Abstract
Claimed by the inventions is a cable tray (23, 140) comprising a first part (51) constituting one piece having a uniform thickness, the first part (51) forming at least a first support surface (52) of a first accommodation (53) for the plurality of cables (54), the first part (51) having a plurality of first through holes (15) formed by a first plurality of edges (19) in the first part (51), wherein at least a part of each said edge (19) protrudes and is directed with an angle away from the support surface (52) of the first accommodation (53), where 45<<180. Also a method of manufacturing such a cable tray is claimed by the invention.
Claims
1. A cable tray comprising: a first part comprising one piece having a uniform thickness, the first part forming at least a first support surface of a first accommodation for the plurality of cables, the first part having through holes each formed by an edge in the first part, and that at least a part of each of the edge protrudes and is directed with an angle away from the first support surface of the first accommodation; wherein 45<<180; and wherein the edge of at least one of the through holes is oriented at the angle from the first support surface.
2. The cable tray according to claim 1, wherein the edge of at least two adjacent through holes in the first part is orientated at the angle from the first support surface.
3-5. (canceled)
6. The cable tray according to claim 1, wherein 160<<180, so that edges from two adjacent through holes are angled towards each other.
7. The cable tray according to claim 1, wherein the through holes are formed and located in relation to each other so that edges of two adjacent through holes define a tray member; wherein the tray member is formed as a beam with longitudinally uniform cross shape; and wherein the tray member is formed at least partly between adjacent located through holes.
8-9. (canceled)
10. The cable tray according to claim 1, wherein the first part comprises at least one side part of the one piece; wherein the at least one side part is angled towards the first part and defines a second support surface of the first accommodation for the plurality of cables; wherein the at least one side part is provided with a longitudinally extending cable tray edge which protrudes and is directed with an angle away from at least one of the first support surface and the second support surface of the first accommodation; and wherein 70270.
11-12. (canceled)
13. The cable tray according to claim 1, further comprising: a tray bottom as comprising the first support surface; and tray sides comprising side parts; wherein the tray bottom and/or the tray sides comprise first tray members extending at a first angle .sub.1 towards a longitudinal direction of the cable tray and second tray members extending at a second angle .sub.1 towards the longitudinal direction of the cable tray; wherein the first tray members and the second tray members are permanently coupled to each other; wherein the first and second tray members together define the tray bottom and/or the tray sides; and wherein each of the first tray members and the second tray members is formed as a beam having a cross section in the form of a U-profile.
14. The cable tray according to claim 13, wherein an open side of the U-profiled beams is oriented away from the cable tray.
15. The cable tray according to claim 13, further comprising: a flat bottom; and flat sides which; wherein the flat bottom and/or flat sides comprises the first tray members and the second tray members.
16-20. (canceled)
21. The cable tray according to claim 13, wherein the through holes are each limited by two opposing first tray members and by two opposing second tray members.
22. The cable tray according to claim 14, wherein a width of a smallest hole of the through holes has a width that is larger than a width of any of the first tray members and the second tray members.
23. The cable tray according to claim 13, wherein all of the first tray members and the second tray members have approximately the same cross sectional form and cross sectional size.
24. The cable tray according to claim 13, wherein the first tray members have a longitudinal elongations; and wherein the second tray members have a transverse elongation such that the first angle .sub.1 is equal to approximately 0 and such that the second angle .sub.1 is equal to approximately 90.
25. The cable tray according to claim 24, wherein at least one of the through holes is of a rectangular form with two opposing long sides and two opposing short sides.
26. The cable tray according to claim 21, wherein a size and a form of the through holes are identical for a main part of the through holes, particularly in the tray bottom.
27. The cable tray according to claim 21, wherein at least one of the through holes is provided with a cover member either as part of the beam or as an attached and demountable cover member.
28. The cable tray according to claim 13, wherein both the first tray members and the second tray members defining the cable tray are produced from one single piece of metal, preferably from a steel coil.
29. (canceled)
30. A method of manufacturing a cable tray, for example for supporting electrical wires, wherein a flat metal sheet starting material comprises one side surface as a support side for an accommodation for a plurality of cables, the flat metal sheet starting material being processed by the following steps: a) the flat metal sheet starting material being punched with through holes, each of the through holes comprising an edge; b) bending the edge an angle away from a support surface, resulting in a formed material; c) bending the formed material an angle into a final form of the cable tray, wherein 30140.
