Patent Publication Number: US-9841043-B2

Title: Cable tray support

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to a cable tray support for supporting a cable tray in an elevated position. 
     BACKGROUND OF THE DISCLOSURE 
     Cable trays are used to support and house cables, wires, conduits and/or other components. The cable trays may be suspended from an elevated structure, such as ceiling, using a strut channel fastened to spaced apart threaded rods. Typically, upper fasteners, each comprising a washer and nut, are threaded on the lower ends of the rods, and then the threaded rods are inserted through openings or slots in one side of the strut channel. After the strut channel is received on the rods, lower fasteners, each comprising a washer and nut, are threaded on the lower ends of the rods such that the strut channel is between the upper and lower fasteners. While holding the strut channel above the lower fasteners, the lower fasteners are rotated on the threaded rods to move the lower fasteners to vertical positions generally corresponding to the desired vertical location of the strut channel. After positioning the lower fasteners, the upper fasteners are tightened on the rods to clamp the strut channel between the upper and lower fasteners. 
     The above process of positioning the strut channel on the rods in the desired vertical location and fastening the strut channel to the rods may be a cumbersome and time-consuming for the installer. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect, a cable tray support generally comprises an elongate support body having opposite first and second longitudinal ends, a length extending between the first and second longitudinal ends, opposite first and second sides extending lengthwise, and opposite upper and lower surfaces. A first rod opening generally adjacent the first longitudinal end of the support body extends through the upper and lower surfaces. The first opening further extends through one of the first and second sides of the support body toward the other of the first and second sides to allow a first support rod to laterally enter the first opening. A second rod opening generally adjacent the second longitudinal end of the support body extends through the upper and lower surfaces. The second opening further extends through one of the first and second sides of the support body toward the other of the first and second sides to allow a second support rod to laterally enter the second opening. A first lateral closure member adjacent the first opening is movable to a closed position to inhibit the first support rod, when received in the first opening, from laterally exiting the first opening. A second lateral closure member adjacent the second opening is movable to a closed position to inhibit the second support rod, when received in the second opening, from laterally exiting the second opening. 
     In another aspect, a method of assembling a trapeze hanger system generally comprises providing a cable tray support. The cable tray support comprises an elongate support body having opposite first and second longitudinal ends, a length extending between the first and second longitudinal ends, opposite first and second sides extending lengthwise, and opposite upper and lower surfaces. A first rod opening generally adjacent the first longitudinal end of the support body extends through the upper and lower surfaces. The first opening further extends through one of the first and second sides of the support body toward the other of the first and second sides to allow a first support rod to laterally enter the first opening. A second rod opening generally adjacent the second longitudinal end of the support body extends through the upper and lower surfaces. The second opening further extends through one of the first and second sides of the support body toward the other of the first and second sides to allow a second support rod to laterally enter the second opening. A first lateral closure member adjacent the first opening is movable to a closed position to inhibit the first support rod, when received in the first opening, from laterally exiting the first opening. A second lateral closure member adjacent the second opening is movable to a closed position to inhibit the second support rod, when received in the second opening, from laterally exiting the second opening. The first support rod is inserted laterally into the first rod opening such that a length of the first support rod extends generally transverse to the length of the support body. The first lateral closure member is moved to the closed position to inhibit the first support rod from exiting the first opening in the lateral direction. The second support rod is inserted laterally into the second rod opening such that a length of the second support rod extends generally transverse to the length of the support body. The second lateral closure member is moved to the closed position to inhibit the second support rod from exiting the second opening in the lateral direction. 
     In another aspect, a method of making a cable tray support generally comprises providing sheet metal, and die-cutting the sheet metal to form: an elongate support body having opposite first and second longitudinal ends, a length extending between the first and second longitudinal ends, opposite first and second sides extending lengthwise, and opposite upper and lower surfaces; a first rod opening generally adjacent the first longitudinal end of the support body and extending through the upper and lower surfaces, the first opening further extending through one of the first and second sides of the support body toward the other of the first and second sides to allow a first support rod to laterally enter the first opening; a second rod opening generally adjacent the second longitudinal end of the support body and extending through the upper and lower surfaces, the second opening further extending through one of the first and second sides of the support body toward the other of the first and second sides to allow a second support rod to laterally enter the second opening; a first lateral closure member adjacent the first opening, the first lateral closure member being movable to a closed position to inhibit the first support rod, when received in the first opening, from laterally exiting the first opening; and a second lateral closure member adjacent the second opening, the second lateral closure member being movable to a closed position to inhibit the second support rod, when received in the second opening, from laterally exiting the second opening. 
