CABLE DUCT

Abstract

An cable duct is presented herein. The cable duct includes a cover plate having a double sided hinge allowing the cover to be opened from one of two sides. The cover has a pair of saddle features longitudinally extending along distal edges of the cover plate, a base plate arranged opposite the cover plate, and a sidewalls extending from the base plate to the cover plate. Each sidewall defines a lobe mechanism on a sidewall end opposite the base plate that is configured to engage the corresponding saddle feature releasably secure the cover plate to the sidewall. Each saddle feature is configured to pivot about the lobe mechanism. Each lobe mechanism includes a rounded outer lobe portion having a first radius and a rounded inner lobe portion having a second radius. The first radius is greater than the second radius.

Claims

1. A cable duct defining a cavity configured to retain an elongate conductor, comprising: a cover plate defining a first saddle feature longitudinally extending along a first distal edge of the cover plate and a second saddle feature longitudinally extending along a second distal edge of the cover plate opposite the first distal edge; a base plate arranged opposite the cover plate; a first sidewall extending from a longitudinal edge of the base plate to the cover plate, wherein the first sidewall defines a first lobe mechanism on a first sidewall end opposite the base plate configured to engage the first saddle feature and releasably secure the cover plate to the first sidewall, wherein the first saddle feature is configured to pivot about the first lobe mechanism; and a second sidewall extending from another longitudinal edge of the base plate to the cover plate, wherein the second sidewall defines a second lobe mechanism on a second sidewall end opposite the base plate configured to engage the second saddle feature and releasably secure the cover plate to the second sidewall, wherein the second saddle feature is configured to pivot about the second lobe mechanism, wherein each of the first and second lobe mechanisms include a rounded outer lobe portion having a first radius and a rounded inner lobe portion having a second radius, and wherein the first radius is greater than the second radius.

2. The cable duct according to claim 1, wherein the first lobe mechanism is a mirror-image of the second lobe mechanism and the first saddle feature is a mirror image of the first saddle feature.

3. The cable duct according to claim 2, wherein the first lobe mechanism defines a detent step intermediate the outer lobe portion and the inner lobe portion.

4. The cable duct according to claim 3, wherein the first lobe mechanism is attached to the first sidewall by a serpentine portion having a first curved portion that is inwardly angled toward a center of the cable duct and a second curved portion that curves outwardly away from the center of the cable duct.

5. The cable duct according to claim 4, wherein the serpentine portion defines a longitudinal channel intermediate the first sidewall and the first lobe mechanism.

6. The cable duct according to claim 5, wherein the first saddle feature is characterized as having a C-shape and defines a first saddle arm and a second saddle arm and wherein the first lobe mechanism is received in a saddle cavity defined between the first and second saddle arms.

7. The cable duct according to claim 6, wherein the first saddle feature is configured to pivot from a closed position in which the first lobe mechanism is engaged with the first saddle feature and the second lobe mechanism is in contact with, but not engaged with, the second saddle feature to a partially open position in which the second lobe mechanism is disengaged from the second saddle feature and an end of the first saddle arm is disposed within the longitudinal channel and wherein a first force is required to be applied to the cover plate to move the first saddle feature from the closed position to the partially open position.

8. The cable duct according to claim 7, wherein the first and second saddle arms are not in tension as the first saddle feature is moved from the closed position to the partially open position.

9. The cable duct according to claim 7, the first saddle feature rotates through an angle of about 90 degrees between a locked position, in which the first lobe mechanism is engaged with the first saddle feature and the second lobe mechanism is engaged with the second saddle feature, and the partially open position.

10. The cable duct according to claim 7, wherein the first saddle feature is configured to pivot from the partially open position to a fully open position in which an end of the second saddle arm is in contact with the detent step and the end of the first saddle arm is disposed within the longitudinal channel and wherein a second force, greater than the first force, is required to be applied to the cover plate to move the first saddle feature from the partially open position to the fully open position.

11. The cable duct according to claim 10, wherein the first and second saddle arms are in tension as the first saddle feature is moved from the partially open position to the fully open position.

12. The cable duct according to claim 10, the first saddle feature rotates through an angle of about 105 degrees between a locked position, in which the first lobe mechanism is engaged with the first saddle feature and the second lobe mechanism is engaged with the second saddle feature, and the fully open position.

