Patent Publication Number: US-2009223152-A1

Title: Wire Tray Stock

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to wire tray stock comprising a plurality of wire tray modules. 
     BACKGROUND 
     In raised floor systems, floor panels are supported by a series of pedestals or columns secured to a subfloor. The floor panels are usually square, and the supporting pedestals are typically arranged in a grid formation (e.g., a 2′×2′ formation) so as to define a series of generally cuboidal spaces between adjacent pedestals. Cable routed through the under-floor space is supported in trays (e.g., basket cable trays) that run between the pedestals supporting the floor. 
     Typically, the trays are wire trays comprising a plurality of longitudinal wires and a plurality of cross wires extending generally transverse to the longitudinal wires. The cross wires are spaced at uniform intervals along the entire length of the tray. The trays can be selectively cut at the jobsite to form shorter tray segments, depending on the desired layout of the trays underneath the floor. A shorter tray segment is cut from a wire tray at the job site by measuring the desired length of the tray segment and transversely cutting the longitudinal wires between the uniformly spaced cross wires. 
     SUMMARY 
     In one aspect, wire tray stock generally comprises adjacent first and second wire tray modules extending along a length of the wire tray stock. The modules are integrally connected to one another and have generally uniform lengths. A cross-cut zone extends transverse to the wire tray stock between the first and second tray modules. Each of the first and second modules comprises opposite end cross wires extending generally transverse to the length of the wire tray stock and defining opposite longitudinal ends of the wire tray module. A plurality of intermediate cross wires are disposed between the end cross wires and extend generally transverse to the length of the wire tray stock. Adjacent cross wires of the plurality of intermediate cross wires are spaced apart by first distance intervals along the length of the wire tray stock. The cross-cut zone has a width defined by the distance between adjacent end cross wires of the first and second tray modules. The width is less than the first distance intervals between the intermediate cross wires of the wire tray modules. The first and second wire tray modules are detachable from each other by cutting through the cross-cut zone. 
     In another aspect, a method of making wire tray stock comprising a plurality of integral wire tray modules integrally connected to one another and having generally uniform lengths generally comprises providing a plurality of generally parallel, spaced apart longitudinal wires arranged to extend along a length of the wire tray stock. A plurality of first cross wires are secured to the longitudinal wires so that the first cross wires are generally transverse to the longitudinal wires and are spaced from one another a first distance along the length of the wire tray stock. At least one pair of adjacent second cross wires are secured to said longitudinal wires so that the second cross wires of said pair are generally transverse to the longitudinal wires and spaced from one another a second distance along the length of the wire tray stock that is less than the first distance between adjacent first cross wires. The adjacent second cross wires define a cross-cut zone between adjacent wire tray modules. 
     In yet another aspect, a method of selling wire tray stock generally comprises offering for sale the wire tray stock comprising a plurality of wire tray modules integrally connected and spaced apart along a length of the wire tray stock. The wire tray modules are visually discernible from each other along the length of the wire tray stock so that the modules can be identified and selectively cut from the wire tray stock in the field. 
     In another aspect, wire tray stock generally comprises a plurality of wire tray modules extending along a length of the wire tray stock. The modules are integrally connected to one another and have generally uniform lengths. A plurality of cross-cut zones extend transverse to the wire tray stock between the modules. Each wire tray module of said plurality of modules comprises opposite end cross wires extending generally transverse to the length of the wire tray stock and defining opposite longitudinal ends of said wire tray module. A plurality of intermediate cross wires are disposed between the end cross wires and extend generally transverse to the length of the wire tray stock. Adjacent cross wires of the plurality of intermediate cross wires are spaced apart by first distance intervals along the length of the wire tray stock. Each cross-cut zone of the plurality of cross-cut zones has a width defined by the distance between adjacent end cross wires of respective adjacent tray modules. The combined widths of the cross-cut zones are less than about 20% of the length of the wire tray stock. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective of one embodiment of wire tray stock including a plurality of tray modules; 
         FIG. 2  a top plan view of the wire tray stock of  FIG. 1 ; 
         FIG. 3A  is an enlarged, partial top plan view of  FIG. 2 ; 
         FIG. 3B  is an enlarged, partial top plan view of  FIG. 3A ; 
         FIG. 4  is an enlarged, partial top plan view of  FIG. 3A  illustrating cuts made through a cross-cut zone of the stock to separate adjacent tray modules; 
         FIG. 5  is an enlarged perspective of one of the tray modules cut from the wire tray stock; 
         FIG. 6  is a perspective of an underfloor cable management system including wire tray modules individually mounted to tray stands; 
         FIG. 7  is similar to  FIG. 6  except that the tray stock is mounted on the tray stands as a unit; and 
         FIG. 8A  is similar to  FIG. 2  except that scrap regions of the wire tray stock are shaded for illustrative purposes; and 
         FIG. 8B  is a top plan view of a conventional wire tray unit with scrap regions of the unit shaded for illustrative purposes. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings, and in particular to  FIGS. 1 and 2 , one embodiment of a wire tray stock constructed according to the teachings of the present invention is generally indicated at  10 . The illustrated wire tray stock configured as a wire cable basket having a generally U-shaped cross-section defining a channel  12  with open longitudinal ends. It is understood that the wire tray stock  10  may have other configurations without departing from the scope of the present invention. By way of example but not limitation, the wire tray may be generally configured as planar grating. Other configurations are possible. The wire tray stock  10  of the illustrated embodiment has a length L 1  of about 302.8 cm (119.2 in), a width W 1  of about 50.8 cm (20 in), and a height of about 15.24 cm (6 in). The wire tray stock  10  may have other dimensions. For example, the wire tray stock  10  can have a width of about 15.24 cm (6 in) or about 30.48 cm (12 in) and can have a height of about 5.08 cm (2 in) or about 10.16 cm (4 in). Other lengths of the wire tray stock are discussed below. 