     Other aspects and features will be in part apparent and in part pointed out hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a right side perspective of a trapeze hanger system supporting a cable tray in an elevated position, the trapeze hanger system including a cable tray support; 
         FIG. 2  is a left side perspective of  FIG. 1 ; 
         FIG. 3  is a left side perspective of the cable tray support; 
         FIG. 4  is a right side perspective of  FIG. 3 ; 
         FIG. 5  is a perspective of the cable tray support being received on spaced apart support rods of the trapeze hanger system; 
         FIG. 6  is a perspective of the cable tray support received on the support rods; and 
         FIG. 7  is a perspective of the cable tray support fastened to the support rods. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Referring to  FIGS. 1 and 2 , a cable tray support is generally indicated at reference numeral  10 . As shown in  FIG. 1 , the cable tray support  10  is adapted to support a cable tray, generally indicated at  12 , in an elevated position. In particular, in the illustrated embodiment the cable tray support  10  is suspended from an elevated structure, such as ceiling or other structure, by fastening the cable tray support to first and second support rods  14   a ,  14   b , respectively, depending from the elevated structure to form what is commonly called a trapeze hanger system. The support rods  14   a ,  14   b  may be threaded (e.g. all-thread rods), and first and second pairs of cable tray support fasteners, generally indicated at  16   a ,  16   b , respectively, are secured to the respective first and second support rods  14   a ,  14   b  to fasten the cable tray support  10  to the rods. In a specific application, a plurality of cable tray supports  10  may be used to support a cable tray run, including a plurality of cable trays  12 , in an elevated position. As is generally known in the art, the cable tray  12  is used to support a cables, wires, and/or conduits in an elevated position. The illustrated cable tray  12  is of the type typically referred to as a ladder-type cable tray, although the cable tray support  10  may be used with other types of cable trays. 
     Referring to  FIGS. 3 and 4 , the cable tray support  10  comprises an elongate support body, generally indicated at  20 , having opposite first and second longitudinal ends  22   a ,  22   b , respectively, and a length extending between the first and second longitudinal ends. Opposite first and second sides  24   a ,  24   b , respectively, extend along the length of the support body  20 , and a width extends between the opposite sides. The illustrated support body  20  has a generally planar upper surface  26 —which functions as a support surface for the cable tray  12 —and an opposite generally planar lower surface (not visible in the drawings). The illustrated support body  20  has a generally rectangular perimeter shape and is generally thin (e.g., 12-20 gauge, or 16 gauge in one example), although the support body may have other shapes and thickness without departing from the scope of the present invention. Because the support body  20  is generally thin, the cable tray support  10  includes first and second flanges  28   a ,  28   b , respectively, extending downward from the respective first and second sides  24   a ,  24   b  and running along the length of the support body. The flanges  28   a ,  28   b  increase the rigidity of the support body  20  to increase the load that the support body can support without causing substantially bending (and failure) of the support body (i.e. the flanges increase flexural strength of the support body). 
