Abstract:
A cable support assembly for routing electrical, communication, or data cables throughout a building. The cable support assembly includes cable trays and brackets for securing the cable trays to an overhead structure. Tray couplers are provided for coupling trays together. The brackets include a base member and a hinge arm pivotally attached to the base member. The brackets are first secured to the overhead structure to establish a desired path for the cables. The hinge arms on the installed brackets are pivoted downwards and a cable tray section inserted therein. The hinge arms and cable tray sections may be rotated upwards and latched to the base members to lock the cable trays in place. Adjacent cable trays may be joined with couplers to create a cable support assembly in which the cable tray provides support for any electrical, communication, or data cables installed therein.

Description:
FIELD OF THE INVENTION 
   This invention relates to cable supports and specifically to a cable support assembly or cable raceway that supports electrical cables in such a manner that the bend radius of individual cables is minimized. 
   BACKGROUND OF THE INVENTION 
   The installation of electrical cables in buildings is typically accomplished by drilling holes in wooden support elements such as joists or studs or using existing holes in metal support elements and routing the cables through the holes. Routing electrical cables in this manner causes each cable to be supported by the narrow thickness of the support element and will lead to sagging of cables in the open spaces between the support elements. Unfortunately, for the installation of low voltage cables such as communication or database cables, sagging can disturb the conductors within the cables. Bending and twisting of conductors can adversely affect the data transmission rate, which becomes very critical in cables having higher transmission rates, such as Category 5 telecommunications cables. 
   Various methods proposed for the support of low voltage electrical cables include the use of hangers for supporting the cables and cable pans or raceways. 
   What is needed is a simple cable support assembly in which the cable tray provides the support for the installed cables. The cable support assembly should also allow easy lowering of the cable tray, when desired, to facilitate inspection, repair, or installation of additional cables. 
   SUMMARY OF THE INVENTION 
   The invention is a cable support assembly for routing electrical, communication, or data cables throughout a building. The cable support assembly includes cable trays and brackets for securing the cable trays to an overhead structure. Tray couplers are provided for coupling tray sections together. The brackets include a base member and a hinge arm pivotally attached to the base member. The brackets are first secured to the overhead structure to establish a desired path for the cables. The hinge arms on the installed brackets are then pivoted downwards and a cable tray inserted therein. The hinge arms and cable trays are then rotated upwards and latched to the base members to lock the cable tray sections in place. The cables are then placed on the cable trays. Adjacent cable trays are joined with couplers to create a cable support assembly in which the cable tray provides support for any electrical, communication, or data cables installed therein. 
   OBJECTS AND ADVANTAGES 
   Several advantages are achieved with the cable support assembly of the present invention, including:
         (1) The hanger brackets of the cable support assembly are located exterior of the cable tray, thereby ensuring that the cables or cable bundles are supported by the cable tray and not by the hangers, thereby eliminating any possibility of cable sag which could be detrimental to the data transfer capabilities of the installed cables.   (2) The cable brackets of the present invention enable easy pivoting insertion of the cable tray prior after the brackets have been secured to the building structure.   (3) The cable brackets include a latching mechanism that enable the cable tray sections to be securely latched into position after brackets are aligned and installed.       

