Cable management system

Abstract

To provide a cable management system designed to support cables in solar applications.SOLUTION: The cable management system includes a U-shaped bracket and at least one clamp half. The U-shaped bracket has a base with two arms, each arm including a locking slot. The clamp halves have a top, a bottom, a front, a back, and sides with button pads extending from the sides. The clamp halves are installed in the U-shaped bracket such that the button pad slides in the fixed slot to position the clamp halves in the U-shaped bracket. The clamp halves separate and support a cable installed in the U-shaped bracket.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of U.S. Patent Application No. 18 / 651,879, filed May 1, 2024, which is a continuation-in-part of U.S. Patent Application No. 17 / 950,565, filed September 22, 2022, both of which are hereby incorporated by reference in their entirety.

[0002] The present invention relates to cable management systems, and more particularly to messenger wire cable management systems for solar applications. [Background technology]

[0003] Electricity generation using solar panels is a rapidly growing sustainable energy source. Each solar panel requires an electrical connection to collect electrical energy for use, storage, or connection to the power grid. While the electrical energy produced by a single panel does not require a large conductor, the panels are interconnected, requiring larger conductor sizes to accommodate the amount of current generated by the panels and flowing through the conductors. Therefore, large solar farms can produce large amounts of energy that require large cables to carry the current. Cables are often suspended and routed from brackets suspended from messenger wires. The number of cables within each bracket varies, but some installations require more than 20 cables per bracket. When cables are run adjacent to each other within a bracket, the current limits of the cables are required to be reduced. Free air space and derating of cables are specified in the National Electrical Code, NEC 100 and NEC 310, respectively. Free air space reduces the need for reduced current-carrying limits for conductors. Therefore, maintaining cable separation within the bracket can reduce or eliminate the cable derating factor. As a result, there is a need for an improved bracket that securely holds and separates cables, is easy to install, and includes a minimum number of components. Summary of the Invention

[0004] A cable management system for supporting cables in solar applications includes a U-shaped bracket and at least one clamp half disposed within the U-shaped bracket. The U-shaped bracket has a base with two arms, each arm including a locking slot. The clamp half has a top, bottom, front, rear, and sides, with button pads extending from the sides. The button pads slide within the locking slots to position the clamp half within the U-shaped bracket. The clamp half isolates and supports the cables installed in the U-shaped bracket. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a perspective view of a partially assembled cable management system of the present invention. [Figure 2] FIG. 2 is a perspective view of a U-shaped bracket of the cable management system of FIG. 1. [Figure 3] 2 is a perspective view of a clamp half of the cable management system of FIG. 1. [Figure 4] FIG. 2 is a perspective view of the partially assembled cable management system of FIG. 1 with multiple cables positioned on the clamp halves. [Figure 5] FIG. 5 is a perspective view of the cable management system of FIG. 4 with the top clamp half positioned within a U-shaped bracket and secured to the bottom clamp half to form a cable clamp. [Figure 6] FIG. 6 is a perspective view of the cable management system of FIG. 5 with a second cable clamp and a cable positioned within the bracket. [Figure 7] FIG. 10 is a perspective view of an alternative cable management system. [Figure 8] FIG. 8 is a perspective view of a U-shaped bracket of the cable management system of FIG. [Figure 9] FIG. 8 is a perspective view of a closure bracket of the cable management system of FIG. 7. [Figure 10] 8 is a perspective view of one end of a closure bracket secured to a U-shaped bracket of the cable management system of FIG. 7. [Figure 11] FIG. 8 is a perspective view of a cable clamp assembly installed within a U-shaped bracket of the cable management system of FIG. 7. [Figure 12] FIG. 12 is a top perspective view of the bottom cable clamp half of the cable clamp assembly of FIG. [Figure 13] FIG. 12 is a bottom perspective view of a cable clamp half of the cable clamp assembly of FIG. [Figure 14] FIG. 12 is an exploded view of the cable clamp assembly of FIG. 11. [Figure 15]FIG. 15 is a perspective view of a dampening insert installed in the cable clamp assembly of FIG. 14. [Figure 16A] 8 is a bottom perspective view of a cable spacer installed in the cable management system of FIG. 7. [Figure 16B] 8 is a top perspective view of a cable spacer installed in the cable management system of FIG. 7. [Figure 17] FIG. 8 is a perspective view of a U-shaped bracket of the cable management system of FIG. 7 positioned over a messenger wire. [Figure 18] FIG. 18 is a perspective view of the U-shaped bracket placed over the messenger wire of FIG. 17 with the bottom cable clamp halves partially installed adjacent to each other on the U-shaped bracket. [Figure 19] FIG. 19 is a perspective view of the U-shaped bracket placed over the messenger wire of FIG. 18 with the bottom cable clamp halves installed adjacent to each other on the U-shaped bracket. [Figure 20] FIG. 20 is a perspective view of the U-shaped bracket of FIG. 19 placed over a messenger wire with the bottom cable clamp half installed on the U-shaped bracket with the cable placed in the bottom cable clamp half. [Figure 21] FIG. 21 is a perspective view of the U-shaped bracket of FIG. 20 placed over a messenger wire with the bottom cable clamp half and cable installed on the U-shaped bracket with the top clamp half placed over the cable. [Figure 22] 22 is a perspective view of the U-shaped bracket placed over the messenger wire with the cable clamp assembly and cable installed on the U-shaped bracket of FIG. 21 with a closure bracket placed on top of the cable clamp assembly. [Figure 23] 8 is a perspective view of the cable management system of FIG. 7 installed on a messenger wire with multiple cables routed within a cable clamp assembly. [Figure 24] 24 is a perspective view of the cable management system of FIG. 23 and a second aligned cable management system routing cable. DETAILED DESCRIPTION OF THE INVENTION