31. The method of manufacturing a cable tray according to claim 30, wherein, in step a) the flat metal sheet starting material is punched with holes which are separated by strips; and wherein, in step b) the strips are being formed into U-shaped beams defined as tray members.
32. The method of manufacturing a cable tray according to claim 30, wherein, in step c) the formed material is bent at a pre-defined angle along at least one bending line being parallel to a longitudinal direction of the cable tray.
33-35. (canceled)
36. A cable tray comprising: a first part comprising one piece having a uniform thickness, the first part forming at least a first support surface of a first accommodation for the plurality of cables, the first part having through holes each formed by an edge in the first part, and that at least a part of each of the edge protrudes and is directed with an angle away from the first support surface of the first accommodation; wherein 45<<180; wherein the edge of at least one of the through holes is oriented at the angle from the first support surface; wherein the edge of at least two adjacent through holes in the first part is orientated at the angle from the first support surface; wherein the through holes are formed and located in relation to each other so that edges of two adjacent through holes define a tray member; wherein the tray member is formed as a beam with longitudinally uniform cross shape; and wherein the tray member is formed at least partly between adjacent located through holes.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The invention will now be described in more detail with reference to exemplifying embodiments thereof illustrated in the accompanying drawings, in which
[0055] FIG. 1 illustrates a manufacturing step of an embodiment according to the present invention;
[0056] FIG. 2a discloses a perspective view of a part of a first product produced under the manufacturing step of FIG. 1;
[0057] FIG. 2b discloses a schematic view of angles for the tray members;
[0058] FIG. 3 illustrates a top view of the product according to FIG. 2;
[0059] FIG. 4 illustrates a side view of the product in FIG. 3;
[0060] FIG. 5 illustrates an end view of the product in FIG. 3;
[0061] FIG. 6 illustrates and end view of a second product according to the invention;
[0062] FIG. 7 illustrates an enlarged end view of the top part of the product in FIG. 5;
[0063] FIG. 8 illustrates an enlarged top view of a top corner part of the product in FIG. 3;
[0064] FIG. 9 illustrates an enlarged side view of the end part of the product in FIG. 4;
[0065] FIG. 10a-d illustrates various cross shapes of beams defining the tray members;
[0066] FIG. 11a-c illustrates further various cross shapes of beams defining the tray members;
[0067] FIG. 12a-d illustrates other types of various cross shapes of beams defining the tray members;
[0068] FIG. 13a-c illustrates various cross shapes of side part edges of a cable tray;
[0069] FIG. 14 discloses a perspective view of a part of a second product produced under the manufacturing step;
[0070] FIG. 15a-b illustrates various patterns of cable tray beams according to the invention;
[0071] FIG. 16 illustrates a cable tray pattern corresponding to the cable tray in FIG. 14;
[0072] FIG. 17 illustrates a further pattern for the beams of a cable tray according to the invention;
[0073] FIG. 18 illustrates a further pattern for the beams of a cable tray according to the invention;
[0074] FIG. 19a-b illustrates a further embodiment of first and second crossing tray members.
DESCRIPTION OF THE INVENTION
[0075] FIG. 1 illustrates a flat starting metal sheet material 10 disclosed in the figure by the border of the dashed lines 11, 12, 13 and the center type line 14. From this flat metal sheet material a first step being a punching operation will take place in order to form the actual type of a cable tray product. In the embodiment disclosed in FIG. 1 the product will be a cable tray which corresponds to prior known wire trays. The punching operation produces a plurality of through holes 15 over almost the entire metal sheet surface leaving strips 16 of the sheet material as borders between all the holes 15 and along each side of the sheet material. All strips have the same width after this punching operation. As can be seen in the figure the punching operation also can produce a cover member 17 closing off one hole, which cover member 17 also can be provided with a mounting hole 18 in the punching operation. The cover member 17 can be made either as a non-punched area or as a specially punched hole defining ridges and/or grooves for attaching a later provided cover member. Thus, FIG. 1 discloses twenty-one holes and seven holes crossed by the center type line 14. One of these twenty-one holes is covered by the cover member 17. However the number and sizes of the holes can be combined and varied in order to serve various needs of a complete cable tray product.
[0076] For clarity purposes of FIG. 1, only one hole 15 is illustrated just after the punching operation, in which the edges of the hole is disclosed by the dashed lines 19.