   (4) The latching mechanism facilitates easy release of the cable tray sections for inspection or repair of existing cables or easy installation of additional cables. 
   (5) The latching mechanism enables lowering of one side of the cable tray when released. As a result the cable tray sections continue to support the cables in the lowered position. This provides enhanced protection of the cables or cable bundles over prior art cable trays in which the cable trays must be snapped off or completely removed and leave the cables supported only by the hangers. 
   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front elevation view of the preferred embodiment of a base member portion of a bracket according to the present invention. 
       FIG. 2  is a side view of the base member taken along line  2 - 2  of  FIG. 1 . 
       FIG. 3  is a bottom view of the base member taken along line  3 - 3  of  FIG. 1 . 
       FIG. 4  is a front elevation view of the preferred embodiment of a hinge arm portion of a bracket according to the present invention. 
       FIG. 5  is a side view of the hinge arm taken along line  5 - 5  of  FIG. 4 . 
       FIG. 6  is a side view of the hinge arm taken along line  6 - 6  of  FIG. 4 . 
       FIG. 7  is a bottom view of the hinge arm of  FIG. 6 . 
       FIG. 8  is a top view of the preferred embodiment of a cable tray according to the present invention. 
       FIG. 9  is an end view of the cable tray taken along line  9 - 9  of  FIG. 8 . 
       FIG. 10  is a front elevation view of the preferred embodiment of a coupler according to the present invention. 
       FIG. 11  is a top view of the coupler taken along line  11 - 11  of  FIG. 10 . 
       FIG. 12  is a sectional view of the coupler taken along line  12 - 12  of  FIG. 10 . 
       FIG. 13  is a plan view of the preferred embodiment of an end cap according to the present invention. 
       FIG. 14  is a sectional view of the end cap taken along line  14 - 14  of  FIG. 13 . 
       FIG. 15  is a front elevation view of the preferred embodiment of a latch bracket assembly according to the present invention with the hinge arm pivoted to an open position. 
       FIG. 16  is an end view of the latch bracket assembly of  FIG. 15  with a cable tray inserted in the latch bracket and the hinge arm pivoted upwards and latched to the base member portion of the latch bracket. 
       FIG. 17  is an end view of a coupling secured to a cable tray according to the present invention. 
       FIG. 18  is a sectional view of the end cap of  FIG. 13  secured to the cable tray of  FIG. 9 . 
       FIG. 19  is a top view of a portion of a cable support assembly according to the present invention. 
       FIG. 20  is top view of a portion of a cable support assembly with electrical cables inserted within the cable tray. 
   

   INDEX TO REFERENCE NUMERALS IN DRAWINGS 
   
       
       
         
             30  cable support assembly 
             32  bracket 
             34  cable tray 
             36  base member 
             38  hinge arm 
             40  building structure 
             42  fastener 
             44  first end of hinge arm 
             46  second end of hinge arm 
             48  horizontal support member 
             50  first side of horizontal support member 
             52  second side of horizontal support member 
             54  integral flange member 
             56  seat 
             58  juncture of horizontal support member and flange 
             60  attachment arrangement 
             62  aperture in flange 
             64  aperture in horizontal support member 
             66  first end of base member 
             68  second end of base member 
             70  circular pin 
             72  lateral slot 
             74  hook 
             76  tab 
             80  slot on hinge arm 
             82  first leg of hinge arm 
             84  second leg of hinge arm 
             86  third leg of hinge arm 
             88  bottom wall of cable tray 
             90  sidewall of cable tray 
             92  end of cable tray 
             94  interior channel 
             96  coupler 
             98  bottom wall of coupler 
             100  sidewall of coupler 
             102  top lip 
             104  inner lip 
             106  separator tab 
             108  end cap 
             110  end wall 
             112  outer edge 
             114  peripheral wall 
             116  post 
             118  joist 
             120  communications cable 
           d 1  distance between post and peripheral wall of end cap 
           d 2  thickness of bottom wall and sidewall of cable tray 
           θ angle of cable tray sidewalls with respect to bottom wall 
         
       
     
