Abstract:
The present invention is directed to a telescoping wire cable tray system. The wire cable tray system includes an outer wire cable tray and an inner wire cable tray positioned within the outer wire cable tray. The inner wire cable tray slides or telescopes with respect to the outer wire cable tray enabling the length of the wire cable trays to be adjusted during installation of the wire cable tray system. The wire cable tray system may include trapeze support bars, clamps, side walls or downspout fittings.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/179,483, filed May 19, 2009 and U.S. Provisional Application No. 61/219,433, filed Jun. 23, 2009, the subject matter of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a wire cable tray system and, in particular, the invention relates to a telescoping wire cable tray system with adjustable length wire cable trays to accommodate various overhead applications. 
         [0003]    Wire cable tray systems are used in data centers and other areas to run cables overhead or below raised floors. Cable tray systems are generally shipped in long sections (e.g., 10 feet) and cut to fit during installation. Cutting and deburring cable trays during installation is very time consuming, and the cut ends can be sharp. 
         [0004]    Therefore, there is a need for a cable tray system that allows for adjusting the length of the cable trays without cutting the cable trays during installation. 
       SUMMARY 
       [0005]    A wire cable tray system comprised of a plurality of wire cable trays and at least one trapeze support device for supporting the wire cable trays. The wire cable trays include a plurality of transverse wires and a plurality of longitudinal wires. The trapeze support device includes a trapeze support bar and at least one locking clip. The trapeze support bar includes a channel defined by a bottom and side walls extending from the bottom. The side walls include an upper support surface and a lower support surface. The locking clip slides over the channel to secure the trapeze support device to the wire cable trays. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  illustrates a top perspective view of the telescoping wire cable tray system of the present invention; 
           [0007]      FIG. 1A  illustrates a detailed view of section A of the telescoping wire cable trays of  FIG. 1 ; 
           [0008]      FIG. 1B  illustrates a detailed view of section B of the telescoping wire cable trays of  FIG. 1 ; 
           [0009]      FIG. 1C  illustrates a detailed view of section C of the telescoping wire cable trays of  FIG. 1 ; 
           [0010]      FIG. 2  illustrates an end view of the telescoping wire cable trays of  FIG. 1 ; 
           [0011]      FIG. 3  illustrates a detailed view of section A of the telescoping wire cable trays of  FIG. 2 ; 
           [0012]      FIG. 4  illustrates end views of the outer wire cable tray and the inner wire cable tray of the telescoping wire cable trays of  FIG. 2 ; 
           [0013]      FIG. 5  illustrates a top perspective view of an alternative embodiment of the telescoping wire cable tray system of the present invention; 
           [0014]      FIG. 5A  illustrates a detailed view of section A of the telescoping wire cable trays of  FIG. 5 ; 
           [0015]      FIG. 5B  illustrates a detailed view of section B of the telescoping wire cable trays of  FIG. 5 ; 
           [0016]      FIG. 5C  illustrates a detailed view of section C of the telescoping wire cable trays of  FIG. 5 ; 
           [0017]      FIG. 6  illustrates an end view of the telescoping wire cable trays of  FIG. 5 ; 
           [0018]      FIG. 7  illustrates a partial top perspective view of the outer wire cable tray of  FIG. 5 ; 
           [0019]      FIG. 8  illustrates a side view of the outer wire cable tray of  FIG. 7 ; 
           [0020]      FIG. 9  illustrates a partial top perspective view of the inner wire cable tray of  FIG. 5 ; 
           [0021]      FIG. 10  illustrates a side view of the inner wire cable tray of  FIG. 9 ; 
           [0022]      FIG. 11  illustrates a detailed view of section B of the telescoping wire cable trays of  FIG. 6 ; 
           [0023]      FIG. 12  illustrates end views of the outer wire cable tray and the inner wire cable tray of the telescoping wire cable trays of  FIG. 6 ; 
           [0024]      FIG. 13  illustrates a prior art bend radius downspout fitting for a wire cable tray which does not provide bend radius control above the cable tray; 