[0006] The present invention is directed to a cable management system 20 for solar applications. The cable management system includes a U-shaped bracket 30 and multiple clamp halves 80 that form a cable clamp (see FIGS. 5-6). The U-shaped bracket 30 provides a stable and secure platform for the polymer cable clamp. Figure 1 shows the U-shaped bracket 30 with one clamp half 80 positioned therein.

[0007] As shown in FIG. 2 , the U-shaped bracket 30 includes a base 32 with a top 34, a bottom 36, a front 38, a rear 40, a first side 42, and a second side 44. Extending from the first and second sides 42, 44 of the base 32 are arms 46. The arms 46 include vertical members 48 that extend to horizontal members 50. Each arm 46 includes a locking slot 52 located at the center of the arm 46. The locking slot 52 includes an enlarged entry end 54 located within the horizontal member 50. The entry end 54 allows the clamp half 80 to be installed within the bracket 30 without manipulating the bracket 30. Each locking slot 52 extends from the entry end 54 of the horizontal member 50, down the center of the vertical member 48, to a circular bottom 56 with a locking tab 58 within the vertical member 48 of each arm 46.

[0008] A messenger wire latch 60 is disposed at the distal end of horizontal member 50 of arm 46. Messenger wire latch 60 secures messenger wire 120 for solar applications. Messenger wire latch 60 includes a vertical member 62 connected to a spring hook 64. Messenger wire latch 60 provides range acquisition capabilities in accepting messenger wires 120 of various diameters. Messenger wire latch 60 facilitates installation and reduces the number of parts required for a cable management system.

[0009] 3, clamp half 80 includes a top portion 82, a bottom portion 84, a front portion 86, a rear portion 88, a first side portion 90, and a second side portion 92. Each side portion 90, 92 of clamp half 80 includes a button pad 94 extending from the center of each side portion 90, 92 via a shaft 96.

[0010] The top 82 of the clamp half 80 includes multiple saddles 100. The saddles 100 are semicircular and include a cushioning insert 102. The cushioning insert 102 has flexible ribs 104, which allow for the use of multiple cables of different diameters or a single cable placed in each of the saddles 100 within a single clamp half 80. The flexible ribs 104 securely hold a variety of cable sizes while preventing damage to the cable. The cushioning insert 102 may be a separate molded component that is manually inserted into the clamp half 80, or the cushioning insert 102 may be manufactured along with the clamp half 80 via an overmolding process.

[0011] The front 86 and rear 88 of the clamp half 80 include a releasable latch 110 with a thumb tab 112. The front 86 and rear 88 of the clamp half 80 also include a notch 114 or opening with a ledge 116. The releasable latch 110 extending from the front 86 of the clamp half 80 aligns with the notch 114 and ledge 116 on the rear 88 of the clamp half 80, and the releasable latch 110 extending from the rear 88 of the clamp half 80 aligns with the notch 114 and ledge on the front 86 of the clamp half 80. As shown in FIGS. 5-6 , the two clamp halves 80 are snapped together by the releasable latches 110 engaging the ledge 116 defined by the notch 114 to create a cable clamp assembly.