[0077] Thereafter a second step defined as a strip forming operation is taken place. During this strip forming operation the excess border material 20 along all holes and all edges are bent 90 in the same direction from the first support surface of the starting metal sheet surface. This strip forming operation contains both a bending operation and a plastic forming operation of the metal sheet. The result of the starting metal sheet material after these two steps is disclosed in the figure by the solid lines. As can be seen in later described embodiments the angle of the edges can be varied.
[0078] A third step being a bending operation along two bending lines 21, 22 each of which is parallel to the longitudinal elongation of the cable tray and which is indicated in FIG. 1 by the two center type lines.
[0079] The first step being a punching operation and the second step being a forming operation can be made in a single combined punching/forming operation step, however punching by making holes and forming by bending and stretching the edges will be made during such a combined step.
[0080] FIG. 2a discloses the resulting product of a first embodiment after the three forming steps of the invention indicated above. The resulting product being a cable tray 23 which corresponds to a previous known wire tray. In the figure the forming operation of the strips disclosed in FIG. 1 has now became first tray members 24 extending at a first angle towards the longitudinally direction 25 of the cable tray 23 and second tray members 26 extending at a second angle towards the longitudinally direction of the cable tray. The form of each tray member 24, 26 is as beams each of which having a cross section in the form of a U-profile 29 with the open side of the U-profile directed outwards from the cable tray 23. In this first disclosed embodiment the first angle equals to approximately 0 and the said second angle equals to approximately 90. However other values of the angles and results in other types of holes in the cable tray and thus constitutes other embodiments of the invention. Other suitable values of the angles are 45 for both and .
[0081] In FIG. 2b the angles .sub.n and .sub.n to the longitudinally direction 25 of the cable tray has been defined in view to the direction of the first tray member 24, .sub.n and in view to the direction of the second tray member 26, .sub.n. In this schematic figure the angles are approximately 45 for both .sub.n and .sub.n. The index n represents further angles for first tray members and second tray members respectively.
[0082] In this invention it is also possible to have one set of angles for both and in the bottom part 27 of the cable tray and another set of angles for both and in the side parts 28 of the cable tray.
[0083] FIG. 3 discloses top view of the cable tray 23 with the beams in the form of first tray members 24 and second tray members 26. Also the cover member 17 and its mounting hole 18 can be seen in the figure. Cover member/members with the respective mounting hole can of course be located in one or more of the holes located on the side parts of the cable tray. Other types of attaching means for various devices than mounting holes can be provided in the cover member. As is recognized from this top view is that the U-shaped beams are orientated so that the open side of the beam cannot be seen in a top view of the cable tray. This is also a fact concerning top side longitudinally directed beams 31, 32 in which the open side of the U-shaped beams is directed out from the cable tray. This orientation is important since it will avoid damaging the electrical cables supported by the cable tray. The holes 15 in the cable tray are in this embodiment rectangular. It is also clear from the figure by the curved center lines that cable trays according to the invention can be produced in different suitable lengths. The connections 33 between each first tray member 24 and each second tray member 26 are made as part of the members since the tray members are produced from the same sheet of metal.
[0084] FIG. 4 discloses a side view of the cable tray 23 where the top beam 32 is shown with its open side of the U-profile 29 from outside the cable tray.
[0085] FIG. 5 is an end view of the cable tray 23 in FIGS. 2a, 3 and 4 clearly disclosing that the longitudinally directed U-shaped beams having its open sides of the a U-profiles 29 directed outwards from the cable tray. The figure also discloses the second tray members 26 at the end of the cable tray. The sides of the cable tray have been formed by a 90 bend at both sides where one side part 28 has been bent along one of the longitudinally directed bending lines 22 disclosed in FIG. 1. The cable tray 23 has a first part 51 with a first support surface 52 of a first accommodation 53 for a number of cables 54.
[0086] FIG. 6 discloses an end view of a second embodiment of a cable tray 63 according to the invention which cable tray 63 has been formed according to the previous described steps from an identical starting metal sheet material as disclosed in FIG. 1. What differs in this embodiment is that the two bending lines have been located closer to each other and therefore this cable tray have a closer bottom part 64 and longer side parts 65 having a second support surface 66 facing towards the accommodation, i.e. the proportions of the bottom and the sides has been changed resulting in a new product only by changing the location of the bending lines 21, 22 disclosed in FIG. 1. In this figure the angle between the first part, here the bottom part 64, and one side part 65 is 90. The end of the side part is provided with a longitudinally extending cable tray edge 67 which protrudes and is directed away from the first support surface 66 of the first accommodation.