  
   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 16  there is shown a preferred embodiment of a cable support assembly  30 , which includes a bracket  32  and an elongated cable tray  34 . The bracket  32  includes a base member  36  and a hinge arm  38 . The bracket  32  is shown in  FIG. 16  secured to a building structure  40  by fasteners  42 . 
   As shown in  FIG. 15 , the hinge arm  38  is pivotally attached at a first end  44  to the base member  36 . The hinge arm  38  further includes a second end  46  adapted to latch to the base member  36 . 
   Referring to  FIGS. 1-3 , the base member  36  includes a horizontal support member  48  having a first  50  and second side  52 . An integral flange member  54  extends upwardly from the first side  50  of the horizontal support member  48 . A seat  56  is defined by the juncture  58  of the horizontal support member  48  and the integral flange  54 . The base member  36  includes an attachment arrangement  60  for securing the bracket to a building structure (not shown). The attachment arrangement  60  includes apertures  62  in the flange  54  and fasteners  42  (see  FIG. 16 ) associated with one or more of the apertures. The attachment arrangement  60  further includes apertures  64  in the horizontal support member  48  through which fasteners (not shown) can be driven to secure the base member  36  to a building structure. If preferred, the base member  36  may be placed against a support with the seat  56  fit flush against a rafter or joist, in which case fasteners can be driven into the rafter or joist though both the flange  54  and the horizontal support member  48  for added strength. The base member  36  includes two ends  66 ,  68  and a circular pin  70  supported at each of the ends  66 ,  68 . The circular pin  70  at the second end  68  of the base member  36  defines a lateral slot  72  between the circular pin  70  and the horizontal support member  48 . 
   With reference to  FIGS. 5-7 , the first end  44  of the hinge arm  38  includes a bent over portion or hook  74  forming a slot  80  therein and the second end  46  includes a tab  76  extending from the body of the hinge arm  38 . The hinge arm  38  further includes a first leg  82  extending downward from the first end  44 , a second leg  84  extending horizontally from the first leg  82 , and a third leg  86  extending upward from the second leg  84 . 
   As shown in  FIG. 15 , the tab  76  is capable of engaging the circular pin  70  at the second end  68  of the base member  36  when pushed into the lateral slot  72 . Pushing the second end  46  of the hinge arm  38  into the lateral slot  72  locks the second end  46  of the hinge arm  38  to the base member  36 . The hook  74  of the hinge arm  38  is snapped over the circular pin  70  at the first end  66  of the base member  36  after which the hinge arm  38  will pivot about the circular pin  70 . 
   Referring to  FIGS. 8-9 , the elongated cable tray  34  includes a bottom wall  88 , two sidewalls  90 , and two ends  92 . The sidewalls  90  are preferably at an angle θ of between 95 and 110 degrees with respect to the bottom wall  88 . The bottom wall  88  and sidewalls  90  of the cable tray  34  define an interior channel  94  capable of receiving and supporting therein electrical, communication, or data cables or cable bundles (not shown). The cable tray  34  is provided in lengths, as measured between the two ends  92 , preferably between 4 and 15 feet. 
   With reference to  FIGS. 10-12 , the cable support assembly includes a coupler  96  for connecting two of the cable trays together. The coupler  96  includes a bottom wall  98 , two sidewalls  100 , top lip  102  extending inwardly from the sidewalls  100 , and an inner lip  104  extending downward from the top lip  102 . A separator tab  106  extends upward from the bottom wall  98  of the coupler  96 . The separator tab  106  will function to limit the distance a cable tray may be inserted in the coupler  96 . 
   Referring to  FIGS. 13-14 , the cable support assembly of the present invention includes an end cap  108  for closing the open end of the cable tray. The end cap  108  includes an end wall  110  having an outer edge  112  and a peripheral wall  114  extending orthogonally from the outer edge  112 . One or more posts  116  extend orthogonally from the end wall  110  proximate the peripheral wall  114 . The posts  116  extend as far as does the peripheral wall  114  from the end wall  110 . 
