GB2543510A

GB2543510A - Coupler

Info

Publication number: GB2543510A
Application number: GB1518469.0A
Authority: GB
Inventors: Austin Grahame; Parry Jac
Original assignee: Marco Gearing Ltd
Current assignee: Marco Gearing Ltd
Priority date: 2015-10-19
Filing date: 2015-10-19
Publication date: 2017-04-26
Anticipated expiration: 2035-10-19
Also published as: GB2543510B; GB201518469D0

Abstract

A coupler 10, for attaching a first wire mesh tray 102 to a second wire mesh tray 102, comprising; a first end region (14, figure 1) and a second end region (16); a first engagement element 18 being adapted for engagement with a first wire portion 106b of the first wire mesh tray; a second engagement element (26) being adapted for engagement with a second wire portion 106a of the first wire mesh tray; and a third engagement element 30 being adapted for engagement with a first wire portion 106a of a second wire mesh tray 102. Preferably the second engagement element comprises hooks and is connected to the second wire portion of the first wire mesh tray first, the coupler then pivots around the second wire portion to engage the first engagement element with the first wire portion of the first wire mesh tray. Once both couplers 10 and 10 are attached the second wire mesh tray is coupled into the third engagement elements of the couplers.

Description

COUPLER

The present invention relates to a coupler for assembly of wire mesh cable trays. In particular, the present invention relates to a coupler that provides improved ease of assembly of wire mesh cable trays.

Cable support systems are conventionally used during installation of cables within a building to guide and hold cables in the required position. Cable support systems typically comprise a plurality of cable trays and a coupling device for joining the trays together. Conventional cable trays comprise elongated tray members having a shallow U-shaped cross-section. Conventional cable trays comprise a plurality of wires extending parallel to the longitudinal axis of the elongate tray member and a plurality of wires extending substantially transverse to the longitudinal axis of the elongate tray member. During installation, the cable trays are aligned and connected together by one or more coupling devices. The coupling devices are conventionally secured to or between adjacent wires extending parallel and/or perpendicular to the longitudinal axes of each of the adjacent elongate tray members.

However, some couplers comprise multiple components which require assembly around the trays in order to achieve coupling of the trays. This increases the cost of manufacture and the time and cost of installation. Other couplers are of single component design. However, these can be difficult to secure in place, requiring the use of tools such as specialist assembly tools or screwdrivers and the like, thereby requiring time and effort on the part of the installer to engage the couplers in place relative to the wire mesh trays. In an effort to address this, single component couplers have been developed which fully extend around the wires of the mesh trays. However, often these couplers are located on the inner surfaces of the mesh trays and, due to the methods of engagement employed by the couplers, it can be difficult to fit them in place and require significant time and effort by the installer.

There is therefore a need for a coupler with improved design that allows easier assembly of wire mesh cable trays.

The present invention seeks to address the problems of the prior art. A first aspect of the present invention provides a coupler for attaching a first wire mesh tray to a second wire mesh tray, the coupler comprising an elongate body defining a longitudinal axis and having a first end region and a second end region separated longitudinally from the first end region; a first engagement element which extends from the first end region of the body, and which defines a first engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the first engagement portion being adapted for engagement with a first wire portion of a first wire mesh tray; a second engagement element which extends from the second end region of the body, and which defines a second engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the second engagement portion being adapted for engagement with a second wire portion of a first wire mesh tray; and a third engagement element which extends from the second end region of the body, and which defines a third engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the third engagement portion being adapted for engagement with a first wire portion of a second wire mesh tray.

As all the engagement elements extend from the body, it is possible to manufacture the coupler from a single piece of metal, cut to form the various engagement elements which are subsequently bent into the correct position to engage with the wire mesh tray.

In one embodiment, the first engagement element, the second engagement element and the third engagement element extend from the body in the same direction. This provides the advantage that the coupler can be engaged with the wire mesh tray from a single direction and can therefore be a one piece component, rather than a multi-piece component that requires attachment to the wire mesh tray from different directions.