     Referring still to  FIGS. 2 and 3 , first and second rod openings  32   a ,  32   b , respectively, are formed in the support body  20  and extend through the upper surface  26  and the lower surface thereof. The first rod opening  32   a  is generally adjacent to the first longitudinal end  22   a  of the support body  20 , and the second rod opening  32   b  is generally adjacent to the second longitudinal end  22   b . The first rod opening  32   a  extends through the first side  24   a  toward the second side  24   b  of the support body, and the second rod opening  32   b  extends through the second side toward the first side, although the first rod opening  32   a  may extend through the second side toward the first side and/or the second rod opening may extend through the first side toward the second side. The first rod opening  32   a  is configured to allow the first rod  14   a  to laterally enter the first rod opening (e.g., enter through the first side  24   a  toward the second side  24   b ), and the second rod opening  32   b  is configured to allow the second rod  14   b  to laterally enter the second rod opening (e.g., enter through the second side  24   b  toward the first side  24   a ). Moreover, as shown in  FIG. 4 , the first flange  28   a  has a longitudinal end  33   a  terminating before the first rod opening  32   a  to allow the first support rod  14   a  to laterally enter the first rod opening  32   a , and as shown in  FIG. 3 , the second flange  28   b  has a longitudinal end  33   b  terminating before the second rod opening  32   b  to allow the second support rod  14   b  to laterally enter the second rod opening. In the illustrated embodiment, each rod opening  32   a ,  32   b  has a rod-entry portion  34   a ,  34   b  extending through the corresponding one of the first and second sides  24   a ,  24   b  of the support body  20 , and a rod-holding portion  35   a ,  35   b  in communication with the rod-entry portion and spaced inward from the corresponding one of the first and second sides of the support body. Each illustrated rod-holding portion  35   a ,  35   b  has a generally semi-circular perimeter and is sized to allow entry of the corresponding rod  14   a ,  14   b  therein. Each illustrated rod-entry portion  34   a ,  34   b  has a generally rectilinear perimeter for reasons which will be apparent from the below disclosure. The rod opening  32   a ,  32   b  may have other shapes and sizes without departing from the scope of the present invention. 
     The cable tray support  10  further comprises first and second lateral closure members  36   a ,  36   b  disposed on the support body  20 . The first lateral closure member  36   a  is adjacent the first rod opening  32   a , and the second lateral closure member  36   b  is adjacent the second rod opening  32   b . The first and second closure members  36   a ,  36   b  are independently movable relative to the support body  20  to closed positions (shown in  FIG. 6 ) to inhibit the respective support rods  14   a ,  14   b  from laterally exiting the corresponding rod openings  32   a ,  32   b , more specifically the rod-holding portions  35   a ,  35   b  of the rod openings. In the illustrated embodiment, each lateral closure member  36   a ,  36   b  comprises a bendable tab that is connected to the support body  20  via a living hinge  40   a ,  40   b . In particular, as shown in  FIGS. 3 and 4 , each lateral closure member  36   a ,  36   b  extends generally upward from the support body  20  in an open position to allow the corresponding one of the rods  14   a ,  14   b  to enter the corresponding rod opening  32   a ,  32   b . Each of the lateral closure members  36   a ,  36   b  is movable (e.g., pivotable about the corresponding living hinge  40   a ,  40   b  and/or bendable along its length) toward the rod-entry portion  34   a ,  34   b  of the corresponding rod opening  32   a ,  32   b  to the closed position, in which the lateral closure member enters the rod-entry portion  34   a ,  34   b  and/or is generally transverse to the corresponding rod received in the rod opening to inhibit the rod from laterally exiting the corresponding rod opening. Each lateral closure member  36   a ,  36   b  has a tool slot  44   a ,  44   b  (broadly, a tool opening) extending therethrough for receiving a tool, such as a flat head screwdriver, to facilitate bending of the lateral closure member about the corresponding living hinge  40   a ,  40   b  and/or along its length. It is understood that the lateral closure members may be of other configurations for inhibiting lateral removal of the corresponding support rods from the rod openings without departing from the scope of the present invention. 
     In the illustrated embodiment, first and second cable tray clips  50   a ,  50   b  are disposed on the support body  20  for use in securing the cable tray  12  to the cable tray support  10 , and/or positioning the cable tray  12  on the upper surface  26   a  of the support body, and/or inhibiting the cable tray from moving along the length of the support body. The first and second cable tray clips  50   a ,  50   b  are disposed generally adjacent the respective first and second longitudinal ends  22   a ,  22   b  of the support body  20  and longitudinally inward of the respective first and second rod openings  32   a ,  32   b . As shown in  FIGS. 1 and 2 , the first and second cable tray clips  50   a ,  50   b  are independently movable relative to the support body  20  to engage respective first and second lower flanges  52   a ,  52   b  of the cable tray  12 . In the illustrated embodiment, each cable tray clip  50   a ,  50   b  comprises a bendable tab that is connected to the support body  20  via a living hinge  54   a ,  54   b . Each cable tray clip  50   a ,  50   b  has a tool slot  56   a ,  56   b  (broadly, a tool opening) extending therethrough for receiving a tool, such as a flat head screwdriver, to facilitate bending of the cable tray clip about the corresponding living hinge  54   a ,  54   b  and/or along the length of the cable tray clip. It is understood that the cable tray clips  50   a ,  50   b  may be other configurations or may be omitted from the cable tray support  10  without departing from the scope of the present invention. 
