially cylindrical passage with open ends adapted for receiving the cable, the arm having a free end which is releasibly couplable to the lock member.        
 
         [0021]     In a further aspect, the invention provides a system for fastening an electrical cable to a wall stud or the like comprising: 
        a. a rectilinear frame with first and second ends and a predetermined length,     b. a leg communicatively connected to the frame at the first end, the leg being for coupling contact with the wall stud, the leg having an aperture disposed at a predetermined location thereon;     c. a fastener selected from the group of fasteners consisting of a nail and a screw, the fastener being adapted for driving into the wall stud through the leg aperture;     e. a lock member connected to the frame at a predetermined location, the lock member having a mating notch; and     f. a flexible arm connected to the frame at the second end, the arm having a curvilinear configuration defining a substantially cylindrical passage with open ends adapted to receive the electrical cable in use, the arm having a free end with a mating notch which is releasibly couplable to the mating notch of the lock member.        
 
         [0027]     The features, advantages, benefits and objects of the invention will become clear to those skilled in the art by reference to the following description, claims and drawings. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING  
       [0028]      FIG. 1  is a perspective view of the cable fastener of the present invention.  
         [0029]      FIG. 2  is a side or elevation view of the cable fastener operatively disposed and securing a cable to a structural member, such as a wall stud.  
         [0030]      FIG. 3  is a plan or top view, partially in crossection, of an operatively disposed cable fastener.  
         [0031]      FIG. 4  is a front view of the cable fastener.  
         [0032]      FIG. 5  is a top view of the cable fastener.  
         [0033]      FIG. 6  is a back view of the cable fastener.  
         [0034]      FIG. 7  is and end view of the cable fastener.  
         [0035]      FIG. 8  is an opposite end view of the cable fastener.  
         [0036]      FIG. 9  is an elevation view of a wall frame with a plurality of cable fasteners of the present invention operatively disposed. 
     