Preferably, the first engagement element, the second engagement element and the third engagement element extend from the body in a direction towards the first and second wire mesh trays. This allows the coupler to be applied to and engaged with the wire mesh tray from the outside of the wire mesh tray. This permits ease of installation as an installer can easily access the outside of the wire mesh trays to attach the couplers.

The coupler is preferably adapted to extend between longitudinal wires on the first tray. By extending between longitudinal wires and only engaging with the transverse wires, the installation process is significantly simplified. In addition, the coupler sits between the longitudinal wires, which is a convenient assistance in accurately locating the couplers in place. This will keep them positioned in parallel and the presence of the longitudinal wires will prevent any slipping of the coupler along the transverse wires, once located in place, thereby strengthening the assembly.

The coupler may also be adapted to extend between longitudinal wires on the second tray. Thus, all the advantages set out above are also provided with respect to the second tray. Further, it assists with ensuring that the trays are engaged in good alignment with one another.

In a further embodiment, the coupler further comprises a longitudinal abutment extending from the body between the first and second engagement elements in an opposing direction to the first and second engagement elements, the longitudinal abutment being adapted to locate adjacent a third wire portion of the first wire mesh tray, the third wire portion extending in a direction perpendicular to the first and second wire portions. The third wire portion would typically be a longitudinal wire of the wire mesh tray i.e. extending perpendicular to the transverse wires to which the couplers would typically be engaged. The abutment serves to contact the longitudinal wire when the coupler is engaged, thus strengthening the assembly without the disadvantages and complications of a more complex engagement arrangement between the coupler and the longitudinal wires of the wire mesh trays.

Preferably, the second engagement element comprises a hook element adapted to extend around the second wire portion of the first wire mesh tray. The hook allows the coupler to engage a wire of the wire mesh tray from a specific orientation and then subsequently rotate about that wire, whilst remaining in engagement with the wire so as to orient the coupler correctly for engagement with a further wire of the wire mesh tray. However, it is to be appreciated that alternative arrangements known to the skilled person and appropriate to achieve the same purpose may be envisaged, such as a channel or other formation that extends partially around the wire.

The second element may comprise a plurality of hook elements, each hook element adapted to extend around the second wire portion of the first wire mesh tray. By having more than one hook element, the wire may be located more stably within the second engagement member whilst minimising the weight and thus the cost (whilst increasing the ease of handling) than one solid hook that extends from the body fully across the full distance of the coupler body in a direction transverse to the longitudinal axis defined by the coupler body.

In a further embodiment, the second engagement element and the third engagement element define a recess there-between, the recess being adapted to receive a portion of the first wire portion of the second wire mesh tray therein. It will be appreciated that, as an alternative, the third engagement element may be arranged so as to provide a recess without relying on the second engagement member to define a recess therebetween. However, the present arrangement increases the simplicity of the design and the ease of manufacture, whilst minimising the cost of materials and the coupler weight, without compromising the strength of the coupler.

Preferably, the recess is adapted to releasably receive a portion of the first wire portion of the second wire mesh tray therein. This provides versatility as the wire mesh tray assembly may be assembled and disassembled at will.

The coupler will typically be composed of metal. However, it is to be appreciated that the coupler may comprise any other material known to the skilled person and suitable for the function. For example, the couple may comprise any suitable plastic material or carbon fibre material that is sufficiently strong to couple the wire mesh trays to which it is to be engaged.

The wire mesh trays described herein are typically comprised of metal. However, it is to be appreciated that the coupler will function as described with a mesh tray of any suitable material provided that the coupler and mesh tray are suitably dimensioned for engagement with one another. A second aspect of the present invention provides a wire mesh tray assembly comprising a first wire mesh tray and a coupler according to a first aspect of the present invention, wherein the first engagement element of the coupler is engaged with the first wire portion of the first wire mesh tray and the second engagement element of the coupler is engaged with the second wire portion of the first wire tray. In this way, the wire mesh trays may be provided to an installer with the coupler already engaged with a wire mesh tray, thereby speeding up the wire tray assembly operation. The installer simply has to engage a further wire mesh tray with the tray-coupler assembly. This increases the ease of installation as well as saving a significant amount of time on the part of the installer.