     First and second hold-down openings  60   a ,  60   b  extend through the upper surface  26   a  and the lower surface of the support body  20  for receiving respective first and second hold-down clamps (not shown). Hold-down clamps for securing cable trays to cable tray supports are generally known in the art and are not discussed in detail herein. The first and second hold-down openings  60   a ,  60   b  are disposed generally adjacent the respective first and second longitudinal ends  22   a ,  22   b  of the support body  20  and longitudinally inward of the respective first and second rod openings  32   a ,  32   b . In particular, the first and second hold-down openings  60   a ,  60   b  are adjacent the respective first and second cable tray clips  50   a ,  50   b . The hold-down clamps are optionally used to more permanently and more securely secure the cable tray  12  to the support body  20 , as compared to the cable tray clips  50   a ,  50   b . It is understood that the hold-down openings  26   a ,  26   b  may be other configurations or may be omitted from the cable tray support  10  without departing from the scope of the present invention. 
     As shown in  FIGS. 1 and 2 , the cable tray support  10  may be part of the trapeze hanger system for supporting the cable tray  12 . Referring to  FIG. 5 , as a non-limiting example, to assemble the trapeze hanger system, the first and second support rods  14   a ,  14   b —which depend from the elevated structure and are spaced apart from one another—are inserted laterally into the respective first and second rod openings  32   a ,  32   b , and into the corresponding rod-holding portions  35   a ,  35   b , such that the cable tray support  10  extends horizontally between the support rods and lengths of the support rods extend generally transverse to the length of the support body. In one embodiment, the cable tray support  10  is first orientated horizontally between the support rods  14   a ,  14   b  such that the length of the support body  20  extends generally transverse to the space extending between the first and second support rods. The cable tray support  10  is then rotated horizontally, as shown in  FIG. 5 , to move the first side  24   a  of the support body  20  toward the first support rod  14   a , and the second side  24   b  of the support body toward the second support rod  14   b . As shown in  FIG. 6 , the first and second support rods  14   a ,  14   b  enter the respective first and second rod openings  32   a ,  32   b  as the cable tray support  10  is rotated horizontally. It is understood that the support rods  14   a ,  14   b  may be inserted into the rod openings  32   a ,  32   b  in other ways, particularly in an embodiment where the rod openings are disposed on the same side of the cable tray support. 
     As shown in  FIG. 6 , after inserting the support rods  14   a ,  14   b  into the corresponding rod openings  32   a ,  32   b  (more specifically, into the corresponding rod-holding portions  35   a ,  35   b ), the first and second lateral closure members  36   a ,  36   b  may be moved to their closed positions to inhibit the first and second support rods from laterally exiting the respective first and second openings, as disclosed above. After this step, in one embodiment the cable tray support  10  may be movable up and down along the support rods  14   a ,  14   b  to allow adjustment of the vertical position of the cable tray support  10  on the rods. In another embodiment, the lateral closure members  36   a ,  36   b , in their closed positions, may engage the support rods  14   a ,  14   b  (e.g., engage threads of the support rods) to inhibit the cable tray support  10  from moving up and down along the support rods. 