     As will become apparent throughout this disclosure, the wire tray stock  10  of the illustrated embodiment is particularly suited for use with an underfloor management system comprising a series support stands having support surfaces on which wire trays are mounted. In particular, the wire tray stock  10  is suited for use with an underfloor management system generally designated  14  in  FIG. 6  and described in U.S. patent application Ser. No. 11/866,647, assigned to the assignee of the present application. The underfloor management system  14  will be explained in more detail below. 
     Referring to  FIGS. 1 and 2 , the wire tray stock  10  comprises a plurality of parallel longitudinal wires  16  extending along the length L 1  of the tray stock. The longitudinal wires  16  are spaced apart from one another across the width W 1  of the tray stock. A plurality of generally parallel U-shaped cross wires  18 A,  18 B extending transverse to the length L 1  of the tray stock  10  are secured to the longitudinal wires  16 , e.g., to the upper portions of the longitudinal wires. (The distinction between the cross wires indicated at  18 A and those indicated at  18 B will be explained below.) It is understood that the cross wires  18 A,  18 B may be substantially straight or have other shapes without departing from the scope of the present invention. The cross wires  18 A,  18 B are spaced apart from one another and laid out along the length L 1  of the tray stock  10  so as to define a plurality of individual wire tray modules, each generally indicated at  22 , that are integrally connected to one another along the length of the wire tray stock. In the illustrated embodiment, the wire tray stock  10  includes five (5) wire tray modules, although it is understood that the wire tray stock can include more or less modules within the scope of the present invention. The tray modules  22  have substantially uniform lengths L 2 . For example and without limitation, the tray modules  22  may have uniform lengths L 2  of between about 65 cm (25.6 in) and about 55 cm (21.7 in). In the illustrated embodiment, the tray modules  22  have lengths L 2  of about 59.5 cm (23.2 in). The modules  22  may have other uniform lengths L 2  without departing from the scope of the invention. The lengths L 2  of the modules  22  may be dependent on the layout of the underfloor management system  14 . 
     Referring to  FIGS. 1-3A , each wire tray module  22  includes two cross wires designated  18 A, which constitute “end cross wires” and define opposite longitudinal ends of the tray module. Each tray module  22  also includes a plurality of the cross wires  18 B, which constitute “intermediate cross wires”, that are disposed between the corresponding end cross wires  18 A. Referring to  FIG. 3A , the intermediate cross wires  18 B of each tray module  22  are spaced apart from one another by first distance intervals  26  along the length L 2  of the tray module. In one example, the first distance intervals  26  are generally uniform, each measuring about 10.0 cm (3.9 in). The respective intermediate cross wires  18 B that are adjacent to the end cross wires  18 A are spaced from the corresponding end cross wires by second distance intervals  28 . In one example, the second distance intervals  28  are generally uniform and measure about 9.2 cm (3.6 in). 
     Referring to  FIGS. 3A ,  3 B and  4 , the wire tray stock comprises a plurality of cross-cut zones  30  disposed between adjacent end cross wires  18 A of adjacent wire tray modules  22 . In one embodiment, the cross-cut zones  30  are disposed at generally uniform intervals along the length L 1  of the wire tray stock  10 . For example, centerlines C ( FIG. 3A ) of the cross-cut zones  30  may be spaced at intervals I of about 61 cm (24 in) along the length L 1  of the wire tray stock  10 . Referring to  FIG. 3B , each cross-cut zone  30  has width W 2  defined by the spacing between the adjacent end cross wires  18 A of adjacent tray modules  22 . In one embodiment, the widths W 2  of the cross-cut zones  30  are less than the first distance intervals  26  between the intermediate cross wires  18 B and less than the second distance intervals  28  between adjacent intermediate cross wires and respective end cross wires  18 A. In one example, the widths W 2  of the cross-cut zones  30  are generally uniform, each measuring between about 0.5 in (1.3 cm) and 5.1 cm (2.0 in), and more preferably about 2.5 cm (1.0 in). Other widths W 2  are suitable. 