The wire mesh tray assembly may further comprise a second wire mesh tray, wherein the third engagement element of the coupler is engaged with the first wire portion of the second wire mesh tray. A third aspect of the present invention provides a method of engaging a coupler according to a first aspect of the present invention with a wire mesh tray, the method comprising: (a) providing a coupler according to a first aspect of the present invention; (b) providing a first wire mesh tray with a first wire portion and a second wire portion parallel to the first wire portion; (c) engaging the second engagement element of the coupler with the second wire portion; (d) pivoting the coupler about the second engagement element to bring the first wire engagement element and the first wire portion into communication; and (e) applying force to the coupler in a direction towards the first wire portion to engage the first wire engagement element and the first wire portion into engagement with one another.

As described, no tools are required during the engagement of the coupler with a wire mesh tray. An installer can simply engage the coupler with a wire mesh tray by suitably orienting the coupler relative to the tray and applying modest pressure to the coupler to finalise the engagement and secure the coupler in place.

Preferably, the first wire mesh tray is further provided with a third wire portion opposing the first wire portion and a fourth wire portion opposing the second wire portion, the method further comprising the steps of: (f) providing a second coupler according to a first aspect of the present invention; (g) engaging the second element of the second coupler with the fourth wire portion; (h) pivoting the second coupler about the second engagement element to bring the first wire engagement element of the second coupler and the third wire portion into communication; and (e) applying force to the coupler in a direction towards the third wire portion to engage the first wire engagement element and the third wire portion into engagement with one another.

Thus, two couplers may be engaged with the wire mesh tray. A fourth aspect of the present invention provides a method of coupling a first and second wire mesh tray, the method comprising; (a) carrying out the method of claim 14; (b) providing a second wire mesh tray with a first wire portion and a second wire portion opposing the first wire portion; (c) applying force to bring the first and second wire portions of the second wire mesh tray towards one another; (d) aligning the first and second wire portions of the second wire mesh tray with the second wire engagement elements of the first and second couplers, respectively; and (h) releasing the force to bring the first wire portion of the second wire mesh tray into engagement with the second wire engagement element of the first wire mesh tray and the to bring the second wire portion of the first wire tray into engagement with the fourth wire engagement element of the first wire mesh tray.

The coupling of two adjacent wire mesh trays using a coupler according to the present invention may therefore be achieved without the use of any tools. All that is required is the application of modest force by an installer to the appropriate portions of the coupler during the installation process in order to secure the coupler in place relative to the two wire mesh trays, thereby achieving secure coupling of the trays with one another.

Preferably, the one or more couplers is releasable engaged with the one or more mesh wire trays. Thus, each wire mesh tray may be disengaged from the coupler by application of suitable force to release the coupler from engagement with the trays.

Embodiments of the present invention will now be described by way of example only and with reference to the following figures in which:

Figure 1 is a perspective view from the front of a one embodiment of a coupler in accordance with the present invention;

Figure 2 is a perspective view from the rear of the coupler of figure 1;

Figure 3 is a rear view of the coupler of figure 1;

Figure 4 is a front view of the couple of figure 1;

Figure 5 is a plan view from a first end of the coupler of figure 1;

Figure 6 is a plan view from a second opposing of the couple of figure 1;

Figure 7 is a side view of the couple of figure 1;

Figure 8 is a perspective view of the coupler of figure 1 being aligned for engagement with a first wire mesh tray;

Figure 9 is a perspective view of the coupler of figure 1 in engagement with the first wire mesh tray;

Figure 10 is a perspective view of the couple and wire mesh tray of figure 9 partially engaged with a second mesh tray;

Figure 11 is a perspective view of two wire mesh trays coupled together with two of the couplers of figure 1;

Figure 12 is an enlarged view of a portion of figure 11.