     After positioning the cable tray support  10  in the desired vertical position on the support rods  14   a ,  14   b , the cable tray support may be fastened to the support rods using the first and second pairs of support fasteners  16   a ,  16   b , as shown in  FIG. 7 . The first and second pairs of support fasteners  16   a ,  16   b  may include nut-washer combination fasteners received (e.g., threaded) on the support rods  14   a ,  14   b . For illustrative purposes, as shown in  FIG. 5 , the first pair of support fasteners  16   a  comprises upper and lower slip-on lock nut washers  68   a ,  68   b , respectively, sold by B-Line by Eaton as the BUZZNUT™ slip-on lock nut washer, and the second pair of support fasteners  16   b  comprises upper and lower standard nut-washer combination fasteners  70   a ,  70   b , respectively. Other fasteners may be used. In one example, shown in  FIG. 5 , the lower support fasteners  68   b ,  70   b  may first be positioned on the respective support rods  14   a ,  14   b  in the general location of the desired position of the cable tray support  10 . The cable tray support  10  may then be received on the support rods  14   a ,  14   b , as set forth above, and supported by the lower support fasteners  68   b ,  70   b . As shown in  FIG. 7 , with the cable tray support  10  in the desired position on the support rods  14   a ,  14   b , the upper fasteners  68   a ,  70   a  (and optionally the lower fasteners  68   b ,  70   b ) can be tightened (e.g., threaded on the rods) to engage the support body  20  and capture the support body between the upper and lower support fasteners. The terminal ends  33   a ,  33   b  of the respective flanges  28   a ,  28   b  provide clearance for the installer to engage the lower fasteners  68   b ,  70   b  with a tool, such as a wrench. Other ways of fastening the cable tray support to the support rods do not depart from the scope of the present invention. 
     After (or before) fastening the cable tray support  10  to the support rods  14   a ,  14   b , the cable tray  12  may be secured to the cable tray support. For example, the cable tray  12  may be placed on the upper surface  26   a  of the support body  20 , and the first and second lower flanges  52   a ,  52   b  of the cable tray can be engaged by the respective first and second cable tray clips  50   a ,  50   b , as shown in  FIGS. 1 and 2 . It is envisioned that in one embodiment the cable tray clips  50   a ,  50   b  may be optionally employed by the installer, such that as sold to the customer and/or delivered to the job site, the cable tray clips are provided in the downward position as shown in  FIGS. 3 and 4  (e.g., the clips are generally parallel to or coplanar with the support body  20 ). In such an embodiment, to employ the cable tray clips  50   a ,  50   b , the clips are bent to an upward position as shown in  FIGS. 5-7 , such as by using the tool inserted in the tool slots  56   a ,  56   b , before placing the cable tray  10  on the upper surface  26   a  of the support body  20 . The cable tray  12  is then placed on the upper surface  56   a  and the first and second cable tray clips  50   a ,  50   b  are pressed downward, such as by using the tool, to engage the respective first and second flanges  52   a ,  52   b  of the cable tray  10 , as shown in  FIGS. 1 and 2 . Hold-down clamps (not shown) may be optionally fastened to the cable tray support  10  using the hold-down openings,  60   a ,  60   b  to securely fasten the cable tray  12  to the cable tray support. 
     In one embodiment, the cable tray support  10  may be made by known metal fabrication processes and techniques. For example, the cable tray support  10  may be fabricated from sheet metal (e.g., steel or aluminum sheet metal or other types of sheet metal). The gauge of the sheet metal, in one example, may be 14-20 gauge, or other gauges, and may depend on the type of metal. The cable tray  10  may be die-cut from the sheet metal in one or more die-cutting steps to form: the support body  10 ; the first and second rod openings  32   a ,  32   b ; the first and second lateral closure members  36   a ,  36   b  (the rod-entry portions  34   a ,  34   b  of the first and second rod openings  36   a ,  36   b  being at least partially formed during formation of the lateral closure members); the tool slots  44   a ,  44   b  in the lateral closure members; the cable tray clips  50   a ,  50   b ; the tool slots in the cable tray clips  56   a ,  56   b ; the hold-down openings  60   a ,  60   b ; and the terminal ends  33   a ,  33   b  of what will be the first and second flanges  28   a ,  28   b . One or more forming steps, which may be performed after, before, or simultaneously with the one or more die-cutting steps, form the first and second flanges  28   a ,  28   b . It is understood that the cable tray support  10  may be fabricated in other ways without departing from the scope of the present invention. Moreover, the cable tray support  10  may be made in other ways, besides being fabricated from sheet metal, without departing from the scope of the present invention. 
     Modifications and variations of the disclosed embodiments are possible without departing from the scope of the invention defined in the appended claims. 
     When introducing elements of the present invention or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
     As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.