Abstract:
A cable positioning bracket is provided for mounting to a building component, e.g. a wall stud. The bracket has an anchor plate for being connected to the broad surface of the building component and a pair of side plates for being connected to the narrow surface of the building component. A pair of platforms are positioned adjacent to a slot for supporting one or more cables. A series of opposed tabs are provided in several embodiments, the tabs oriented to engage and support one or more cables. One side plate pivots away from the building component by means of a hinge plate to insert the cable or cables. The tabs in one embodiment are formed with side strips surrounding a window, the strips allowing arcuate bending of the tabs to minimize fatigue failure.

Description:
RELATED APPLICATION 
     This application is a continuation-in-part of application Ser. No. 12/800,331 filed May 13, 2010. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the field of wiring support devices for use in building construction, and more particularly to a bracket for positioning cables at a predetermined distance from a wall surface. 
     BACKGROUND OF THE INVENTION 
     In 1990, the National Electrical Code (NEC) was revised to require that electrical wires and cables mounted within a wall structure must be at least one-and-one-quarter (1.25) inches behind the inner wall surface. This code provision is intended to reduce the likelihood that a nail, or other sharp implement, would damage the insulation and potentially cause an electrical fire. The NEC further requires that a cable is secured at the 1.25 inch offset within 12 inches of an electrical box or other fitting, and at intervals of not more than 4.5 feet along a run. 
     A number of devices have been developed to implement the NEC requirement for a 1.25 inch offset, as described in the following patents: 
     U.S. Pat. No. 5,067,677 to Miceli is for a Wire Harness. This device is for mounting on the face of a wall stud to hold a number of wires spaced between the surfaces of a wall. The device has one arm for mounting to a stud and a second arm for attaching wires. A series of clips are placed along the second arm for receiving and holding wires. 
     U.S. Pat. No. 5,141,185 to Rumbold et al. is for a Wiring Clip. This patent discloses a clip having an L-shaped portion to be secured to a stud and a strut and hinged arm remote from the L-shaped portion, the arm is adapted for being folded back and locked around several wires. 
     U.S. Pat. No. 5,587,555 to Rinderer is for a Conductor Holding Device. This conductor holder has a support member having two perpendicular arms, one arm for being affixed to a stud and the other arm being formed with one or more holes. A clamp having a leg and a head is mounted with the leg through the one hole in the arm and the head holding the conductor at a fixed distance from a wall surface. 
     A commercial cable positioning bracket has been introduced by Erico International Corporation of Solon, Ohio under the brand name Caddy®. This bracket mounts to a building structural component, e.g. a stud, and uses a bendable tab to press a cable against a vertical plate. The Caddy® bracket is marked “Patent Pending.” 
     SUMMARY OF THE INVENTION 
     A cable positioning bracket is configured for being mounted to a wall stud and for positioning a series of cables a selected distance from the inner surfaces of the wall. The bracket is formed with an anchor plate that is attached in parallel contact with the wall stud. A horizontal platform extends perpendicularly out from the anchor plate, and a side plate extends down from the platform. A portion of the side plate is attached to the stud. A second horizontal platform is connected to the first horizontal platform by a hinge member. A second side plate extends down from the second platform. A first series of tabs is formed along the first platform, and a second series of tabs is formed along the second platform with the first and second tabs facing toward one another. The tabs are positioned and sized to bend when engaging cables. The second platform and side plate are pivoted out by bending the hinge member to allow insertion of the cables in parallel to the stud. When the cables are in position, the second platform and side plate are pivoted back to enclose the cables, with the two sets of tabs engaging the cables. The second side plate is then attached to the stud to stabilize the bracket and hold the cables at a fixed distance from the wall surfaces. In a further embodiment, the cables are engaged by the platforms without bendable tabs. In another embodiment, tabs are provided with windows punched through to enable arcuate bending, rather than bending along a line. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is best understood in conjunction with the accompanying drawing figures in which like elements are identified by similar reference numerals and wherein: 
         FIG. 1  is a perspective view of a cable positioning bracket according to a first embodiment of the invention mounted to a wall stud and holding a series of cables in a desired position, the cables connected at a lower end thereof to an electrical junction box. 