Figures 1 to 7 show a coupler 10 comprising an elongate body 12 having a first end region 14 and a second end region 16 opposing the first end region 14. First end region 14 comprises a first engagement member 18 extending therefrom. First engagement member 18 comprises a first curved element 19 extending from elongate body 12 and curving towards second end region 16. First engagement member 18 further comprises a second curved element 20 which extends from elongate body and curves in a direction towards the first curved element 19. First and second curved elements 19, 20 define first engagement portion 21 which is dimensioned to receive a wire 100 of a wire mesh tray 102 therein.

First curved element 19 is further provided with an abutment 22 creating a gap 24 of slightly smaller dimension that the cross-section of wire 100. First curved element 21 is further provided with a guide 25 to guide the wire 100 of a wire mesh tray 102 towards the abutment 22 and first engagement portion 21. Thus, force must be applied to the wire mesh tray 102 to slightly deflect abutment 22 and increase the gap 24 so that wire 100 may be forced past abutment 22 and through gap 24 into first engagement portion 20. Once wire 100 has passed abutment 22, abutment 22 returns to its initial position, thus retaining wire 100 is retained within first engagement portion 20.

Second end region 16 of coupler 10 comprises a second engagement element 26 which extends from the second end region 16 of elongate body 12. In the embodiment shown in the figures, second engagement element 26 comprises two hooks 28, 28’ which extend away from elongate body 12. Hooks 28, 28’ are parallel to one another and are located on opposing edges of elongate body 12. Hooks 28. 28’ define a second engagement portion 27 dimensioned to extend around a portion of a wire 100 of a wire mesh tray 102.

Second end region 16 of coupler 10 further comprises a third engagement element 30 which extends from the second end region 16 of elongate body 12. Third engagement element 30 is formed as a two integral portions, the first portion comprising a curved element 32 with a curvature dimensioned to fit a portion of the external contours of a wire 100’ of a second wire mesh tray 102’. The second portion of the third engagement element 30 is a guide element 34 that extends from the first portion and provides a guide surface adapted to guide wire 100’ into third engagement portion 36.

Wire mesh trays 102,102’ comprise a channel formed from a plurality of longitudinal wires 104 and a plurality of intersecting transverse wires 106,106’.

Figures 8 and 9 show the engagement of couplers 10, 10’ with wire mesh tray 102.

Coupler 10 is aligned with wire mesh tray 102 in a suitable orientation so as to bring hooks 28, 28’ into engagement with transverse wire 106a. Once hooks 28, 28’ are located around wire 106a, coupler 10 is rotated about wire 106a to bring first engagement member 18 towards transverse wire 106b. Transverse wire 106b is then guided via guide 25 towards abutment 22. Force is then applied in the direction shown by arrow A to push coupler 10 towards wire 106b until wire 106b is pushed past abutment 22, through gap 24 and into first engagement portion 21. Wire 106b is retained in place in first engagement portion 21 by means of abutment 22.

Thus, coupler 10 is fitted securely onto wire mesh tray 102.

Figure 10 shows a second coupler 10’ fitted to opposing portions of transverse wires 106a, 106b so that each coupler 100 is securely positioned in place opposite one another on wire mesh tray 102. The second coupler 10’ is fitted to the wire mesh tray 102 in the same way as described above. Due to the fact that coupler 10’ is being fitted to an opposing side of wire mesh tray 102, coupler 10 will require inverting prior to fitting in order that, once engaged, it is fitted as a mirror image of the first coupler i.e. both couplers are facing one another and the elongate body 12 of each coupler extends longitudinally with respect to the wire mesh tray 102 and is fitted from the outside of the wire mesh tray 102 i.e. the elongate body 102 extends along the outside of each side of wire mesh tray 102, with the transverse wires 106a, 106b located between the couplers 10,10’.