[0087] FIG. 7 discloses in an enlarged view the top part of one side from FIG. 5. The longitudinal beams with their U-profile 29 are arranged with their open sides facing outwards from the cable tray. The profile sides 71 of the longitudinally beams being the first tray members is attached or is a part of the profile sides 72 of the crossing and transversally extending beams being the second tray members. These second tray members have been bent at the bending line 22 as previously described.
[0088] FIG. 8 disclose in an enlarged top view the connection area 81 between first tray members 24 and second tray members 26. As can be seen the connection between the said members is made from the same metal sheet material so in the connection area the beams is continuously converted into each other for smooth connection surfaces. Thus, there are no level differences, neither vertically nor horizontally, between the different tray members 24, 26. This connection area 81 between the tray members is the result of the punching and forming operation steps in producing a cable tray according to the invention.
[0089] FIG. 9 discloses an outside view of a corner of the cable tray. In this view the inside of the U-profiles 29 are shown which at the connection area 81, the surfaces of the U-profiles are smooth and connected to each other in the same way as can be seen from the outside. Also the edges 91 of the U-profiles 29 run continuously from one beam to another crossing beam.
[0090] In the FIGS. 10a-13c various cross shapes of beams and side edges are disclosed where FIG. 10a discloses the cross shape of a beam both provided longitudinally and transversally in the cable tray previous described as a U-profile. This cross shape discloses a beam that has a curved web 101 and parallel legs 102. This design of a beam is a design that can be used in all embodiments for a beam between two adjacent through holes in the respective first part of each of the embodiments of the cable tray.
[0091] FIG. 10b discloses a similar cross shape but in which the web 101 has a flat surface as a support surface facing towards the cables.
[0092] FIG. 10c discloses a similar cross shape but in which the web 101 is longer than in FIG. 10b giving the cables a larger support surface.
[0093] FIG. 10d discloses a similar cross shape as disclosed in FIG. 10b but having shorter legs 102.
[0094] In these four embodiments the angle between the support surface, represented by the outer surface of the web in the figures facing the first accommodation, and the direction of the parallel legs is 90. The end of these legs seen in the cross section of the beam is the same as the side edges of the respective through hole.
[0095] In the FIGS. 11a-11c variations of the embodiment disclosed in FIG. 10b are disclosed. These variations are in FIG. 11a-11b provided with a groove 110 arranged centrally in the web 101 and directed along the tray member 24. As in FIG. 10b the angle between the support surface represented by the web and the direction of the leg 102 of the beam is 90.
[0096] FIG. 11b discloses an embodiment similar to the embodiment disclosed in FIG. 11a but having a further bending of the legs 102 away from the support surface represented by the web 101. Here the angle is approximately 115. For such an angle the punching for bending the edges of the holes might be made from both sides of the cable tray body.
[0097] FIG. 11c discloses a corresponding embodiment to the embodiment disclosed in FIG. 11b, but instead of providing the web 101 with a groove the web is provided with a ridge 111 along the tray member 24. Also in this embodiment the angle is approximately 115.
[0098] In the embodiments disclosed in the FIGS. 12a-12d indicating cross shapes of a beam which also can be both provided longitudinally and transversally in the cable tray. FIG. 12a corresponds to the embodiment disclosed in FIG. 10a but the angle between a leg 102 and the support surface 101 is less than 90 and in the figure disclosed the angle is about 70 for both legs 102.
[0099] In FIG. 12b a further corresponding embodiment as in FIG. 10a/12a is disclosed but here the angle from the support surface 101 is about 110 for both legs 102.
[0100] In the embodiment in FIG. 12c, a similar embodiment as in FIG. 10a is disclosed but in the present embodiment the legs of the beam has different angles .sub.1, .sub.2 between each leg 121, 122 and the support surface 101. In the embodiment disclosed, .sub.1 is about 70 and .sub.2 is about 110.
[0101] FIG. 12d discloses a further embodiment of a beam between adjacent holes which beam has been formed to a cylindrical shape. With the same definitions as previously used the angle for each tip of the legs are about 160-180, which indicates that the tip of the legs are pointing towards each other.