           [0025]      FIG. 14  illustrates a side view of a bend radius downspout fitting for the wire cable tray system of the present invention; 
           [0026]      FIG. 15  illustrates a top perspective view of two bend radius fittings of  FIG. 14  installed adjacent each other in one grid space on a wire cable tray; 
           [0027]      FIG. 16  illustrates a side view of two bend radius fittings of  FIG. 14  installed on a wire cable tray; 
           [0028]      FIG. 17  illustrates an exploded perspective view of the telescoping wire cable trays of  FIG. 1  to be installed on a trapeze support bar and connected to a ceiling member by a hanger bar; 
           [0029]      FIG. 18  illustrates a side view of the trapeze support bar and locking clip of  FIG. 17  secured to the telescoping wire cable trays; 
           [0030]      FIG. 19  illustrates a perspective view of the telescoping wire cable trays of  FIG. 17  installed on the trapeze support bar and connected to the ceiling member by the hanger bar; 
           [0031]      FIG. 20  illustrates a perspective view of the telescoping wire cable trays of  FIG. 17  installed on the trapeze support bar and connected to a ceiling member by a threaded rod; 
           [0032]      FIG. 21  illustrates a bottom perspective view of a clamp being installed on the overlapping wire cable trays of  FIG. 1B ; 
           [0033]      FIG. 22  illustrates a top perspective view of the clamp of  FIG. 21  being installed on the overlapping wire cable trays; 
           [0034]      FIG. 23  illustrates a side view of the clamp of  FIG. 21  being installed on the overlapping wire cable trays; 
           [0035]      FIG. 24  illustrates a bottom perspective view of the clamp of  FIG. 21  installed on the overlapping wire cable trays; 
           [0036]      FIG. 25  illustrates a top perspective view of the clamp of  FIG. 24  installed on the overlapping wire cable trays; 
           [0037]      FIG. 26  illustrates a side view of the clamp of  FIG. 24  installed on the overlapping wire cable trays; 
           [0038]      FIG. 27  illustrates a top perspective view of an alternative clamp installed on the overlapping wire cable trays of  FIG. 1B ; 
           [0039]      FIG. 28  illustrates a perspective view of a wire form side wall of the present invention installed on the inner wire cable tray of  FIG. 1A ; 
           [0040]      FIG. 29  illustrates a side view of the wire form side wall of  FIG. 28  installed on the inner wire cable tray; 
           [0041]      FIG. 30  illustrates a perspective view of the wire form side wall installed on the outer wire cable tray of  FIG. 1C ; 
           [0042]      FIG. 31  illustrates a side view of the wire form side wall of  FIG. 30  installed on the outer wire cable tray; 
           [0043]      FIG. 32  illustrates a perspective view of the wire form side wall installed on the overlapping wire cable trays of  FIG. 1B ; 
           [0044]      FIG. 33  illustrates a side view of the wire form side wall of  FIG. 32  being installed on the overlapping wire cable trays; 
           [0045]      FIG. 34  illustrates a side view of the wire form side wall of  FIG. 32  installed on the overlapping wire cable trays; 
           [0046]      FIG. 35  illustrates a perspective view of the wire form side wall of  FIG. 32  installed on the overlapping wire cable trays in an alternative position; 
           [0047]      FIG. 36  illustrates a perspective view of an alternative wire from side wall of the present invention installed on the inner wire cable tray of  FIG. 1A ; 
           [0048]      FIG. 37  illustrates a front view of the alternative wire form side wall of  FIG. 36  installed on the inner wire cable tray; and 
           [0049]      FIG. 38  illustrates a cross sectional view of the alternative wire form side wall of  FIG. 37  taken along line  38 - 38 . 
       
    
    
     DETAILED DESCRIPTION 
       [0050]      FIGS. 1-4  illustrate the telescoping wire cable tray system  20  of the present invention. As best seen in  FIGS. 1A-C , the telescoping wire cable tray system  20  includes an outer wire cable tray  30  and an inner wire cable tray  50 . Each wire cable tray includes a plurality of transverse wires  32 ,  52  and a plurality of longitudinal wires  42 ,  62 . The transverse wires  32 ,  52  form a generally flat top  40  for supporting cables routed in the wire cable tray system  20 . 