[0012] Once the two messenger wires 120 are installed for solar application (not shown), the U-shaped bracket 30 is snapped onto the messenger wires 120. The clamp half 80 is positioned so that the bottom 84 of the clamp half 80 rests on the base 32 of the U-shaped bracket 30, and inserted into the U-shaped bracket 30 with the saddle 100 of the clamp half 80 facing upward. The button pad 94 extending from the sides 90, 92 of the clamp half 80 is inserted into the entrance end 54 of the locking slot 52 of the U-shaped bracket 30. The clamp half 80 slides toward the base 32 of the U-shaped bracket 30 via the button pad 94 in the locking slot 52. As shown in FIG. 1 , the clamp half 80 is locked into place within the U-shaped bracket 30 when the button pad 94 passes through the locking tab 58 of the locking slot 52. The button pad 94 rests on the circular bottom 56 of the locking slot 52. The locking slots 52 also maintain alignment of the clamp halves 80 when multiple clamp halves are installed in a U-shaped bracket.

[0013] As shown in FIG. 4, the first layer of cables 140, 150 is loaded into the clamp half 80. Once the layer of cables 140, 150 is installed, the second clamp half 80 is installed into the U-shaped bracket 30. As shown in FIG. 5, the second or upper clamp half 80 is installed with the saddle 100 facing downward. The two clamp halves 80 are snapped together by the releasable latch 110 engaging the ledge 116 defined by the notch 114 to create the cable clamp assembly. When cable needs to be added or removed, the releasable latch 110 can be quickly and easily pulled open using the thumb tab 112. The installer can unlock the cable halves 80 by pushing the thumb tab 112 inward and pulling the cable clamp assembly apart.

[0014] If desired, additional cable clamp assembly layers are added to the U-shaped bracket 30 using the same installation steps described above. For example, as shown in Figure 6, a second cable clamp assembly with a cable is installed in the U-shaped bracket.

[0015] The cable management system of the present invention provides brackets with locking slots that aid in ease of assembly and attachment of clamp halves. The clamp halves of the present invention ensure cable separation that maintains cable free space. The cable management system of the present invention provides an improved system with minimal components for supporting cables in solar applications.

[0016] 7-24 illustrate an alternative cable management system 200 for routing and managing various cable diameters and gauges. The cable management system 200 includes a U-shaped bracket 230 (FIG. 8) with a messenger wire latch 260, a closure bracket 300 (FIGS. 9-10), and multiple cable clamp halves 380 (FIGS. 11-15).

[0017] As shown in FIG. 8 , the U-shaped bracket includes a base 232 with a top 234, a bottom 236, a front 238, a rear 240, a first side 242, and a second side 244. Extending from the first and second sides 242, 244 of the base 232 are arms 246. The arms 246 include vertical members 248 that extend to horizontal members 250. Each arm 246 includes a slot 252 located at the center of the arm 246. The slot 252 includes an enlarged entry end 254 located within the horizontal member 250. The entry end 254 allows the cable clamp half 380 to be installed within the bracket 230 without manipulating the bracket 230. Each slot 252 extends from the entry end 254 of the horizontal member 250, down the center of the vertical member 248, and to a bottom 256 within the vertical member 248.

[0018] The arm 246 and base 232 each include gussets 270, 274 to provide strength and protection against natural or accidental damage. One gusset 270 extending from each arm includes a closure bracket fastening hole 272. The gussets 270, 274 also support the cable clamp halves 380, keeping them contained within the U-shaped bracket 230.

[0019] A messenger wire latch 260 is disposed at the distal end of horizontal member 250 of arm 246. Messenger wire latch 260 secures messenger wire 120 for solar applications. Messenger wire latch 260 includes a vertical member 262 connected to a spring hook 264. Messenger wire latch 260 provides range acquisition capabilities in accepting messenger wire 120 of various diameters. Messenger wire latch 260 facilitates installation and reduces the number of parts required for a cable management system.

[0020] As shown in FIG. 7, after the cable clamp halves 380 are installed, the closure bracket 300 is installed within the U-shaped bracket 230. As shown in FIGS. 7 and 9, the closure bracket 300 includes a flat member 302 that extends the length of the base 232 of the U-shaped bracket 230. The flat member 302 has a top 304, a bottom 306, a front 308, a rear 310, a first side 312, and a second side 314. The closure bracket 300 includes a flange 316 extending from the front 308 and a flange 322 extending from the rear 310. Each flange 316, 322 includes holes 318, 324 into which PEM nuts 320, 326 are attached. The closure bracket 300 also includes two gussets 328 that extend from the front 308 and rear 310 in opposite directions from the flanges 316, 322. The gussets 328 provide additional strength to the U-shaped bracket. As shown in Figure 10, the flanges 316, 322 of the closure bracket 300 are attached to the U-shaped bracket 230 with fasteners 330 via PEM nuts 320, 326.