[0102] The FIGS. 13a-13c disclose various cross shapes of side part edges of a cable tray in which FIG. 13a discloses the cross shape of an edge 130 that is curved outwards from a support surface 131 of the side part. The edge is pointing away from the support surface by the angle . The edge is bent/curved and thus directed 180 from the support surface 131 of the side part, as can be seen by the line which is bent first 90 and then further 90 in the figure.
[0103] In the FIG. 13b the edge 130 of the side part is bent =90 away from the support surface 131.
[0104] In the FIG. 13c the edge is bent further 180 compared to the embodiment in FIG. 13b which means that the angle =90+180=270 between the edge 130 and the side support surface 131.
[0105] In all embodiments the dimensions of the web as well as the legs can be varied. And also all embodiments of the beams and side edges are formed from a one piece cable tray body by punching and plastically pressing and/or bending the sheet material into its final shape. When the beams are longitudinally extending in the cable tray then roller pressing is an advantageous forming method for the edges of the punched holes.
[0106] In FIG. 14a further embodiment of a cable tray 140 according to the invention is disclosed. In FIG. 2a the cable tray 23 is disclosed having rectangular rows and columns of holes separated by the said tray members 24, 26. But in FIG. 14 the first cable tray member 24 extends along the whole length of the cable tray 140 while the second cable tray members 26 are not sideways aligned with each other but instead are longitudinally displaced in relation to each other. This will create a different embodiment of the cable tray 140.
[0107] Other different embodiments of the invention can be recognized and such examples are presented in the schematic FIGS. 15-18.
[0108] FIG. 15a discloses an embodiment corresponding to FIG. 2a but in which the rounded corners 150 of the holes 15 has a larger radius than the embodiment disclosed in FIG. 2a. The angles and as defined in FIG. 2b are 0 and 90 respectively.
[0109] FIG. 15b discloses an embodiment corresponding to FIG. 2b in which the angles .sub.1 and .sub.1 between the first and second cable tray members 24, 26 respectively and the longitudinally direction 25 of the cable tray both are 45.
[0110] FIG. 16 discloses an embodiment corresponding to FIG. 14 but in which the rounded corners 150 of the holes 15 has a larger radius than the embodiment disclosed in FIG. 14. The angles and as defined in FIG. 2b are 0 and 90 respectively.
[0111] FIG. 17 discloses an embodiment in which the holes 170 are made triangular which means that the beams are represented by first cable tray members 171, second cable tray members 172 and third cable tray members 173. As can be recognized from the FIG. 17 the angles and .sub.1 respective .sub.2 as defined in FIG. 2b are 0, 60 and 120 respectively.
[0112] FIG. 18 discloses an embodiment in which the holes 181 are made circular werein the areas between the holes no longer can be defined as beams but instead are identified as cable supporting areas 182. These areas have been made in the same way as the previously described beams, i.e. by punching the holes and plastically bending and/or stretching the supporting areas for the cables so that the edges 183 of the holes 181 are bent away from the supporting surfaces of the cable supporting areas 182 in the same manner as for the previously described holes.
[0113] FIG. 19a discloses a part of cable tray embodiment having parallel straight first tray members 191 and parallel straight second tray members 192 crossing each other at a perpendicular angle. The first tray members 191 together define a bottom surface having an elevated level of the cable tray compared to the bottom surface defined by the second tray members 192. Although the cable tray members 191, 192 define two different bottom levels of the cable tray the production method is the same as the method previously described. Thus, the beams defining the cable tray members 191, 192 have been pressed from a single piece of sheet material. In the crossing between a first tray member 191 and a second tray member 192 it is provided material extension zones 193 in which the sheet material have been plastically deformed at a larger degree than in the corresponding zones in the previous disclosed embodiments. The disclosed embodiment provides for lateral supporting ridges for the cables placed in the cable tray.
[0114] FIG. 19b discloses the same beam crossings as disclosed in FIG. 19a from an outside view below the cable tray. Each beam defines a U-shape 194 which is open towards the outside of the cable tray. Also the extension zones 193 are part of this U-shape which also are open towards the outside of the cable tray.
[0115] Further embodiments of the inventions are where the holes are formed elliptical or with other shapes and arranged in specific patterns over the first support surface of a first accommodation for the plurality of cables are also part of the invention.
[0116] As can be seen from the FIGS. 1, 2a, 3, 4, 8, 9 and 14 producing cable trays according to these embodiments of the present invention makes it also possible to cut the cable tray to a desired length near the connection areas of the tray.