         FIG. 2  is a cable positioning bracket of  FIG. 1  mounted to a stud, the bracket in the open condition prior to inserting cables. 
         FIG. 3  is a side elevation view of the bracket of  FIG. 1  taken in the direction indicated by line  3 - 3  of  FIG. 1  with a series of cables held therein, the cables shown in dashed lines. 
         FIG. 4  is an end elevation view of the bracket of  FIG. 1  taken in the direction indicated by line  4 - 4  of  FIG. 1  with a series of cables held therein, the cables shown in dashed lines. 
         FIG. 5  is a top plan view of the bracket of  FIG. 1  as punched from a planar sheet prior to being folded. 
         FIG. 6  is a top plan view of a bracket according to a second embodiment of the invention as punched from a planar sheet prior to being folded. 
         FIG. 7  is a perspective view of a cable positioning bracket according to a third embodiment of the invention, the bracket mounted to a wall stud and shown in the open condition prior to inserting cables. 
         FIG. 8  is a top plan view of the bracket of  FIG. 7  as punched from a planar sheet prior to being folded. 
         FIG. 9  is a perspective view of a cable positioning bracket according to a fourth embodiment of the invention, the bracket mounted to a wall stud and shown in the open condition prior to inserting cables. 
         FIG. 10  is a top plan view of the bracket of  FIG. 9  as punched from a planar sheet prior to being folded. 
         FIG. 11  is an enlarged cross sectional view taken along line  11 - 11  of  FIG. 10  with a tab shown in dashed lines illustrating the bend condition. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , a cable positioning bracket  10  of the present invention is mounted to a wall stud  16 . As illustrated, cable positioning bracket  10  is fully closed around a set of three cables. Wall stud  16  has a broad side  16   b  and a narrow side  16   n . Wall stud  16  may be either a wood stud or a metal stud, as is known in the trade. A wall structure, e.g. gypsum board or drywall, will be mounted to the narrow side  16   n  of wall stud  16 , with another wall structure mounted to the opposite narrow side of wall stud  16 . An electrical junction box  14  is mounted to wall stud  16 , illustrated a short distance below cable positioning bracket  10 . However, as will be understood from the description to follow, cable positioning bracket  10  may be located anywhere along the run of a cable or cables as may be required by a Local Code or the NEC. A set of cables  20 ,  22  and  24 , shown as, but not restricted to, metal sheathed cable, are connected to electrical junction box  14  at their respective ends and are held at a selected distance from the narrow side  16   n  as well as the opposite narrow side of wall stud  16 . As discussed above, the distance from each wall structure must be at least 1.25 inches. The width W of the broad side  16   b  of a commonly used wall stud  16  is approximately 3.50 inches. Therefore, positioning cables  20 ,  22  and  24  at least 1.25 inches from each narrow side of wall stud  16  leaves a space of 1.0 inch for the cables to reside. While three cables  20 ,  22  and  24  are shown, different numbers of cables, e.g. 2 cables or 5 cables, may be used within the scope of the invention. 
