Abstract:
A reversible protective cable chute assembly for routing low voltage cables through walls. The protective cable chute includes a cover plate with an integral cable shield and a removable panel. The cover plate and panel each include an aperture therein for securing the cable chute assembly to an electrical box or low voltage frame. An alignment device is provided on the removable panel to enable rapid alignment of the panel with either side of the cable chute. An opening and passageway is provided in the cable shield portion of the cover plate for receiving low voltage cables for the purpose of routing them through the wall and into an adjacent room. The removable panel provides a convenient means for adding or removing cables after the initial installation.

Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 12/075,326 filed Mar. 11, 2008 and still pending, which is commonly owned by the assignee of the present invention and the entire contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to the installation of low voltage wiring in buildings and specifically to a two-piece protective cable chute assembly for routing low voltage electrical or communications cables through interior walls. 
     BACKGROUND OF THE INVENTION 
     In U.S. patent application Ser. No. 12/075,326 filed Mar. 11, 2008, there was disclosed a reversible protective cable chute with an integral cover plate for use in routing low voltage wires and cables through interior walls. The reversible cable chute included a plate with a cable shield extending there from. The cable chute could be mounted in any of four possible orientations depending on the requirements of the location and the particular installation. The reversible cable shield provided an easy, convenient means of covering an electrical box or low voltage frame for the purpose of routing low voltage wires or cables there through. 
     Although the aforementioned reversible cable chute provided a device for improved routing of low voltage cables through walls, the current invention provides further enhancements to the functionality of the reversible cable shield. By providing a two-piece cover plate, the reversible cable chute assembly of the present invention enables the addition of cables after initial installation without having to remove the cable chute from the electrical box. Also, if the installer forgot to install the single-piece cable chute initially and installed the cables, subsequent installation of the single-piece cable chute would require that the cables be disconnected from the low voltage device and the single-piece chute guided over the cables to secure it to the electrical box. The two-piece cable chute assembly of the present invention enables an installer to route additional cables or remove previously inserted electrical cables by simply removing a panel from the cover plate of the assembly and replacing the panel after the cables have been routed there through. 
     SUMMARY OF THE INVENTION 
     The invention is a reversible protective cable chute assembly for routing low voltage cables through walls. The protective cable chute includes a cover plate with an integral cable shield and a removable panel. The cover plate and panel each include an aperture therein for securing the cable chute assembly to an electrical box. An alignment device is provided on the removable panel to enable rapid alignment of the panel with either side of the cable chute. An opening and passageway is provided in the cable shield portion of the cover plate for receiving low voltage cables for the purpose of routing them through the wall and into an adjacent room. The removable panel provides a convenient means for adding or removing cables after the initial installation. 
     OBJECTS AND ADVANTAGES 
     Several advantages are achieved with the reversible protective cable chute assembly of the present invention, including:
         (1) The reversible protective cable chute assembly provides a convenient device for routing low voltage cables through walls and easily adding to or removing cables after initial installation.   (2) The cable chute assembly includes embodiments that enable use with a conventional single or conventional double gang electrical box or low voltage frame for providing cable passageways through walls.   (3) Several orientations or configurations are available to the installer to provide several options for an attractive installation. The reversible protective cable chute assembly can be mounted with the cable shield extending outward or inward and with the nose portion opening oriented upward or downward, thereby enabling selection of one of four possible mounting installations for added flexibility in routing cables through walls.   (4) Mounting the protective cable chute assembly with the cable shield extending inward enables placement of low voltage components in close proximity of the wall-mounted cable chute.   (5) Use of the reversible protective cable chute of the present invention is compatible with conventional electrical boxes and low voltage frames thereby enabling an installer to utilize existing installed electrical boxes and low voltage frames for routing low voltage cables and avoiding the need to install specialized boxes.       