13. The cable duct according to claim 2, wherein the second lobe mechanism defines a detent step intermediate the outer lobe portion and the inner lobe portion.

14. The cable duct according to claim 13, wherein the second lobe mechanism is attached to the second sidewall by a serpentine portion having a first curved portion that is inwardly angled toward a center of the cable duct and a second curved portion that curves outwardly away from the center of the cable duct.

15. The cable duct according to claim 14, wherein the serpentine portion defines a longitudinal channel intermediate the second sidewall and the second lobe mechanism.

16. The cable duct according to claim 15, wherein the second saddle feature is characterized as having a C-shape and defines a first saddle arm and a second saddle arm and wherein the second lobe mechanism is received in a saddle cavity defined between the first and second saddle arms.

17. The cable duct according to claim 16, wherein the second saddle feature is configured to pivot from a closed position in which the second lobe mechanism is engaged with the second saddle feature and the first lobe mechanism is in contact with, but not engaged with, the first saddle feature to a partially open position in which the second lobe mechanism is disengaged from the second saddle feature and an end of the second saddle arm is disposed within the longitudinal channel and wherein a first force is required to be applied to the cover plate to move the second saddle feature from the closed position to the partially open position.

18. The cable duct according to claim 17, wherein the first and second saddle arms are not in tension as the second saddle feature is moved from the closed position to the partially open position.

19. The cable duct according to claim 17, the second saddle feature rotates through an angle of about 90 degrees between a locked position, in which the second lobe mechanism is engaged with the second saddle feature and the first lobe mechanism is engaged with the first saddle feature, and the partially open position.

20. The cable duct according to claim 17, wherein the second saddle feature is configured to pivot from the partially open position to a fully open position in which an end of the second saddle arm is in contact with the detent step and the end of the first saddle arm is disposed within the longitudinal channel and wherein a second force, greater than the first force, is required to be applied to the cover plate to move the second saddle feature from the partially open position to the fully open position.

21. The cable duct according to claim 20, the second saddle feature rotates through an angle of about 105 degrees between a locked position, in which the second lobe mechanism is engaged with the second saddle feature and the second lobe mechanism is engaged with the second saddle feature, and the fully open position.

22. The cable duct according to claim 20, wherein the first and second saddle arms are in tension as the first saddle feature is moved from the partially open position to the fully open position.

23. The cable duct according to claim 1, wherein the first sidewall comprises a first plurality of fingers defining a gap therebetween, each finger in the first plurality of fingers defining the first lobe mechanism on a first finger end opposite the base plate and wherein the second sidewall comprises a second plurality of fingers defining a gap therebetween, each finger in the second plurality of fingers defining the second lobe mechanism on a second finger end opposite the base plate.

24. The cable duct according to claim 23, wherein each first lobe mechanism and each second lobe mechanism contains a hollowed out section such that the hollowed first and second lobe mechanisms have a uniform wall thickness.

25. The cable duct according to claim 23, wherein each finger in the first plurality of fingers and each finger in the second plurality of fingers define restrictor features configured to keep electrical wiring that is threaded between the fingers in a known position.

26. The cable duct according to claim 23, wherein each finger in the first plurality of fingers and each finger in the second plurality of fingers define a break-off point include a chamfered neck allowing the finger to be twisted off and removed from the first or second sidewalls.

27. The cable duct according to claim 23, wherein the base plate defines an inner base rail and an outer base rail and wherein the first and second side walls define a locking feature received intermediate the inner and outer base rails.

28. The cable duct according to claim 27, wherein the base plate defines a plurality of score lines along the bottom of base plate to provide a mechanism for removal of a section of the inner base rail and the outer base rail.

29. The cable duct according to claim 23, wherein the base plate defines a plurality of cable duct mounting slots staggered to provide a variety of mounting points along the base plate.

30. The cable duct according to claim 23, wherein the base plate defines a plurality of cable tie mounting buckles configures to secure a wire cable to the base plate.

31. The cable duct according to claim 23, wherein the first sidewall and the second side walls are formed by an injection molding process and wherein edges of each finger in the first and second plurality of fingers are rounded.