    
     DETAILED DESCRIPTION  
       [0037]     This application shows and describes one embodiment of the present invention, generally indicated by the reference numeral  10 . The embodiment of the invention is intended to be illustrative and not to be exhaustive or limit the invention to the exact forms disclosed. The embodiment is chosen and described so that persons skilled in the art will be able to understand the invention and the manner and process of making and using it.  
         [0038]     Referring to  FIG. 1 a  preferred embodiment of the fastener  10  of the present invention is shown. The fastener  10  engages, clamps and fastens articles such as cables to external structures. The fastener  10  is particularly useful for fastening electrical cables to wall studs in new and renovated buildings. The fastener  10  is particularly useful for commercial building applications. The fastener  10  can also be used in other fields such as electrical wiring of residential buildings, low voltage wiring (such as telephone, computer network, audiovisual, and the like) wiring of various craft (such as motor vehicles, watercraft, and aircraft), plumbing and the like. The fastener  10  is compliant with the National Electrical Code, and NEC 300.4, 300.30, and 334.30 in particular.  
         [0039]     The fastener  10  basically includes a frame  11 , a leg  12 , an arm  13  and a lock member  14 . Referring also to  FIGS. 2 and 3 , fastener  10  is connectable to a structural member  21 , in this case a wall stud, of a building or the like. The arm  13  is movable to permit placing an article such as a cable  24  through passage  15 . In this manner, the cable  24 , or a plurality of cables  26   a ′- c ′, are coupled to the stud  21  and releasibly held in place a predetermined distance therefrom.  
         [0040]     Referring also to  FIGS. 4-7 , the frame  11  of the fastener  10  has an rectilinear, slightly elongated, preferably flat and smooth configuration with a first or proximal end and a second or distal end  36 . The frame  11  provides a base structure for the remaining elements of the fastener  10  and in particular, provides a means of spacing the cable or other fastened article from the structural building member other base. Leg  12  is connected to the first (proximal) end of the frame  11  and preferably is disposed at a right angle thereto. The leg  12  is for contact with a structural building member or other base. Aperture  16  is preferably centrally disposed in leg  12  and provides a convenient means of centering and disposing a fastener or anchor through the leg  12  and into the structural member. Arm  13  is connected to the opposite, second (distal) end  36  of the frame  11 . The arm  13  preferably has a substantially curvilinear inside configuration. This configuration defines a circumferential dimension of cylindrical cable passage  15 . The arm  13  provides a means of engaging and holding a cable or other article. The opposite end of the arm  13  is preferably configured to releasibly mate with lock member  14 . The arm  13  has a bracket member  37  that depends from the end of the arm  13  at a right angle. A lip member  38  depends from the bracket member  37  at a right angle thereto to form a shallow coupling notch of a predetermined dimension. Lock member  14  includes a post  39  which is connected to and extends from the frame  11 . A bracket  40  depends from the end of the post  39 , at a right angle thereto. A lip  41  depends from the bracket  39  to form a coupling notch. The locking member  14  coupling notch releasibly mates with the arm member  13  coupling notch.  
         [0041]     The fastener  10  is preferably constructed of a polymeric material such as polypropylene. The fastener material is rigid enough to provide structural stability and hold a cable to a stud  21  or the like. The material is flexible enough to permit flexing of the arm  13  during cable placement and locking. Also, it should be pliable enough so that the frame  11  flexes if any part of the fastener  10  is impacted by a nail or screw, for example one which is intended to be driven into the stud  21  but which misses, whereby the fastener avoids penetration of the held cable by such nail or screw. The material should be pliable in cold weather (about 32 degrees F.) Alternative polymers include styrene. Further in the alternative, the fastener  10  may be constructed of a metal provided that the edges of all surfaces are rounded off or other wise smoothed.  
         [0042]     The size of the fastener  10  may be selected to accommodate different sizes of cables and cable connection applications. The fastener  10  illustrated is capable of connecting one or more wires or cables (corrugated round (AC)  26  or flat (NM)  26   a ′- c ′) of sizes up to approximately #4/2 gauge. As such, the fastener  10  preferably has a length (“a”) of 3 inches, a width (“b”) of ¾ inch, and a height (“c”) of 2 inches as is best shown in  FIGS. 4 and 5 . As is best shown in  FIG. 7 , leg  12  preferably has a height (“d”) of ¾ inch and a width (“e”) of ¾ inch to provide an adequate mating surface with respect to the stud. As is best shown in  FIG. 5 , the major diameter (“f”) of the arm is approximately 1 inch maximum. Importantly, the distance from the passage  15  to the stud  21  (“g”) is 1⅝ inches to provided adequate separation of the cable from the stud  21  (particulary the center of the stud  21 , as is also best shown in  FIG. 5 . This minimizes the potential for sharp objects such as screws or nails intended to be driven into a stud or other structural member (often out of sight of the worker due to the presence of gypsum board or other wall forming material) to which the fastener  10  is attached, or tools used around the structural member, from impacting and penetrating the held wires or cables. In the preferred embodiment, the structural elements of the fastener  10  are constructed in a unitary device. A preferred material thickness is ⅛ inch. The dimensions described above may be modified, preferably proportionally, to construct fasteners for securing smaller or larger cables.  
         [0043]     Referring again to  FIGS. 2 and 3 , in use, the fastener  10  is connectable to a structural member  21 , in this case a wall stud, of a building or the like. Wall stud  21  is shown as a solid wood member. However, it is within the purview of this invention that the fastener  10  may be connected to studs constructed of metal or other materials and to other structural members such as conduits, pipes, walls, blocks, slabs, bricks, fixtures, furnishings, earth, and the like. The fastener  10  is grasped by the installer and the leg  12  is placed in contact with the stud  21 . The leg  12  is shown abutting the side surface of a stud (which is shown as the 1¾ inch width side of a standard 2×4, but which may be a 2×6 or other size member), but the fastener may be attached to the front or face surface  22  of the stud  21  depending upon the cabling application. A secondary fastener such as a nail  29  is driven through aperture  16  until the shaft  30  of the nail  29  is fully inserted into the stud  21  and the head  31  contacts the leg  12 . Alternative secondary fasteners  29  may be used such as a screw, bolt, adhesive, magnet or the like may be used. Referring to  FIG. 9 , a plurality of fasteners  10 ,  10 ′,  10 ″ . . . may be secured to the stud  21 , neighboring studs  21 ′,  21 ″ . . . or other building elements, preferably aligned with one another, to provide a desired cable  24 ,  24 ′,  24 ″ . . . routes and configurations. The fastener  10  is useful in connection with installations of utility boxes  50  and other electrical system components. The arm  13  of the fastener  10  is depressed disengage arm lip  38  from bracket lip  41 . Arm  13  is flexed away from frame  11  to permit placing cable  24  fully into passage  15 . Next, arm  13  is released and moves towards frame  11  via a spring-like action. . One or more cables  24 , lines or the like are placed in the passage  15 . Arm  13  is depressed to engage arm lip  38  with bracket lip  41 . In this manner, the cable  24  is locked in place in passage  15  and coupled to the stud  21 . The cable  24  can be removed from the fastener  10  by again depressing the arm  13  to unlock the cable. Although the fastener  10  is shown providing a vertically aligned cable path  15 , the fastener  10  may be arranged to orient the path  15  horizontally or at any angle with respect to earth.  
         [0044]     Cable  24  is shown in  FIG. 2  as common ROMEX type cable comprising a metallic outer jacket  25 , and a plurality of internal wires  26   a - d , each having a wire conductor  28  surrounded by insulation  27 . However, other types of cables, wires, or conductors, including non-corrogated and flat structures, or other articles in general, may be used with the fastener such as flat cables  26   a ′- c ″ in  FIG. 3 . Further, although the apparatus and method have been described in connection with the field of electrical wiring, it can readily be appreciated that it is not limited solely to such field, and can be used in other fields including, but not limited to plumbing, HVAC.  
         [0045]     The fastener  10  of the present invention is preferably constructed by an extrusion process, but it may be made by an injection molding process.  
         [0046]     The descriptions above and the accompanying drawings should be interpreted in the illustrative and not the limited sense. While the invention has been disclosed in connection with an embodiment or embodiments thereof, it should be understood by those skilled in the art that there may be other embodiments which fall within the scope of the invention as defined by the claims. Where a claim, if any, is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures, material-based equivalents and equivalent materials, and act-based equivalents and equivalent acts.