         [0051]    As illustrated in  FIG. 4 , each transverse wire  32  of the outer wire cable tray  30  includes a top portion  34 , side walls portions  36  and bottom portions  38 . The outer wire cable tray  30  includes longitudinal wires  42  positioned underneath the top portion  34  of the transverse wires  32 . The three longitudinal wires  42  are parallel and are positioned an equal distance apart, and they provide support to the transverse wires  32 . A longitudinal wire  42  is also positioned above each bottom portion  38  of the transverse wires  32  at the end of the transverse wires  32  thereby forming a slot or track  44  between the side walls  36  of the transverse wires  32  and the longitudinal wire  42 . 
         [0052]    The transverse wires  52  of the inner wire cable tray  50  include a top portion  54  and side walls  56 . The inner wire cable tray  50  includes three parallel longitudinal wires  62  positioned above the transverse wires  52  and a longitudinal wire  62  positioned at the end of each side wall  56  of the transverse wires  52 . 
         [0053]    As illustrated in  FIGS. 2-3 , when the inner wire cable tray  50  is positioned in the outer wire cable tray  30 , the longitudinal wires  62  of the inner wire cable tray  50  and the longitudinal wires  42  of the outer wire cable tray  30  are positioned adjacent to each other allowing the wire cable trays to slide or telescope with respect to each other to adjust the length of the wire cable tray system. As best seen in  FIG. 3 , the longitudinal wires  62  at the end of the transverse wires  52  of the inner wire cable tray  50  are positioned in the slot or track  44  formed by the longitudinal wires  42  and the side walls  36  of the transverse wires  32  thereby restricting the relative lateral movement of the wire cable trays as the wire cable trays telescope with respect to each other. 
         [0054]    In one embodiment, the outer and inner wire cable trays are designed with a 100 mm×9.5 in. grid spacing to enable the wire cable tray openings to align with cabinet top openings in a line of standard cabinets of various standard widths. Typically, there are three standard widths of data center cabinets. Each of these standard widths is a multiple of the distance between transverse wires of the wire cable tray. For example, the wire cable tray system openings approximately align with Panduit&#39;s NET-ACCESST™ cabinet top openings illustrated and described in U.S. Pat. No. 7,498,512. 
         [0055]      FIGS. 5-12  illustrate the components and assembly of an alternative embodiment of the telescoping wire cable tray system  20 , referred to as wire cable tray system  120 . The wire cable tray system  120  includes truss style side walls to strengthen the structure of the wire cable trays. 
         [0056]      FIGS. 7-8  illustrate the truss style side walls  132  of the outer wire cable tray  130  formed by the transverse wires  134 . The transverse wires  134  include a top portion  136 , a downwardly extending diagonal wall  138  which loops to form a flat bottom portion  140  and an upwardly extending diagonal wall  142  that ends with a transverse stub  144 . Each transverse stub  144  is positioned adjacent to the top portion  136  of an adjacent transverse wire  134 . The longitudinal wires  146  of the outer wire cable tray  130  are positioned underneath the top portion  136  of the transverse wires  134 . A longitudinal wire  146  is also positioned at each end of the bottom portions  140  to form a slot or track  148  (see  FIG. 12 ) between the side walls  132  of the transverse wires  134  and the longitudinal wire  146 . 
         [0057]      FIGS. 9 and 10  illustrate the truss style side walls  151  of the inner wire cable tray  150  formed by the transverse wires  152  and a longitudinal side wire  162 . The transverse wires  152  include a top portion  154 , a downwardly extending wall  156  and an upwardly extending wall  158  ending in a stub  160 . Each stub  160  is positioned adjacent to the top portion  154  of an adjacent transverse wire  152 . 