32. A cable duct defining a cavity configured to retain an elongate conductor, comprising: a cover plate defining a first hinge mechanism longitudinally extending along a first distal edge of the cover plate and a second hinge mechanism longitudinally extending along a second distal edge of the cover plate opposite the first distal edge; a base plate arranged opposite the cover plate; a first sidewall extending from a longitudinal edge of the base plate to the cover plate, wherein the first sidewall defines a first lobe mechanism on a first sidewall end opposite the base plate configured to engage the first hinge mechanism and releasably secure the cover plate to the first sidewall, wherein the first hinge mechanism is configured to pivot about the first lobe mechanism; and a second sidewall extending from another longitudinal edge of the base plate to the cover plate, wherein the second sidewall defines a second lobe mechanism on a second sidewall end opposite the base plate configured to engage the second hinge mechanism and releasably secure the cover plate to the second sidewall, wherein the second hinge mechanism is configured to pivot about the second lobe mechanism.

33. The cable duct according to claim 32, wherein the first sidewall comprises a first plurality of fingers defining a gap therebetween, each finger in the first plurality of fingers defining the first lobe mechanism on a first finger end opposite the base plate and wherein the second sidewall comprises a second plurality of fingers defining a gap therebetween, each finger in the second plurality of fingers defining the second lobe mechanism on a second finger end opposite the base plate.

34. The cable duct according to claim 33, wherein each finger in the first plurality of fingers and each finger in the second plurality of fingers define restrictor features configured to keep electrical wiring that is threaded between the fingers in a known position.

35. The cable duct according to claim 33, wherein each finger in the first plurality of fingers and each finger in the second plurality of fingers define a break-off point include a chamfered neck allowing the finger to be twisted off and removed from the first or second sidewalls.

36. The cable duct according to claim 33, wherein the base plate defines an inner base rail and an outer base rail and wherein the first and second side walls define a locking feature received intermediate the inner and outer base rails.

37. The cable duct according to claim 36, wherein the base plate defines a plurality of score lines along the bottom of base plate to provide a mechanism for removal of a section of the inner base rail and the outer base rail.

38. The cable duct according to claim 33, wherein the base plate defines a plurality of cable duct mounting slots staggered to provide a variety of mounting points along the base plate.

39. The cable duct according to claim 33, wherein the base plate defines a plurality of cable tie mounting buckles configures to secure a wire cable to the base plate.

40. The cable duct according to claim 33, wherein the first sidewall and the second side walls are formed by an injection molding process and wherein edges of each finger in the first and second plurality of fingers are rounded.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0030] The present invention will now be described, by way of example with reference to the accompanying drawings, in which:

[0031] FIG. 1 is an end view of a closed cable duct according to an embodiment of the invention;

[0032] FIG. 2 is a partial enlargement of a hinge mechanism in the cable duct of FIG. 1 according to an embodiment of the invention;

[0033] FIG. 3 is an end view of a cable duct with an open cover panel according to an embodiment of the invention;

[0034] FIG. 4 is a partial enlargement of a hinge mechanism in the cable duct of FIG. 1 with the cover panel in a fully open position according to an embodiment of the invention;

[0035] FIG. 5A is a partial enlargement of the cable duct of FIG. 1 with the cover panel in the fully closed position according to an embodiment of the invention;

[0036] FIG. 5B is a partial enlargement of the cable duct cover of FIG. 1 with the cover panel partially open according to an embodiment of the invention;

[0037] FIG. 5C is a partial enlargement of the cable duct of FIG. 1 with the cover panel in the fully open position according to an embodiment of the invention;

[0038] FIG. 6 is a perspective view of the cable duct with a hollowed lobe mechanism according to another embodiment of the invention;

[0039] FIG. 7 is a side view of the cable duct sidewall structure of FIG. 1 according to another embodiment of the invention;

[0040] FIG. 8 is a partial enlargement of the cable duct of FIG. 6 showing a front view of the hollowed lobe structure according to another embodiment of the invention;

[0041] FIG. 9 is a partial enlargement of the cable duct of FIG. 6 showing a side profile of the hollowed lobe structure according to another embodiment of the invention;

[0042] FIG. 10 is a partial enlargement of the cable duct of FIG. 1, the sidewall mating with the base plate therein according to another embodiment of the invention; and

[0043] FIG. 11 is a perspective view of a plurality of cable duct cable ducts of FIG. 1, abutting to form a larger cable duct therein according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0044] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed is merely a non-limiting example of the invention that may be embodied in another specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention. The invention contemplates the assembly of various cooperating components fabricated from molded or extruded resilient materials, such as an elastomeric polymer, preferably PVC. The components feature a snap-lock assembly of a combination saddle-lobe hinge mechanism. “Snap-lock” means, for example, the ability to assemble two components by hand, without requiring tools, and providing such positive engagement that the two components will not separate absent an applied force. Such an applied force may be applied by hand or by a tool, for example.