[0021] 11-14 show the cable clamp halves 380 that form the cable clamp assemblies 370. Each cable clamp assembly 370 includes two cable clamp halves 380 and four range acquisition buffer inserts 422 (FIG. 15). Each cable clamp assembly 370 is designed to accommodate two cables.

[0022] As shown in FIG. 12 , each cable clamp half 380 includes a top 382, ​​a bottom 384, a front 386, a rear 388, a first side 390, and a second side 392. The first side 390 and second side 392 of each cable clamp half 380 include a button pad 394 and a button pad slot 398. The button pad 394 extends from the first side 390 and second side 392 via a shaft 396. The button pad slot 398 is sized to receive the button pad 394 from an adjacent cable clamp half 380. The button pad slot 398 extends from the top 382 of the cable clamp half 380 to the bottom 384 of the cable clamp half 380. As shown in FIG. 18 , the button pad slot 398 receives the button pad 394 when the cable clamp halves 380 are placed adjacent to one another.

[0023] Each cable clamp half 380 includes two locating bosses 400 or posts and two boss chambers or holes 402. The locating bosses 400 are positioned diagonally from one another and the boss chambers 402 are positioned diagonally from one another such that when the cable clamp halves 380 are attached together, the locating bosses 400 of the bottom cable clamp half are received within the boss chambers 402 of the top cable clamp half.

[0024] Each cable clamp half 380 includes a T-latch 404 at the rear 388 of the cable clamp half 380 and a T-latch slot 412 at the front 386 of the cable clamp half 380. The T-latch 404 includes a release tab 406, a latch stem 408, and two latches 410. The T-latch slot 412 includes two sets of teeth 414 to provide adjustability and enable range acquisition. The center of each cable clamp half 380 has a mounting bolt hole 416, and the bottom 384 of each cable clamp half 380 includes a fastener head relief 418.

[0025] The saddle 420 of the cable clamp half 380 receives a shock absorbing insert 422. As shown in FIG. 15 , the range acquisition shock absorbing insert 422 includes two latches 424. The latches 424 connect the shock absorbing insert 422 to the cable clamp half 380. The shock absorbing insert 422 also includes a plurality of flexible ribs 426 to accommodate variations in range with cable diameter.

[0026] As the cables are installed in the cable management system, there may be areas where the cables are not routed. The cable spacer 450 is installed within the U-shaped bracket 230 to fill these areas (see FIG. 7 ). As shown in FIGS. 16A-16B , the cable spacer 450 includes a front portion 452, a rear portion 454, a top portion 456, a bottom portion 458, a first side portion 460, and a second side portion 462. The first side portion 460 and the second side portion 462 include a button pad 464 extending from each side via a shaft 466 and a button pad slot 468 extending from the top portion 456 to the bottom portion 458 of the cable spacer 450. The button pad 464 and the button pad slot 468 mate with the button pad 464 and the button pad slot 468 of an adjacent cable clamp half 380 within the cable management system 370.

[0027] 17-24 illustrate the installation of the cable management system. Installation begins by hanging the U-shaped bracket 230 on the messenger wire 120 via the messenger wire latches 260 on either side of the U-shaped bracket 230. The bottom cable clamp halves 380 or the first row of cable spacers 450 are inserted into the U-shaped bracket 230. The button pads 394 extending from the sides of the cable clamp halves 380 slide into the slots 252 in the arms 246 of the U-shaped bracket 230. Adjacent bottom cable clamp halves 380 are connected to each other using the button pads 394 and button pad slots 398. Once the first row of cable clamp halves 380 is installed, the first row of cables 140 is seated on the shock-absorbing inserts 422 of the cable clamp halves 380. Next, the top cable clamp half 380 is installed into the U-shaped bracket 230 over the cables 140. Adjacent top cable clamp halves 380 are connected to each other using button pads 394 and button pad slots 398. The top cable clamp halves are secured to the bottom cable clamp halves via T-latches 404 and T-latch slots 412. The closure bracket 300 can be installed on the cable clamp assembly when the U-shaped bracket 230 is one-third, two-thirds, or fully loaded. If the number of cables to be installed is less than the number of available cable clamp openings, cable spacers 450 are used to fill the rows. As described above, the cable spacers 450 are connected to adjacent cable clamp halves 380 by button pads 464, 394 and button pad slots 468, 398, respectively. Alternatively, the cable clamp halves 380 may be left empty. The installation process continues as needed until all cables in the system have been routed.

