Patent Publication Number: US-7586041-B2

Title: Metal raceway system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation of U.S. application Ser. No. 11/465,518, filed Aug. 18, 2006, which claims priority to U.S. Provisional Application Ser. No. 60/710,414, filed on Aug. 23, 2005, the entirety of which is hereby incorporated by reference. 

   FIELD OF THE INVENTION 
   The present invention relates generally to a metal raceway system and, more specifically, relates to a multiple-channel metal raceway system. 
   BACKGROUND OF THE INVENTION 
   Multiple-channel metal raceways are used to route power wiring (or communication cable) along surfaces such as walls, floors, ceilings or on other fixed structures. Raceways provide a convenient way to manage electrical wiring for multiple circuits and/or communication cables while keeping them out of sight and eliminate the physical and network dangers associated with exposure. The multiple-channel raceways thus provide an aesthetic and easy way to route wiring or cables from a power source or network entrance to a desired location. It is important for these systems, which carry both power and communication cables, to meet the existing applicable standards such as U.L. One way for systems to fail to meet the standards is if gaps or other large spaces exist in the system. 
     FIG. 1  illustrates one example of current multiple-channel metal raceway designs. As shown, a multiple-channel raceway  1  includes a bottom portion  2  and a cover  4 . The bottom portion  2  includes a bottom wall  6  and two sidewalls  8 . Cover  4  attaches onto the top of the bottom portion  2 , creating a channel  7 . During installation of a metal raceway system, faceplates (not shown) having an appropriate number of outlets (electrical power outlets and/or communication outlets) are mounted to the bottom portion and fit into openings created in or between the covers  4 . Faceplates should be mounted thereon in a position to overlap a portion of the cover to avoid gaps or seams between the faceplate and covers. In the case of the raceway system shown in  FIG. 1 , when a standard faceplate is mounted to overlap the covers a gap over the sidewalls will exist. Thus, a specially designed faceplate must be used that fills in the gap. 
   Prior to installation the installers generally have ordered all of the parts, including the faceplates, based on a plan that details the layout of the raceway. The layout includes the number and types of faceplates that are needed or desired. However, during installation, the customer may change the layout, including the location, number and type of faceplates. This can be especially frustrating to the installer, because the installer usually cannot purchase the faceplate off-the-shelf at a supplier and must instead order the parts causing delays in the project. 
   Therefore, there is a need for a multiple-channel metal raceway that is designed to accommodate readily available faceplates that can be purchased off-the-shelf and still meets the applicable standards. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a multi-channel raceway system that includes a base and a cover that is flush with the base when it is coupled to the base. The base includes sidewalls having a top wall with flange members. The cover includes a top portion having two ends with a flange member at each end. The flange members of the cover matingly engage the flange members of the base to enable the cover to be flush with the base. The multi-channel raceway system also includes a faceplate that overlaps a portion of the cover and extends over and is flush with a portion of the top walls of the base when installed on the raceway. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a prior art multiple-channel raceway system; 
       FIG. 2   a  is a perspective view of a multiple-channel raceway system according to one embodiment of the present invention; 
       FIG. 2   b  is an end view of the multiple-channel raceway system of  FIG. 2   a ; and 
       FIG. 3  is a perspective view of the multiple-channel raceway system of  FIG. 2   a , with a faceplate according to one embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
     FIGS. 2   a  and  2   b  illustrate one embodiment of a multiple-channel raceway  10 . The term “multiple-channel raceway” refers to a raceway that has at least one channel and may be divided into multiple channels. In some embodiments, the multiple-channel raceway  10  may only have a large single channel that can accommodate a greater number of cables than a standard “single-channel raceway.” 
   In the embodiments illustrated in  FIGS. 2   a  and  2   b , the multiple-channel raceway  10  has a base  12  and a cover  14 . According to one embodiment of the present invention, the base  12  is a one-piece, roll-formed raceway that includes five walls  16   a ,  16   b ,  16   c ,  16   d , and  16   e . The cover  14  includes a top portion  17 . When the cover  14  is coupled to the base  12 , a channel  18  is created. The channel  18  may be used for receiving cables such as power and/or communication cables. 
   As shown in  FIG. 2   b , a divider  19  is inserted into the channel  18 . The divider  19  is used to isolate the different types of cables from one another. In the illustrated embodiment, the divider  19  includes a single dividing wall  19   a  that is parallel to the sidewalls  16   b ,  16   d  of the base  12  and a base  19   b  that abuts the bottom wall  16   c  of the base  12 . Other types of known dividers may also be used. In this embodiment, two sub-channels (or multiple channels) are created. In other embodiments, the divider  19  may include any number of dividing walls  19   a , creating more sub-channels. Because the base  19   b  of the metal divider  19  is in contact with the bottom wall  16   c  of the base  12 , the base  12  and the metal divider  19  are electrically bonded. For safety reasons, the base  12  is grounded. Thus, the metal divider  19  is also grounded. If only one type of wire and/or cable is to be used, then no divider  19  would be necessary. Also, the cover  14  is electrically bonded to the base  12  and, therefore, grounded. 
   As shown in  FIG. 2   b , one embodiment of coupling the cover  14  to the base  12  will be described. In this embodiment, the base  12  includes a flange  20  and the cover  14  includes a corresponding flange  22 . The flange  20  of the base  12  has a shape that substantially corresponds to the shape of the corresponding flange  22 . In other words, when the cover  14  is coupled to the base  12 , the flange  20  of the base  12  is in mating engagement with the flange  22  of the cover  14 . 