[0045] As shown in FIG. 1, a cable duct 16 includes a cover plate 10 with substantially identical and symmetrical first and second hinge mechanisms 12a, 12b disposed on opposed distal edges 14a, 14b of the cover plate 10. The cable duct 16 consists of a base plate 18, a pair of (first and second) sidewalls 20, and cover plate 10. The cover plate 10 rotates about either the first hinge mechanism 12a or the second hinge mechanism 12b to allow access to cables or anything else preferably stored within the cable duct 16. The saddle feature 24 on the distal edges 14a, 14b of the cover plate 10 snap onto the lobe mechanism 34 on the sidewalls 20. The saddle feature 24 on either distal edges 14a or 14b can be unsnapped from the lobe mechanism 34 to allow opening of the cover plate 10. The cover plate 10 pivots about the saddle feature 24 that remains attached to the lobe mechanism 34 on the respective sidewall 20 when the saddle feature 24 is unsnapped. The base plate 18 and the sidewalls 20 may be separate components or they may be integrally formed. The first and second sidewalls 20 are identical to one another and, as positioned in the base plate 18, are mirror images of each other.

[0046] With reference to FIG. 2, the first and second hinge mechanisms 12a, 12b of the cover plate 10 include a saddle shaped hinge feature, hereinafter referred to as the saddle feature 24 with a first saddle arm 26 and a second saddle arm 28. The first addle arm 26 extends in a planar fashion from the distal edges 14a, 14b of the cover plate 10, and the second saddle arm 28 extends substantially perpendicular to the cover plate 10, the first and second saddle arms 26, 28 form an arcuate shape 30 having a saddle cavity 32 configured to receive the lobe mechanism 34 of the sidewalls 20 (see FIG. 1). The first and second hinge mechanisms 12a, 12b are symmetrical and function in a substantially identical way. The first and second saddle arms 26, 28 include first and second projections 36, 38 respectively, both of which extend inward toward the saddle cavity 32 to contact the lobe mechanisms 34.

[0047] Referring to FIG. 3, the sidewalls 20 include a first curved portion 42 on the distal ends 40 that is inwardly angled toward the center of the cable duct cavity 44, and a second curved portion 46 that distally curves outward away from the center of the cable duct cavity 44, the farthest distal ends of the sidewalls 20 completing in lobe mechanisms 34.

[0048] As shown in FIG. 4, lobe mechanisms 34 are designed to be received between the first and second saddle arms 26, 28 of the saddle feature 24. The lobe mechanism 34 is designed with a detent step 48 on the upper lobe portion 49 to prevent over-rotation of the cover plate 10 beyond 105° and a surface bulge 50 on the lower or outer lobe portion 51 to increase tension between the first and second saddle arms 26, 28 during rotation of the cover plate 10. The longitudinal channel 52 underneath the lobe mechanism 34 on the outer face of the sidewall 20, created by the second curved portion 46 of the distal end 40 of the sidewall 20 (see FIG. 3), receives the first saddle arm 26 of the cover plate 10 when the cover plate 10 is in its full-open position. The cover plate 10 locks into place when either the first hinge mechanism 12a or the second hinge mechanism 12b is in the full open position to prevent inadvertent closure.