         [0058]    The longitudinal side wire  162  is positioned adjacent to the intersection of the downwardly extending wall  156  and the upwardly extending wall  158 . The longitudinal side wire  162  includes a bottom portion  164 , a curved portion  166  and a top portion  168 . The bottom portion  164  of the longitudinal side wire  162  generally extends the length of the inner wire cable tray  150 . As illustrated in  FIG. 11 , the longitudinal side wire  162  is designed to slide in the slot or track  148  to provide a smooth telescoping action over the outer wire cable tray  130 . 
         [0059]    The inner wire cable tray  150  also includes longitudinal wires  170  that are positioned above the top portion  154  of the transverse wires  152 . 
         [0060]      FIG. 13  illustrates a prior art bend radius downspout fitting  200  including a top portion  202  with a bend radius portion  204  extending from one end. The bend radius fitting  200  includes snaps  206 , and the bend radius fitting  200  snaps onto adjacent longitudinal wires to cover the area between adjacent transverse wires. The bend radius portion  204  extends downward into an open area  208  between the transverse wires. As a result, the bend radius portion  204  reduces the available open area  208  for cables to exit the wire cable tray system. 
         [0061]      FIGS. 14-16  illustrate a bend radius fitting  220  for the wire cable tray system. The bend radius fitting  220  includes a bend radius portion  222 , two side flanges  224  and two snap features  226  positioned along the bottom of the bend radius fitting  220 . The bend radius fitting  220  is snapped onto adjacent transverse wires. As best seen in  FIG. 15 , the bend radius fitting  220  does not extend into the open area  228 , thus the entire open area  228  is available for cables exiting the wire cable tray system.  FIG. 16  illustrates cables routed from opposite directions and descending through a common open area  228  in the wire cable tray system. 
         [0062]    The bend radius fitting  220  provides maximum space to route cables and cable connectors through an open area in the wire cable tray while minimizing the spacing between transverse wires in the wire cable tray, which minimizes the sag between the transverse wires of cables supported by the wire cable tray. The bend radius fitting  220  also increases the number of options for longitudinal locations of downspouts in the wire cable tray system. 
         [0063]      FIGS. 17-19  illustrate a trapeze support bar  300  and a hanger bar  340  that support the telescoping wire cable tray system  20  suspended from ceiling member  370 . Although  FIGS. 17-19  illustrate the overlapping wire cable trays of  FIG. 1B  attached to the trapeze support bar  300 , the trapeze support bar  300  and the hanger bar  340  may also support the inner wire cable tray  50  of  FIG. 1A  and the outer wire cable tray  30  of  FIG. 1C . 
         [0064]    The trapeze support bar  300  includes a channel  302  defined by a bottom  303  having a hole  304  and side walls  305 . The channel  302  also includes a lower support surface  310 , support arms  309  and an upper support surface  306  that extend from the side walls  305 . As illustrated in  FIG. 18 , the upper support surface  306  includes outwardly extending flanges  308  that support the upper longitudinal wires  42   a ,  62   a  of the overlapping outer and inner wire cable trays  30 ,  50 , respectively. The lower support surface  310  includes inwardly extending flanges  312  that support the lower longitudinal wires  42   b ,  62   b  of the overlapping outer and inner wire cable trays,  30 ,  50 , respectively. 
         [0065]    A locking clip  320  secures the wire cable trays to the trapeze support bar  300 . The locking clip  320  includes a bottom member  322  with side walls  324  extending therefrom. Each side wall  324  includes a hook  326  for engaging the lower longitudinal wires  42   b ,  62   b  of the outer and inner wire cable trays  30 ,  50 . The locking clip  320  slides over the trapeze support bar  300  until the hooks  326  engage the lower longitudinal wires  42   b ,  62   b . A screw  328 , or other fastener, secures the locking clip  320  to the trapeze support bar  300  and the outer and inner wire cable trays  30 ,  50 . 