     Referring further to  FIG. 1 , an anchor plate  28  of bracket  10  is attached to broad side  16   b  of wall stud  16  by fasteners F, e.g. screws appropriate to the material of wall stud  16 . As illustrated, wall stud  16  is oriented vertically, although bracket  10  of the invention is adaptable to use on horizontal building members, i.e. joists. A horizontally oriented platform  32  extends outwardly from anchor plate  28 , a portion of platform  32  passes behind cables  20 ,  22  and  24  and a portion thereof passes in front of cable  24 . A vertically oriented side plate  34  extends downwardly from platform  32 . A portion of side plate  34  overlaps a portion of narrow side  16   n  of wall stud  16  and is anchored thereto by a fastener F. A second platform  32 ′ is located adjacent to platform  32  with an open gap between. Second platform  32 ′ is connected to the portion of first platform  32  that resides behind cables  20 ,  22  and  24  by a hinge plate  48 , extending upwardly from, and substantially perpendicular to, platforms  32  and  32 ′. While anchor plate  28  and hinge plate  48  are shown extending upwardly from platforms  32  and  32 ′, it will be understood that downward orientation of either or both plates is considered to be within the scope of the present invention. A second side plate  36  extends downwardly from second platform  32 ′, with a portion of second side plate  36  overlapping a portion of narrow side  16   n  of wall stud  16 , and being fastened thereto with a fastener F. As illustrated, bracket  10  is securely mounted to wall stud  16  by anchor plate  28  mounted to broad side  16   b  and side plates  34  and  36  mounted to narrow side  16   n  to securely maintain the position and orientation of cables  20 ,  22  and  24 . 
     Referring further to  FIG. 1 , a tab  44  is formed from platform  32 . Three additional tabs  44 ′,  42 ′ and  40 ′ are formed from the rear portion of platform  32  residing behind cables  20 ,  22  and  24 . Two additional tabs  40  and  42  are formed from second platform  32 ′. When cables  20 ,  22  and  24  are passed between tabs  40  and  40 ′,  42  and  42 ′,  44  and  44 ′, the tabs bend in the direction of movement of the cables, holding the cables securely in position. Whereas three cables of the same size and three pairs of tabs are shown in the example bracket, alternate numbers of cables and alternate numbers and various sizes of tabs may be utilized. 
     Referring now to  FIG. 2 , cable positioning bracket  10  is shown in the open condition as partially mounted to wall stud  16  prior to the insertion of cables. Anchor plate  28  and side plate  34  are mounted with fasteners F to wall stud  16 . While attachment of side plate  34  to wall stud  16  provides a degree of stability to bracket  10 , the invention recognizes that an alternate embodiment without side plate  34  would function similarly in practice. Platform  32  extends outwardly from anchor plate  28 , with the forward portion of platform  32  connected to downwardly oriented side plate  34 . The rear portion of platform  32  has tabs  40 ′,  42 ′ and  44 ′ formed therein. Platform  32 ′ has tabs  40  and  42  formed therein. Side plate  36  extends downwardly from platform  32 ′, with an elongate outer section provided for attachment to wall stud  16 . Hinge plate  48  connects the rear portion of platform  32  with platform  32 ′. Hinge plate  48  is vertically oriented (perpendicular to the plane of platforms  32 ,  32 ′) to be controllably bendable in the direction indicated by arrow A when second platform  32 ′ and second side plate  36  are moved away from wall stud  16 . A gap G is created between side plate  34  and side plate  36 . The bend  49  occurring in hinge plate  48  may be at various positions along the length thereof within the scope of the invention. Alternatively, hinge plate  48  may bend in an arc rather than at a sharp corner. A hole H is positioned near the end of side plate  36  to attach side plate  36  to wall stud  16  after inserting one or more cables through gap G to be placed between front tabs  40 ,  42 ,  44  and rear tabs  40 ′,  42 ′,  44 ′. Side plate  36  is closed in the direction indicated by arrow B to position hole H in side plate  36  below fastener F through side plate  34 . When side plate  36  is attached to wall stud  16 , as shown in  FIG. 1 , cable positioning bracket  10  rigidly and securely holds the cables at the required distance from the wall structure to be mounted to wall stud  16 . 