   The bracket  32  is preferably provided in one piece, as shown in  FIG. 15 , with the hinge arm  38  pivotally attached to the base member  36 . To operate the current invention, brackets  32  are secured to an overhead building structure  40  such as a joist or rafter (see  FIG. 16 ). At least two brackets  32  are secured to the overhead structure to support each cable tray section  34 . Each bracket is secured to the building structure using the attachment arrangement  60 , including fasteners  42  driven through flange  54  or through horizontal support member  48  and into the building structure  40 . Once the brackets  32  are mounted to the building structure  40  as shown in  FIG. 16 , the hinge arm  38  of each bracket is pivoted to the down position as shown in  FIG. 15 . With the hinge arms  38  rotated to the down position, a cable tray (not shown) is then placed within the open hinge arms  38 . The hinge arms  38  and cable tray are then rotated upwards and the second end  46  of the hinge arm  38  including the tab  76  latched to the base member  36  portion of the bracket  32  as shown in  FIG. 16 . Latching the hinge arm  38  to the base member  36  would typically require an installer to first press the second end  46  of the hinge arm  38  inward to slightly compress the cable tray  34 . The installation would be completed by pressing the second end  46  of the hinge arm  38  outward until the second end  46  of the hinge arm  38  latches to the base member  36 . 
   As shown in  FIG. 17 , a coupler  96  is used for securing together two cable trays at their ends. The coupler  96  shown in  FIG. 17  has been slid upon the end  92  of a cable tray  34 . The bottom wall  98  and two sidewalls  100  of the coupler  96  are of a slightly larger dimension than the bottom wall  88  and sidewalls  90  of the cable tray  34  and an end  92  of a cable tray  34  will therefore nest within the coupler  96  and be frictionally held thereto. Two cable trays  34  may therefore be connected together by sliding an end  92  of each cable tray  34  into one of the couplers  96 . Top lip  102  and inner lip  104  of coupler  96  hold cable tray  34  therein and prevent it from sliding out of the coupler  96  and also limit vertical and horizontal movement of the cable tray  34  with respect to the coupler  96 . Coupling the two ends of the cable trays in this manner maintains the bottom walls of the two separate cable trays substantially even and therefore causes no bending or sagging of cables or cable bundles (not shown) when they are laid therein. 
   With reference to  FIG. 18 , an end cap  108  may be used to terminate a cable tray  34 . The end cap  108  is simply slid onto an end of the cable tray  34 . The cable tray  34  is typically molded or extruded of plastic with the bottom wall  88  and the sidewalls  90  of the cable tray  34  of a given thickness. The end cap  108  is configured such that the distance between the post  116  and the peripheral wall  114  (see distance d 1  in  FIG. 13 ) are no more than 0.010 inch larger than the thickness (see thickness d 2  in  FIG. 9 ) of the bottom wall  88  and sidewalls  90  of the cable tray  34 . Sliding the end cap  108  onto the cable tray  34  therefore enables a frictional fit of the end cap  108  to the cable tray  34  with the cable tray  34  frictionally held between the posts  116  and peripheral wall  114  of the end cap  108 . 
   Although they could be constructed of metal or other materials, it is preferred that the components of the cable support assembly  30  of the present invention, including the base member, the hinge arm, the end cap, the coupler, and the elongated cable tray are each formed in one piece of plastic. The base member, the hinge arm, the end cap, and the coupler are preferably molded of plastic and the cable tray can be molded or extruded of plastic. 
   With reference to  FIG. 19 , the top view of a portion of a cable support assembly  30  is shown according to the present invention. The cable support assembly  30  includes cable trays  34 , brackets  32  secured to joists  118 , a coupler  96  securing together two cable trays  34 , and an end cap  108  capping one end of a cable tray.  FIG. 20  depicts a close up view of the left hand portion of  FIG. 19  and with communications cables  120  laid therein and supported by the bottom wall  88  of the cable tray  34 . The advantage of the cable support assembly  30  of the present invention is that the cables  120  are supported by the cable tray  34  and not by the hangers or brackets  32 . There is no chance of the delicate communication cables  120  sagging or bending as a result of being supported primarily by the hangers or brackets, as in prior art cable support systems. 
   Although the description above contains many specific descriptions, materials, and dimensions, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.