         [0066]    The hanger bar  340  includes an upper hanger bar  342  and a lower hanger bar  352 . The upper hanger bar  342  and the lower hanger bar  352  each include a plurality of holes  344 ,  354 , respectively. A first end  356  of the lower hanger bar  352  is secured to the trapeze support bar  300  by a nut and a bolt. A second end  358  of the lower hanger bar  352  mates with a first end  346  of the upper hanger bar  342  so that the lower hanger bar  352  slides inside the upper hanger bar  342 . The holes  344  in the upper hanger bar  342  and the holes  354  in lower hanger bar  352  align to receive a bolt to lock the upper hanger bar  342  and lower hanger bar  352  at a designated height position. A second end  348  of the upper hanger bar  342  is fastened to the ceiling member  370  to suspend the wire cable trays. 
         [0067]      FIG. 20  illustrates the telescoping wire cable trays of the present invention installed on the trapeze support bar  300  and connected to a ceiling member by a threaded rod  380 . The threaded rod  380  may be used as an alternative to the upper and lower hanger bars  342 ,  352  illustrated in  FIGS. 17-19  to secure the telescoping wire cable trays to the ceiling member  370 . A first end  382  of the threaded rod  380  is secured to the trapeze support bar  300  and a second end  384  of the threaded rod  380  is secured to a ceiling member. 
         [0068]      FIGS. 21-26  illustrate a clamp  400  that is used to lock the overlapping outer wire cable tray  30  and the inner wire cable tray  50  of the telescoping wire cable tray system  20 . 
         [0069]      FIGS. 21-23  illustrate the clamp  400  being installed on the outer cable wire tray  30  and the inner cable wire tray  50 . The clamp  400  is formed in an open position to facilitate installing the clamp  400  over the lower longitudinal wires  42   b ,  62   b  of the outer wire cable tray  30  and the inner wire cable tray  50 . The clamp  400  includes a top member  402 , a bottom member  404  and a hook  406 . The bottom member  404  of the clamp  400  includes a slot  408  for receiving a screw  418 , or other fastener, and a retaining clip  410  for holding the screw  418  in place as the clamp  400  is installed on the lower longitudinal wires  42   b ,  62   b  of the overlapping wire cable trays. The bottom member  404  also includes paint piercing edges  412  that extend inward toward the top member  402  of the clamp  400 . The top member  402  includes a fastener  414  for receiving the screw  418  and paint piercing edges  416  that extend inward toward the bottom member  404  of the clamp  400 . The screw  418  is threaded into the fastener  414 . The screw  418  is then tightened until the clamp  400  is closed. As the clamp  400  closes, the paint piercing edges  412 ,  416  are driven into the lower longitudinal wires  42   b ,  62   b  of the overlapping outer and inner wire cable trays  30 ,  50  (see  FIGS. 24-26 ). Once the screw  418  has been fully tightened, the outer and inner wire cable trays  30 ,  50  are locked together. The paint piercing edges  412 ,  416  formed in the clamp  400  allow the clamp  400  to create an electrical and mechanical bond with the wire cable trays. 
         [0070]    As illustrated in  FIGS. 21-26 , the hook  406  of the clamp  400  is wrapped around the side wall  36  of the transverse wire  32  of the outer cable tray  30  and the side wall  56  of the transverse wire  52  of the inner wire cable tray  50  to align the transverse wires  32 ,  52  of the wire cable trays. Although  FIGS. 21-26  illustrate the clamp  400  attached to the overlapping wire cable trays of  FIG. 1B , the clamp  400  may also be attached to the inner wire cable tray  50  of  FIG. 1A  and the outer wire cable tray  30  of  FIG. 1C . 
         [0071]      FIG. 27  illustrates an alternative clamp  420  having a double hook  422 . The double hook  422  allows the clamp  420  to be installed on either side of the side walls  36 ,  56  of the outer and inner wire cable trays  30 ,  50 . 
         [0072]      FIGS. 28-35  illustrate a wire form side wall  500  designed to be used on the telescoping wire cable tray system  20 . The wire form side wall  500  creates a vertical wall along the sides of the wire cable trays for supporting cable routed on the wire cable trays. The wire form side wall  500  has an open frame design so that it can be deployed anywhere along the wire cable trays. The wire form side wall  500  may be mounted on the inner wire cable tray  50  of  FIG. 1A  (see  FIGS. 28 and 29 ), the outer wire cable tray  30  of  FIG. 1C  (see  FIGS. 30 and 31 ) and the overlapping wire cable trays of  FIG. 1B  (see  FIGS. 32-34 ). 