     Referring now to  FIGS. 3 and 4 , cable positioning bracket  10  is shown in the closed condition in side elevation view and end elevation view, respectively. Cables  20 ,  22  and  24  are shown in dashed lines for clarity. Side plate  34  and side plate  36  are coplanar in preparation for being attached to a wall stud (not shown). Anchor plate  28  is substantially perpendicular to side plates  34  and  36 . Hinge plate  48  is substantially perpendicular to side plates  34  and  36 . Tabs  40 ,  42 ,  44 ,  40 ′,  42 ′ and  44 ′ (see  FIG. 2 ) are securely holding cables  20 ,  22  and  24  (see  FIGS. 1 and 3 ) to ensure that distance D (see  FIG. 4 ) is not less than 1.25 inches, as required by the NEC Standard described above. 
     Referring now to  FIG. 5 , cable positioning bracket  10 ′ is illustrated in planar form prior to being bent to the shape described above. The bracket of the invention is preferably formed of galvanized sheet metal approximately 0.025 inch thick, i.e. 24 gauge. It is to be understood that alternate materials and thickness are considered to be within the scope of the invention described. The initial formation of planar bracket  10 ′ of sheet metal is preferably by punch press processing to create slots between tabs  40 ,  42 ,  44 ,  40 ′,  42 ′ and 44′, as well as between side plates  34  and  36 . In addition, holes H are formed for mounting to a wall stud. Subsequent to punching to form the slots and holes of the design, the dashed lines are bent, e.g. by a sheet metal brake, to obtain the three-dimensional shape illustrated in  FIGS. 1-4 . 
     Referring now to  FIG. 6 , an alternate configuration is illustrated as cable positioning bracket  10 ″, shown in planar form. This second embodiment of the invention has three tabs  40 ,  42  and  44  on one side of bracket  10 ″ and a single, long, tab  50  on the opposite side thereof. In addition, all three tabs  40 ,  42  and  44  are formed from platform  32 ′, as different from the previously disclosed embodiment of the invention. Tab  50  may be formed of different widths, therefore leaving the gap between tab  50  and tabs  40 ,  42  and  44  wider or narrower. Further, an elongate tab similar to tab  50  may be formed on both sides of bracket  10 ″. Other aspects and manufacturing processes relating to this alternate embodiment of the invention are substantially similar to the designs described above. 
     Referring now to  FIGS. 7 and 8 , a cable positioning bracket  50  of a third embodiment of the invention is illustrated in three dimensional bent form and in planar form as punched from sheet material, respectively. In the three dimensional form, bracket  50  is shown as mounted to a wall stud  16  in open condition prior to inserting cables. When in open condition, a gap G remains for insertion of cables. In the planar drawing of  FIG. 8 , dashed lines indicate folding locations to form the three dimensional functional bracket shape of  FIG. 7 . Bracket  50  has an anchor plate  58  for mounting to stud  16  by fasteners F. A horizontally oriented planar main platform  60  extends outwardly from anchor plate  58 , with a rear portion  60 ′ of main platform  60  ending a greater distance from anchor plate  58 . A slot S of a size to receive and hold cables therein is located between plate  60  and rear portion plate  60 ′. A vertically oriented side plate  64  depends downward from main platform  60 . Side plate  64  extends beyond the corner of stud  16  where an additional fastener F further affixes bracket  50  to stud  16 . A hinge plate  68  is positioned at the distal end of rear portion plate  60 ′ with a secondary horizontal platform  62  connected to hinge plate  68 . A vertically oriented side plate  66  depends downward from secondary platform  62 , side plate  66  being elongate to be affixed to stud  16  at a location below side plate  64 . Main platform  60 , rear portion plate  60 ′ and secondary platform  62  are co-planar. When cables are inserted between platforms  60 ,  60 ′ and  62 , and side plate  66  is moved in the direction of arrow B and affixed to stud  16 , a small gap remains between main platform  60  and secondary platform  62 , securely holding cables in bracket  50 . Slot proportions and gap proportions are indicated generally best in  FIG. 8 . 