   Specifically, the flange  20  of the base  12  includes three portions: a first downwardly extending portion  24   a  that extends downwardly into the channel  18  from the top walls  16   a ,  16   e  of the base  12 : a shelf portion  24   b  that extends into the channel  18  in a direction that is parallel with the top walls  16   a ,  16   e ; and a second downwardly extending portion  24   c  that extends downward into the channel  18  in a direction that is parallel to the sidewalls  16   b ,  16   d.    
   The corresponding flange  22  of the cover  14  includes three portions: a first, flat portion  26   a  that is parallel to the top portion  17  of the cover  14  and underlies the cover  14 ; a downwardly extending portion  26   b  that extends downwardly into the channel  18  and is perpendicular to the top portion  17  of the cover  14 ; and a curved portion  26   c  that projects downwardly at an angle into the channel  18 . 
   When the cover  14  is attached to the base  12 , the flange  20  of the base  12  mates with the flange  22  of the cover  14 . More specifically the first, flat portion  26   a  of the cover  14  rests on the shelf portion  24   b  of the base  12  and the downwardly extending portion  26   b  of the cover  14  abuts the second downwardly extending portion  24   c  of the base  12 . The curved portion  26   c  of the cover  14  is designed such that a portion of the curved portion  26   c  is directly below the second downwardly extending portion  24   c  of the base  12 . By having a part of the corresponding flange  22  of the cover  14  underneath the flange  20  of the base  12 , the base  12  and the cover  14  are securely engaged. Also, the curved portion  26   c  of the cover  14  is flexible relative to the flange  20  of the base  12 , which allows the cover  14  to releasably engage the base  12 . Also, the cover  14  is removable from the base  12 . 
   Other embodiments include those in which a portion of the base  12  mates with a corresponding portion of the cover  14 . The above is merely one embodiment of the present invention. In some embodiments, the cover may not be removable. In some embodiments, the cover may be attachable to the base via methods other than mating engagement. In other words, the cover may be attached via welding or a fastener, such as a screw. 
   As can be seen in  FIG. 2   b , when the cover  14  is mated with the base  12 , the top portion  17  of the cover  14  is flush with the top walls  16   a ,  16   e  of the base  12 . In other words, the top portion  17  of the cover  14  is level with the top walls  16   a ,  16   e  of the base  12 . Also, the top portion  17  is as high as the top of the sidewalls  16   b ,  16   d . The width W of the entire top area (cover  14  and two top walls  16   a ,  16   e ) is between about four inches and six inches, preferably between four and a half inches and five and a half inches. In comparison, the width w of the top portion  17  of the cover  14  is between about three and a half inches and five inches, preferably between about four inches and four and three quarters inches. By increasing the width W of the overall top of the multiple-channel raceway  10 , the installer may now install almost any faceplate having a width less than the total width W of the raceway  10 . Prior multiple-channel raceways, such as raceway  1  shown in  FIG. 1 , only have a width that is the same as the width w of the cover, thus, decreasing the ability to use any standard, off-the-shelf faceplate. 
   After mounting of base  12  to the desired mounting surface, the installer may then lay the wires and/or cables in place in channel  18  (or sub-channels) prior to the attachment of the cover  14  onto the base  12 . In other embodiments, the wires and/or cables may be snaked through the channel  18  (or sub-channels) prior to the attachment of the cover  14  onto the base  12 . According to one embodiment, when the base  12 , cover  14  and dividers  19  are all attached, they are all electrically bonded to one another, as described above. 
     FIG. 3  illustrates a perspective view of one embodiment of a multiple-channel raceway system having a base  12  and multiple covers  14 . The covers  14  are coupled to the base  12  leaving an opening  13  for a device bracket and various receptacles (not shown). In this embodiment, a two-gang faceplate  28  with four screw holes  30  is attached to the raceway  10 . The faceplate  28  is positioned over the opening  13  such that the faceplate  28  extends slightly over the edge of the cover  14 . The faceplate  28  also extends over and is flush with a portion of the top walls  16   a ,  16   e  of the base  12 . As a result, when the faceplate is installed on the raceway, there are no gaps or openings between the faceplate and the raceway. Additionally, since the top portion  17  of the cover  14  is flush (or level) with the top walls  16   a ,  16   e  of the base  12 , various standard sized faceplates may be used to cover the opening  13  between the covers in the raceway. 
   Generally, the multiple-channel raceways  10  are sold in lengths of five feet and are then cut to fit the required length. However, in other embodiments, the multiple-channel raceways  10  may be of different lengths. Also, in other embodiments, the height of the base  12  may be varied. In one embodiment, the height is between about 1.40 inches and about 1.80 inches. The multiple-channel raceway may be made of metal, such as painted, galvanized or galvanealed cold-rolled steel. 
   In the illustrated embodiment, a two-gang faceplate is illustrated. However, any faceplate that has at least one dimension that is less than the width W of the raceway  10  may be attached to the multiple-channel raceway. The faceplate may be an off-the-shelf faceplate or a specially ordered faceplate. The faceplate may accommodate any combination of power and/or communication cables. 
   While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing descriptions without departing from the invention.