     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 an exploded perspective view of a preferred embodiment of a reversible protective cable chute assembly in a first configuration according to the present invention depicting a cover plate and a removable panel. 
         FIG. 2  is a front view of the cover plate portion of the protective cable chute assembly of  FIG. 1 . 
         FIG. 3  is a rear view of the cover plate depicted in  FIG. 2 . 
         FIG. 4  is a side view of the cover plate depicted in  FIG. 2 . 
         FIG. 5  is a sectional view of the cover plate taken along line  5 - 5  of  FIG. 4 . 
         FIG. 6  is an end view of the cover plate taken along line  6 - 6  of  FIG. 2 . 
         FIG. 7  is a sectional view of the cover plate taken along line  7 - 7  of  FIG. 2 . 
         FIG. 8  is a front view of the panel portion of the protective cable chute assembly of  FIG. 1 . 
         FIG. 9  is a rear view of the panel of  FIG. 8 . 
         FIG. 10  is a top view of the panel taken along line  10 - 10  of  FIG. 8 . 
         FIG. 11  is a side view of the panel taken along line  11 - 11  of  FIG. 9 . 
         FIG. 12  is a front perspective view of the panel of  FIG. 8 . 
         FIG. 13  is a rear perspective view of the panel of  FIG. 8 . 
         FIG. 14  is a perspective view of the reversible protective cable chute assembly of  FIG. 1  after it has been secured to an electrical box. 
         FIG. 15  is an exploded perspective view of the reversible protective cable chute assembly in a second configuration according to the present invention. 
         FIG. 16  is a perspective view of the reversible protective cable chute assembly of  FIG. 15  after it has been secured to an electrical box. 
         FIG. 17  is a front view of the reversible protective cable chute assembly of the present invention with the panel assembled onto the cover plate. 
     
    
    
     INDEX TO REFERENCE NUMERALS IN DRAWINGS 
     
         
         
           
               20  reversible protective cable chute assembly 
               22  cover plate 
               24  removable panel 
               26  cable shield 
               28  mounting aperture in cover plate 
               29  mounting aperture in panel 
               30  end portion of cover plate 
               32  aperture in end portion 
               34  post 
               36  alignment arrangement 
               38  fastening arrangement 
               40  fastener 
               39  electrical box 
               42  first end of cover plate 
               44  second end of cover plate 
               46  front surface of cover plate 
               48  rear surface of cover plate 
               50  opening in cover plate 
               54  sidewalls of cable shield 
               56  outer wall of cable shield 
               58  lower edge 
               60  cable opening 
               61  axis perpendicular to the front surface of the cover plate 
               62  countersunk area 
               64  raised periphery on cover plate 
               66  outer edge of cover plate 
               68  thin interior plate portion 
               70  recessed area 
               72  front surface of panel 
               74  rear surface of panel 
               76  end of panel 
               78  central vertical axis through panel 
               80  countersunk area 
               82  boss 
               84  inner side of panel 
               86  outer side of panel 
               88  raised periphery 
               92  wall 
               94  vertical axis through cover plate 
               96  bore 
               98  planar horizontal portion of cable shield 
               100  vertical lip of cable shield 
             D 1  distance interior plate portion is recessed from raised periphery 
             Θ 1  angle of sloped portion of cable shield with respect to horizontal 
           
         
       