[0049] Referring to FIGS. 5a, 5b, and 5c, the first and second hinge mechanisms 12a, 12b, enable three phases (I, II, and III) of cover plate 10 rotation. In phase I, the first and second saddle arms 26, 28 are relaxed, and the cover plate 10 freely pivots about the saddle feature 24 of the cover plate 10 that remains attached. Phase I occurs between the fully closed position and a partially open position, e.g. an angle of rotation between 0° and 90°. Phase II occurs between the partially open position and the fully open position. In phase II, the first and second saddle arms 26, 28 are in tension as first saddle arm 26 pivots around the surface bulge 50 of lobe mechanism 34. The cover plate 10 is held open in any position of phase II. In phase III the cover plate 10 is in the fully open position. The second projection 38 on the second saddle arm 28 catches on the detent step 48, which limits rotation past fully open, e.g. 105°, and the first projection 36 on the first saddle arm 26 is received into the longitudinal channel 52. In the phase III, the cover plate 10 is locked in the fully open position. The locking mechanism is robust, yet defeatable with the application of a predetermined force. The resilient material of saddle feature 24 and lobe mechanism 34 facilitates repeated rotation through phases I through III without damage to either the first hinge mechanism 12a or the second hinge mechanism 12b.

[0050] As shown in FIGS. 8 and 9, another non-limiting example of the lobe mechanism 34, hereinafter referred to as a hollowed lobe 54, can be seen. The hollowed lobes 54 contain a hollowed out section 56. The hollowed lobes 54 retain the same profile 58 as lobe mechanisms 34, and the hollowed lobes 54 function identically to lobe mechanisms 34. The hollowed lobes 54 have a uniform wall thickness 60 for increased flow performance when the sidewalls 20 are molded using an injection molding process. The uniform wall thickness 60 of the hollowed lobes 54 generates less heat buildup in the mold, translating to shorter production cycle times as well as a reduction in the amount of plastic required to form the hollowed lobes 54.

[0051] Referring to FIGS. 7 and 10, the sidewalls 20 are comprised of fingers 62, which have restrictors 64 that keep cables, or any other electrical wiring that is threaded between the fingers 62 in a known position. Fingers 62 have break-off points 66 at the base plate 18 where the fingers 62 connect to an injection molded finger stem 68. The break-off points 66 include a chamfered neck 70, allowing the fingers 62 to be easily twisted off and removed from the finger stem 68, providing an additional space for cables to run through the sidewalls 20. When the fingers 62 are twisted off, the fingers 62 break off below the top of inner base rail 82 and outer base rail 84, leaving no material sticking up that could catch on cables that may be running between the fingers 62. This helps to prevents exposure of sharp edges that could damage a cable. The finger stem 68 has a locking feature 72 that allows easy insertion of the sidewalls 20 between inner base rail 82 and outer base rail 84 on base plate 18 while also increasing pull out resistance.

[0052] According to an alternative embodiment the fingers contain a hollowed out section extending vertically along the fingers. The hollowed fingers reduce the amount of plastic required to form the fingers, thereby providing cost and weight savings for the cable duct.

[0053] Accordingly, a cable duct is provided. The hinge mechanisms provide the benefits of allowing the cover plate to open from either side, The hinge mechanism also provides three phases of cover plate 10 rotation. In phase I, e.g. between 0° and 90° rotation, the cover plate pivots freely. In phase II between the partially open position and the fully open position, e.g. between 90° and 105° rotation, the cover plate is held open in the established cover plate position. In phase III, the cover plate is in the fully open position. The modular design of the cable duct provides improved ease of assembly, repair, and customization of the cable duct compared to prior cable duct designs.

[0054] Referring to FIGS. 6 and 10, base plate 18 includes cable duct mounting slots 76, cable tie mounting buckles 78, and score lines 80. Cable duct mounting slots 76 are staggered to create a variety of mounting points throughout the length of the base plate 18. The cable tie mounting buckles 78 retain any variety of frequent wire and cables placed underneath the cable tie mounting buckle 78. Vertical cuts 86 can be made into the inner base rail 82 and outer base rail 84 to remove segments of the inner base rail 82 and outer base rail 84. Score lines 80 along the bottom of base plate 18 create an easy mechanism for removal of any section of the inner base rail 82 and outer base rail 84, after vertical cuts 86 have been made, to provide a smooth surface for intersection with T-intersecting cable ducts (shown in FIG. 11).

[0055] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.

[0056] The examples presented herein are directed to cable ducts configured to retain electrical wiring. However, other embodiments of the cable duct may be envisioned that are adapted for use with fiber optic cables, pneumatic lines, hydraulic lines, or a combination of any of these.

[0057] While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, upper, lower, etc. does not denote any order of importance or orientation, but rather the terms first, second, upper, lower, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.