     Referring to  FIGS. 1-4 , it will be observed that the wire tray modules  22  are readily visually discernible from one another along the length L 1  of the wire tray stock  10  because the distances between adjacent end cross wires  18 A of adjacent modules (i.e., the widths W 2  of the cross-cut zones  30 ) are less than and desirably significantly less than the first distance intervals  26  and the second distance intervals  28 . By way of example but not limitation, W 2  is desirably at least 10% less than intervals  26  and  28 , even more desirably at least 20% less than intervals  26  and  28 , even more desirably at least 30% less than intervals  26  and  28 , even more desirably at least 40% less than intervals  26  and  28 , and even more desirably at least 50% less than intervals  26  and  28 . Because the modules  22  are visually separated by the cross-cut zones  30 , workers at a job site will not waste time measuring individual wire tray modules  22  along the length L 1  of the wire tray stock  10  before cutting the stock, as with conventional wire tray stock having cross wires spaced at uniform intervals along the entire length of the stock. Instead, the individual tray modules  22  are readily discernible simply by looking at the wire tray stock  10 . 
     According to one method of use, a worker(s) at the jobsite cuts individual wire basket modules  22  from the tray stock  10  by transversely cutting the longitudinal wires  16  at the cross-cut zones  30  (i.e., between the adjacent end cross wires  18 A of adjacent tray modules). This procedure is illustrated in  FIG. 4 , which shows a length of tray stock  10  comprising two modules  22 . To remove a tray module  22  from the tray stock  10 , the longitudinal wires are cut along two transverse lines T located within the cross-cut zone  30  generally adjacent to respective end cross wires  18 A defining the cross-cut zone. Portions  33  of the longitudinal wires  16  in the cross-cut zone  30  are scrap. A resultant module  22  is illustrated in  FIG. 5 . Alternatively, a single cut can be made through the cross-cut zone  30 , preferably substantially along the centerline C. 
     Referring to  FIG. 6 , the separated wire tray modules  22  are mounted on a plurality of modular stands, each generally indicated at  34 , of the underfloor management system  14 . The modular stands  34  are disposed between pedestals  36  of a raised floor  38  and include horizontal support surfaces  40  on which the tray modules  22  are mounted. The wire tray modules  22  span across adjacent and aligned stands  34  when mounted thereon. As shown in  FIG. 6 , the support surface  40  of each stand  34  allows end cross wires  18 A of two, generally aligned tray modules  22  to engage the support surface. The modules  22  can be secured to the stands  34  by cable ties, clips or other fastening devices. 
     In an alternative method of use, the worker(s) keeps the stock  10  intact and/or does not cut each and every module  22  from the stock so that at least two of the modules remain integrally connected. In this method (e.g., see  FIG. 7 ), the two or more integral modules  22  are mounted as a unit, preferably spanning across three or more aligned stands  34 . For this embodiment, a desirable spacing between adjacent modules  22  (i.e., the width W 2  of a cross-cut zone  30 ) is generally less than the width of the support surface  40  of each stand  34  on which the modules  22  are mounted. In this way, the relatively narrow cross-cut zones  30  give the worker the option of either cutting each module  22  from the stock  10  and mounting the modules individually on the stands  34  or mounting two or more modules as an integral unit on the stands, without moving one or more stands from their preferred modular arrangement in which they are positioned between respective pedestals  36  of the raised floor  38 . For example and without limitation, the pedestals  36  in the illustrated embodiments of  FIGS. 6 and 7  are spaced 24 inches apart from one another to form a 2′×2′ grid, and therefore, the stands  34  are also spaced 24 inches apart from one another. Because the centerlines C of the cross-cut zones  30  are spaced apart at intervals I measuring 24 inches, the centerlines of the cross-cut zones will substantially align with longitudinal centerlines of the support surfaces  40  of the stands extending transverse to the widths of the support surfaces. Further, because the widths W 2  of the cross-cut zones  30  are less than the widths of the support surfaces  40  of the stands  34 , respective adjacent end cross wires  18 A of adjacent modules  22  will engage the support surface regardless of whether the modules are detached from the stock  10  and mounted individually on the stands or whether two or more modules remain integrally connected and are mounted on the stands as a unit. 