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1  there is shown a preferred embodiment of the present invention, a reversible protective cable chute assembly  20 . The reversible protective cable chute assembly  20  includes a cover plate  22  and a removable panel  24 . The cover plate  22  includes an outward-extending cable shield  26 . One mounting aperture  28  is provided in the cover plate  22  and a separate mounting aperture  29  in the panel  24 . The cover plate  22  includes end portions  30  with apertures  32  therein and the panel  24  includes posts  34  (phantom lines) on the rear side of the panel. The apertures  32  in the cover plate  22  and posts  34  on the removable panel  24  form an alignment arrangement  36  for rapidly aligning the panel  24  with the cover plate  22 . A fastening arrangement  38  for securing the cover plate  22  and panel  24  to an electrical box  39  or low voltage frame include the mounting aperture  28  in the cover plate  22 , the mounting aperture  29  in the panel  24 , and fasteners  40 . 
     With reference to  FIGS. 2 and 3 , the cover plate  22  includes a first end  42 , a second end  44 , a front surface  46 , and a rear surface  48 . An opening  50  extends inward from the second end  44  of the cover plate  22  thereby defining two outwardly extending end portions  30  at the second end  44  of the cover plate  22 . 
     Referring to  FIGS. 4 and 5 , the cable shield  26  extends outward from the front surface  46  of the cover plate  22  around a portion of the opening  50 . The cable shield  26  includes sidewalls  54  and an outer wall  56 . The outer wall  56  and the sidewalls  54  of the cable shield  26  terminate in a lower edge  58 . As shown in  FIG. 5 , the opening  50  is rectangular shaped and extends inward from the second end  44  of the cover plate  22 . The opening  50  extends more than half the length of the cover plate  22  and to approximately ¾ of the distance through the cover plate  22 . The opening  50  ensures that the cover plate  22  will include an open passageway behind the cable shield  26 . 
     With reference to  FIG. 6 , the lower edge  58  of the cable shield  26  defines a cable opening  60 . The cable opening  60  is substantially trapezoidal in shape as the sidewalls  54  of the cable shield  26  slope inward at angle with respect to the front surface  46  of the cover plate  22 . Cable opening  60  is a substantially trapezoidal shape as a result of sidewalls  54  sloping inward at an angle of Θ 1  with respect to an axis  61  perpendicular to the front surface  46  of the cover plate  22 . Preferably, angle Θ 1  is between 10 and 20 degrees. As shown in  FIG. 7 , a mounting aperture  28  is formed near the first end  42  of the cover plate  22 . Mounting aperture  28  includes countersunk areas  62  on both the front surface  46  and rear surface  48  of the cover plate  22 . Providing the countersunk areas  62  on both sides of the cover plate  22  enables the mounting aperture  28  to be a two-way aperture, which enables the mounting aperture  28  to accept fasteners  40  such as oval head or flat head mounting screws (see  FIG. 1 ). Providing a two-way aperture also enables the cover plate  22  to be reversible with respect to an electrical box or low voltage frame it is mounted to as the countersunk areas  62  will be accessible regardless of which surface  46  and  48  of the cover plate  22  is facing outward. 
     As shown in  FIGS. 2 and 7 , the cover plate  22  of the reversible protective cable chute assembly of the present invention further includes a raised periphery  64  around the outer edge  66  of the cover plate  22 . The cover plate  22  thus includes a thin interior plate portion  68  and a recessed area  70  on each of the front surface  46  and the rear surface  48  of the cover plate  22 . The recessed area  70  on the front surface  46  of the cover plate  22  extends between the outward extending cable shield  26  and the raised periphery  64 . As shown in  FIG. 3 , the recessed area  70  on the rear surface  48  of the cover plate  22  extends between the opening  50  and the raised periphery  64 . 
     With reference to  FIGS. 8-13 , the panel  24  includes a front surface  72 , a rear surface  74 , and two ends  76 . A mounting aperture  29  is provided along a central vertical axis  78  through the panel  24 . The mounting aperture  29  includes a countersunk area  80  on the front surface  72  of the panel  24  and an outward extending boss  82  on the rear surface  74  of the panel  24 . The panel  24  further includes an inner side  84 , an outer side  86 , and a raised periphery  88  along the outer side  86 . Two posts  34  extend from the rear surface  74  of the panel  24  near the two ends  76 . 
     With reference to  FIG. 1 , the reversible protective cable chute assembly  20  of the present invention is used to provide an attractive and functional cover for an electrical box  39  or low voltage frame. The reversible protective cable chute assembly  20  of the present invention may be mounted to an electrical box or low voltage frame in any one of four possible configurations by reversing the side of the plate with respect to the box and the wall and by flipping the cover plate  22  end to end. Thus, the cable chute assembly  20  may be mounted in any of four configurations including 1) with the cable shield  26  facing outward and the cable opening  60  facing down, 2) with the cable shield  26  facing outward and the cable opening  60  up, 3) with the cable shield  26  facing inward and the cable opening  60  facing down, and 4) with the cable shield  26  facing inward and the cable opening  60  facing up.  