     Referring now to  FIG. 9 , a cable positioning bracket  70  according to a fourth embodiment of the invention is illustrated as it is mounted to a building component, e.g. wall stud  16 . When in open condition, a gap G remains open for the insertion of cables. A vertically oriented anchor plate  71  is positioned against a side of wall stud  16  and affixed thereto with fasteners F. A horizontally oriented platform  72  and rear portion plate  72 ′ extends outward from anchor plate  71 . A vertically oriented side plate  76  extends downward from platform  72  and has an elongate configuration to be affixed to wall stud  16  with a fastener F. A hinge plate  88  is oriented substantially parallel to anchor plate  71 , extending from the outer end of rear portion platform  72 ′ to a second platform section  74 . A vertically oriented side plate  78  extends down from platform  74  and is elongate to connect to wall stud  16  by inserting a fastener through hole H when bracket  70  is closed. 
     Referring further to  FIG. 9 , a pair of tabs  82  and  82 ′ extend from platform  74  in the direction of rear portion platform  72 ′, and a third tab  84  extends from platform  72  in the direction of rear portion platform  72 ′. When cable positioning bracket  70  is closed and side plate  78  is connected to wall stud  16 , the space between tabs  82 ,  82 ′,  84  and rear portion platform  72 ′ is preferably equal to or slightly smaller than the thickness of a cable to be placed therein. Tab  82 , as being a typical tab of bracket  70 , is formed with a substantially rectangular open window  92  that is bordered by a first strip  94  and a second strip  94 ′. Strips  94 ,  94 ′ are substantially rectangular and are equal in width to each other. The reduction in sheet material created by punching window  92  and leaving strips  94 ,  94 ′ causes tab  82  to bend along a curve rather than in a straight line bend. As is known, a straight line bend concentrates strain in a small area and will result in a fatigue failure of the sheet after multiple bend cycles, whereas a curve bend distributes the strain and increases the useful bending life of the sheet. 
     Continuing in reference to  FIG. 9 , each tab  82 ,  82 ′ and  84  is formed with an inverted ridge  90  at a distal edge thereof. Ridge  90  is formed in the shape of a “V” so as to direct the outermost edge of tabs  82 ,  82 ′ and  84  upward and to reduce the possibility of abrasion of a cable being contacted thereby. An inverted ridge  90 ′ is formed along the inner edge of rear portion platform  72 ′ in substantially mirror image of inverted ridge  90  of tabs  82 ,  82 ′ and  84 . Alternate inverted ridge shapes to accomplish the purpose of minimizing cable surface abrasion while providing secure anchoring, e.g. a “U” shape or an “L” shape, are understood to be within the scope of the present invention. 
     Referring now to  FIG. 10 , a top plan view of cable positioning bracket  70  of  FIG. 9  is shown as it is punched from sheet metal prior to bending. The dashed lines in bracket  70  indicate folding locations to form the sheet into the three dimensional shape of  FIG. 9 . The flat shape is converted by folding anchor plate  71  and hinge plate  88  up while folding side plate  76  and side plate  78  down. 
     Referring now to  FIG. 11 , inverted ridges  90  and  90 ′ are shown in enlarged view taken along line  11 - 11  of  FIG. 10 . Ridge  90 ′ is separated from ridge  90  by a distance C that is equal to or slightly smaller than the width of a cable to be inserted therebetween. The opposed edges of ridges  90 ,  90 ′ are angled toward each other when at rest. When tab  94  is lifted by the insertion of a cable to the position illustrated in dashed lines, tab  94  follows a curve and the outer side of ridge  90  approaches parallel with the cable center line. In this way, scratching or abrasion of the cable is minimized. In addition, the curved bend optimizes the useful life of tab  94  by distributing the strain and deferring fatigue. 
     For reasons of manufacturing efficiency and packaging, the preferred material is the galvanized sheet metal noted above, however alternate gauges and material types are clearly possible. One alternate material available is injection molded plastic resin, e.g. polypropylene or high impact polystyrene resin. 
     While the description above discloses preferred embodiments of the present invention, it is contemplated that numerous variations of the invention are possible and are considered to be within the scope of the claims that follow.