         [0073]    As illustrated in  FIGS. 28 and 29 , the wire form side wall  500  is installed on the inner wire cable tray  50  of  FIG. 1A . The wire form side wall  500  includes an upper portion  502  that extends above the wire cable tray  50 , a loop portion  504  and a lower portion  506  with two ends  508 . The loop portion  504  loops around the upper longitudinal wires  62   a  of the inner wire cable tray  50  connecting the upper portion  502  and the lower portion  506  of the wire form side wall  500 . The two ends  508  of the lower portion  506  are threaded. A hex nut  510  or a push nut is installed on each threaded end. A push nut with a cap to cover the ends of the threads may also be installed. As discussed below, once the wire form side wall  500  is installed on the inner cable tray  50 , the nut  510  is tightened up to the lower longitudinal wire  62   b  of the inner wire cable tray  50  (see  FIG. 29 ). 
         [0074]      FIGS. 30 and 31  illustrate the wire form side wall  500  installed on the outer wire cable tray  30  of  FIG. 1C . As discussed above, the wire form side wall  500  includes an upper portion  502 , a loop portion  504  and a lower portion  506  with threaded ends  508 . The upper portion  502  extends above the outer wire cable tray  30  and the loop portion  506  loops around the upper longitudinal wires  42   a  connecting the upper portion  502  to the lower portion  506 . As illustrated in  FIG. 31 , the upper longitudinal wire  42   a  is positioned at the opening  505  of the loop portion  504 . A nut  510  is installed on each threaded end  508  and is tightened up to the lower longitudinal wire  42   b  of the outer wire cable tray  30 . 
         [0075]      FIGS. 32-34  illustrate the wire form side wall  500  installed on the overlapping wire cable trays  30 ,  50  of  FIG. 1B .  FIG. 33  illustrates a typical installation process of the wire form side wall  500 . First, the nuts  510  are preinstalled on the ends  508  of the wire form side wall  500 . Next, the wire form side wall  500  is positioned so that the nuts  510  hook on to the lower longitudinal wires  42   b ,  62   b  of the wire cable trays as illustrated in  FIG. 33 . The wire form side wall  500  is then rotated upwardly to slide the loop section  504  over the upper longitudinal wire  62   a  of the inner wire cable tray  50  and the upper longitudinal wire  42   a  of the outer wire cable tray  30 . Once the wire form side wall  500  is installed in the vertical position, the nuts  510  are tightened up to the lower longitudinal wire  42   b  of the outer wire cable tray  30  to lock the wire form side wall  500  onto the outer and inner wire cable trays  30 ,  50 . 
         [0076]      FIG. 35  illustrates the wire form side wall  500  installed in an alternative position over the outer wire cable tray  30  and the inner wire cable tray  50  of the telescoping wire cable tray system  20 . The open frame design enables the wire form side wall  500  to be installed anywhere along the telescoping wire cable trays. 
         [0077]      FIGS. 36-38  illustrate an alternative design of the wire form side wall  520 . Although the alternative design is illustrated installed on the inner wire cable tray  50  of  FIG. 1A , the wire form side wall  520  may also be installed on the outer wire cable tray  30  of  FIG. 1C  and the overlapping wire cable trays of  FIG. 1B . The wire form side wall  520  includes an upper portion  522  that extends vertically above the inner wire cable tray  50 , a first loop portion  524  that loops around the upper longitudinal wire  62   a  of the inner wire cable tray  50  and a lower portion  526 . The lower portion  526  of the wire form side wall  520  includes an inwardly extending portion  528  that leads to a second loop portion  530 . The second loop portion  530  loops around the lower longitudinal wire  62   b  with the ends  532  of the wire form side wall  520  extending outwardly from the wire form side wall  520  and the inner wire cable tray  50 . A push nut  534  with a cap  536  is installed at each end  532  of the wire form side wall  520 .