FIG. 1  therefore depicts the reversible protective cable chute assembly  20  of the present invention mounted in a first configuration with the cable shield  26  facing outward and the cable opening  60  facing down. To mount the cable chute assembly  20  to the electrical box  39 , the cover plate is secured to the electrical box  39  by securing fastener  40  through mounting aperture  28 . Low voltage electrical cables (not shown) may then be routed through the cable opening  60 . After all cables are routed through the cable opening  60 , the panel  24  is aligned with the cover plate  22  by inserting posts  34  into apertures  32  in the cover plate  22 . A second fastener  40  is then secured through aperture  29  in panel  24  to close the lower portion of opening  50  in cover plate  22 . If additional low voltage cables are later routed through the cable chute assembly  20 , the removable panel  24  is simply removed from the electrical box  39  by removing the fastener  40  holding the panel  24  to the box  39 , the additional cables are routed into the box  39 , and the panel  24  secured again to the box  39  with fastener  40 . The removable panel  24  feature of the present invention is especially useful in those situations in which low voltage cables have previously been routed through uncovered boxes or frames. Homeowners often run low voltage cables through the boxes and later decide to place a cover over the box to create a more attractive cable installation. In prior art one-piece cable shields, all of the existing low voltage cables would need to the disconnected from the devices to which they were connected, the cable ends passed through the cable opening of the prior art cable shield, and the cable shield then secured to the box. The reversible protective cable chute assembly  20  of the present invention has the advantage of enabling a person to install the assembly  20  to the box or low voltage frame without having to disconnect all of the existing cables first. One simply separates the panel  24  from the cover plate  22 , places the cover plate  22  over the existing cables through opening  50 , connects the cover plate  22  to the electrical box  39  and then connects the panel  24  to the electrical box  39 . 
     With reference to  FIG. 14  there is shown the reversible protective cable chute assembly  20  of  FIG. 1  after it has been secured to the low voltage frame or electrical box. The electrical box or low voltage frame is out of view as the raised periphery  64  of the cover plate  22  extends beyond the box or frame. The raised periphery  64  of cover plate  22  therefore is seated flush against the wall  92 . 
     Referring to  FIGS. 15 and 16 , there is shown a second configuration of the reversible protective cable chute assembly  20  of the present invention with respect to an electrical box  39  installed in a wall  92 . In this configuration the cable shield  26  is oriented toward the electrical box  39 . As shown in  FIGS. 15 and 16 , the removable panel  24  of the cable chute assembly  20  can be secured against the rear surface  48  of the cover plate  22 . After being secured to the electrical box, the panel  24  extends between the end portions  30  of the cover plate  22  and closes the bottom portion of the opening  50  in the cover plate  22 . The removable panel  24  may thus be removed from the electrical box or low voltage frame without first removing the cover plate  22  from the electrical box or low voltage frame. 
     As shown in  FIG. 17 , with the panel  24  and cover plate  22  joined together to form the reversible protective cable chute assembly  20 , the mounting aperture  28  in the cover plate  22  and the mounting aperture  29  in the panel  24  are aligned along a vertical axis  94  through the cover plate  22 . The mounting apertures  28  and  29  are of a spacing and pattern to match the bores  96  of a conventional electrical box  39  or low voltage frame (see  FIG. 1 ). 
     With reference to  FIG. 7 , the cable shield  26  portion of the cover plate  22  further includes a planar horizontal portion  98  extending from the front surface  46  of the cover plate  22  and a vertical lip  100  extending downward from the outer wall  56 . The cover plate  22  includes the interior plate portion  68  which is recessed a substantial distance from the raised periphery  64 . The recessed interior plate portion  68  creates a recessed area  70  on each side of the cover plate that enables the raised periphery  64  of the cover plate  22 , when mounted to a wall (not shown), to contact the wall. For those situations in which an electrical box or low voltage frame (not shown) project slightly from the wall, as is often encountered, the wall is contacted by the raised periphery  64  thereby enabling the electrical box or low voltage frame to project into the recessed area  70 . This enables the protective cable chute assembly to mount flush against the wall for those cases in which the electrical box or low voltage frame project beyond the outer wall surface. The interior plate portion  68  on each side of the cover plate  22  is recessed a depth or distance D 1  from the raised periphery  64 . Preferably, the recessed depth or distance D 1  is at least 0.065 inch to enable sufficient recessed area for accommodating electrical boxes or low voltage frames (not shown) that extend beyond the wall. 
     Referring to  FIG. 1 , in forming the reversible protective cable chute assembly  20  of the present invention, preferably the cover plate  22  and the panel  24  are each molded in one piece of plastic. The cover plate  22  and panel  24  are preferably molded of various plastics including polycarbonate, polyvinyl chloride, acrylonitrile-butadiene styrene, and polyethylene. 
     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.