[0028] The cable management systems of Figures 7-24 provide cable diameter compensation with buffer inserts and variable cable gauges that range across the row and across the cable clamp array. Each cable clamp half routes one circuit of two cables for AC or DC power.

[0029] The cable clamp halves slide easily within the U-shaped bracket and secure to each other. No special tools are required. Alignment bosses allow for easy mating of the cable clamp halves, and adjustment teeth allow for cable placement within the cable clamp halves. The cable management system's rugged design withstands inclement weather and accidental damage.

[0030] While certain preferred embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the teachings of the present invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of example only, and not by way of limitation. The actual scope of the present invention is intended to be defined by the following claims when viewed in their proper perspective based on the prior art.

Claims

1. 1. A cable management system for supporting cables in solar applications, comprising: a one-piece U-shaped bracket having a base with two arms, each arm including a slot extending the length of the arm; a plurality of cable clamp assemblies disposed within the U-shaped bracket, each cable clamp assembly including a first cable clamp half having a top, a bottom, a front, a back, and sides, and a second cable clamp half having a top, a bottom, a front, a back, and sides, each side of the first cable clamp half including a button pad and a button pad slot, and each side of the second cable clamp half including a button pad and a button pad slot, at least one button pad sliding within one of the slots of one of the arms to position the first cable clamp half and the second cable clamp half within the U-shaped bracket, and at least one button pad disposed in the button pad slot of an adjacent first or second cable clamp half; The cable management system, wherein the first cable clamp half and the second cable clamp half are connected to form the cable clamp assembly.

2. The cable management system of claim 1 , wherein the first cable clamp half and the second cable clamp half separate the cables installed in the U-shaped bracket.

3. 2. The cable management system of claim 1, wherein the front portion of the first cable clamp half has a T-latch slot, the rear portion of the first cable clamp half has a T-latch, the front portion of the second cable clamp half has a T-latch slot, and the rear portion of the second cable clamp half has a T-latch.

4. The cable management system of claim 1 , wherein the first cable clamp half and all second cable clamp halves have a plurality of saddles for retaining cables.

5. The cable management system of claim 4 , wherein the saddle has a compression insert with ribs for accommodating cables having different diameters.

6. The cable management system of claim 1 , wherein the at least one button pad extends through the slot in one of the arms and remains disposed adjacent an outer surface of the arm.

7. 10. The cable management system of claim 1, wherein the U-shaped bracket further includes a messenger wire latch for securing a messenger wire in a solar application, the messenger wire latch having a vertical member and a spring hook.

8. The cable management system of claim 7 , wherein the messenger wire latch provides a range of acquisition capabilities to accommodate messenger wires of various diameters.

9. The cable management system of claim 1 , wherein each slot in the arm of the U-shaped bracket has an entry end and a bottom.

10. The cable management system of claim 1 , wherein each arm of the U-shaped bracket has a vertical member and a horizontal member.

11. 11. The cable management system of claim 10, wherein each slot has an entry end in the horizontal member of each arm, the entry ends enabling installation of the first cable clamp half and the second cable clamp half without manipulating the U-shaped bracket.

12. The cable management system of claim 10 , wherein each slot extends down the center of the vertical member of each arm of the U-shaped bracket.

13. The cable management system of claim 10 , wherein each slot extends from an entry end of the horizontal member of the arm to a bottom of the vertical member of the arm.

14. The cable management system of claim 1 , wherein the U-shaped bracket includes gussets extending from the arms and the base to provide strength to the U-shaped bracket.

15. The cable management system of claim 1 , further comprising a closure bracket disposed over the plurality of cable clamp assemblies.

16. The cable management system of claim 15, wherein the closure bracket is a flat member having a flange extending in one direction and a gusset extending in an opposite direction from the flange.

17. 17. The cable management system of claim 16, wherein the U-shaped bracket includes gussets extending from the arms and the base to provide strength to the U-shaped bracket, and the flange of the closure bracket is secured to a gusset extending from the arm of the U-shaped bracket.

18. The cable management system of claim 1 , further comprising a cable spacer disposed between the cable clamp assemblies.

19. 20. The cable management system of claim 18, wherein the cable spacer has a top, a bottom, a front, a back, and sides, each side of the cable spacer including a button pad and a button pad slot, the button pad of the cable spacer being positioned in one of the button pad slots of a first or second cable clamp half.

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