     In yet another exemplary method of use, the wire tray stock  10  is mounted above the floor using, for example, hangers and support rods secured to framing in a building. As is generally known in the art, building requirements require hangers or other types of tray supports to be secured to the tray at certain intervals along the length of the tray. For example, depending on the load requirement for a particular application, the tray may need to be supported at either 2 ft intervals, or 4 ft intervals or 6 ft intervals. Accordingly, the end cross wires  18 A, which are spaced apart by 2 ft intervals, serve as visual references and indicators for installers and/or inspectors to ensure that the trays are supported at the required intervals without measuring the location of each tray support. 
     In addition to increasing efficiency at the job site, the configuration of the wire tray stock  10  also reduces scrap resulting from the removal (i.e., cutting) of the individual tray modules  22  from the tray stock and allows for a greater number of tray modules to be contained within a single piece of tray stock as compared to conventional tray stock of the same or slightly shorter length. Scrap regions of the stock  10  are shaded and indicated by reference character “S” in  FIG. 8A . In one embodiment, the percentage of scrap resulting when all of the tray modules  22  are individually cut from the tray stock  10  is less than about 20%, more desirably less than about 10%, even more desirably less than about 5%, and still more desirably less than about 2%. In the illustrated embodiment, the detailed specifications of which are given above, the percentage of scrap is less about 2%. Also, the combined widths W 2  of the cross-cut zones  30  are desirably less than about 10% of the overall length L 1  of the wire tray stock  10 , more desirably less than about 5%, and even more desirably, less than about 2%. In the illustrated embodiment, the combined widths W 2  of the cross-cut zones  30  are about 2% of the overall length L 1  of the wire tray stock  10 . 
     In comparing the wire tray stock  10  of  FIG. 8A  to a conventional wire tray unit illustrated in  FIG. 8B , it is apparent that the conventional wire tray unit does not provide the above-referenced advantages provided by the illustrated wire tray stock. All of the cross wires of the illustrated conventional wire tray unit in  FIG. 8B  are spaced apart from one another by uniform intervals measuring 10.0 cm (3.9 in), which are equal to the first distance intervals between the intermediate cross wires  18 B of the wire tray stock  10 . Moreover, the length of the conventional wire tray unit is slightly shorter (i.e., 2.8 cm (1.1 in)) than the length of the illustrated wire tray stock  10 . Scrap regions of the prior art wire tray are shaded and indicated by reference character “S” in  FIG. 8B . Through this comparison, it can be seen that the conventional wire tray unit produces 20% scrap when wire basket segments having lengths suitable for use with the underfloor management system  14  in  FIGS. 6 and 7  (i.e., about 60.5 cm (23.8 in)) are cut from the unit. Moreover, it is also evident through this comparison that only four trays having about the same lengths as the modules  22  of the illustrated embodiment can be cut from the conventional wire tray unit, while five modules can be cut from the illustrated wire stock of the present invention. Moreover still, it is also apparent that the conventional wire tray unit produces a large amount of scrap at one of its longitudinal ends. As shown in the illustrated embodiment of the present invention, it is desirable that only the portions of the tray stock  10  disposed in the cross-cut zones  30  become scrap and that no scrap is produced at the ends of the wire tray stock. In other words, it is preferred that the end cross wires  18 A of the respective modules  22  disposed at the ends of the wire tray stock  10  constitute the respective ends of the wire tray stock. 
     In one embodiment, the wire tray stock  10  is manufactured by feeding the longitudinal wires  16  having uniform, selected lengths (e.g., about 3033 cm (119.4 in)) along an assembly line and securing (i.e., welding) straight cross wires  18 A,  18 B of uniform, selected lengths to the longitudinal wires at selected intervals, as taught above, to form a grate-like construction. After forming the grate-like construction of cross wires  18 A,  18 B and longitudinal wires  16 , the cross wires are bent using a press brake, for example, into U-shapes. Other ways of forming the wire tray stock are within the scope of the present invention. 
     In one example, the wire tray stock  10  is offered for sale. The customer purchases a desirable length of the tray stock  10  comprising two or more modules  22  integrally connected to one another. At the job site, individual wire tray modules  22  are selectively cut from the wire tray stock and mounted underneath the raised floor system so that the individual wire tray modules form a raceway for the wires underneath the raised floor. 
     The tray modules may be offered for sale in wire tray stock of varying lengths, based on the number of modules needed. In one embodiment, a manufacturer or retailer or distributor may offer several types of wire tray stock. For example, the manufacturer or retailer or distributor may sell a maximum-length wire tray stock having a length containing a maximum number of wire tray modules  22  (e.g., five as illustrated); one or more intermediate-length wire tray stocks, each having a shorter length than the maximum-length wire tray stock and a correspondingly fewer number of wire tray modules  22  (e.g., three); and a minimum-length wire tray stock having a length containing two or more wire tray modules. Individual wire tray modules  22  may also be offered for sale. 
     When introducing elements of the present invention or the preferred 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. 
     In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained. 
     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.