Figure 10 shows a second wire mesh tray 102’ engaged with coupler 10. This can be seen in an enlarged view in figure 12. Transverse wire 106’a is oriented so as to come into alignment with guide element 34 of third engagement element 30 and is guided into position in third engagement portion 36. To engage the opposing side of wire mesh tray 102’ with the second coupler 10’, it is necessary to apply inward pressure to the opposing side of wire 106’a. This can be done by applying pressure to opposing longitudinal wires 104,104’ in order to bring wire 106’a into alignment with guide element 34’ of third engagement element 30 and is guided into position in third engagement portion 36’. Pressure on the wire mesh tray 102’ can then be released and wire mesh tray 102’ will be retained, under tension, in place relative to couplers 10, 10’.

Thus the two wire mesh trays 102,102’ are now coupled by means of couplers 10, 10’.

To disengage the wire mesh trays 102,102’ from one another, it is necessary to reapply pressure to bring the opposing sides of transverse wire 106’a together and then rotating wire mesh tray 102’ about the engagement point with coupler 10’ to remove transverse wire 106’a from third engagement portion 36’. The pressure can then be released and the opposing end of transverse wire 106’a simply removed from the third engagement portion 36 of coupler 10. Couplers 10, 10’ will remain in secure engagement with wire mesh tray 10.

Couplers 10 maybe provided, as described above, as stand-alone items for use during installation of wire mesh tray assemblies. However, it is to be appreciated that wire mesh trays may be supplied with couplers already in place, ready for engagement with a second wire mesh tray, as described above, during the installation process. This is an efficient way to save a lot of installation time and effort as the coupling operation is more than half completed, with only the final engagement of the adjacent wire mesh tray to be undertaken.

The present invention also permits simple disassembly of wire mesh assemblies without the need for specific skill or any tools. All that is required is the application of manual pressure to one end of the wire mesh tray.

Claims

1. A coupler for attaching a first wire mesh tray to a second wire mesh tray, the coupler comprising: an elongate body defining a longitudinal axis and having a first end region and a second end region separated longitudinally from the first end region; a first engagement element which extends from the first end region of the body, and which defines a first engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the first engagement portion being adapted for engagement with a first wire portion of a first wire mesh tray; a second engagement element which extends from the second end region of the body, and which defines a second engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the second engagement portion being adapted for engagement with a second wire portion of a first wire mesh tray; and a third engagement element which extends from the second end region of the body, and which defines a third engagement portion having an engagement axis substantially perpendicular to the longitudinal axis of the body, the third engagement portion being adapted for engagement with a first wire portion of a second wire mesh tray.

2. A coupler as claimed in claim 1, wherein the first engagement element, the second engagement element and the third engagement element extend from the body in the same direction.

3. A coupler as claimed in claim 2, wherein the first engagement element, the second engagement element and the third engagement element extend from the body in a direction towards the first and second wire mesh trays.

4. A coupler as claimed in any preceding claim, wherein the coupler is adapted to extend between longitudinal wires on the first tray.

5. A coupler as claimed in any preceding claim, wherein the coupler is adapted to extend between longitudinal wires on the second tray.

6. A coupler as claimed in claim 5, wherein the coupler further comprises a longitudinal abutment extending from the body between the first and second engagement elements in an opposing direction to the first and second engagement elements, the longitudinal abutment adapted to locate adjacent a third wire portion of the first wire mesh tray, the third wire portion extending in a direction perpendicular to the first and second wire portions.

7. A coupler as claimed in any preceding claim, wherein the second engagement element comprises a hook element adapted to extend around the second wire portion of the first wire mesh tray.

8. A coupler as claimed in claim 7, wherein the second element comprises a plurality of hook elements, each hook element adapted to extend around the second wire portion of the first wire mesh tray.

9. A coupler as claimed in any preceding claim, wherein the second engagement element and the third engagement element define a recess there-between, the recess being adapted to receive a portion of the first wire portion of the second wire mesh tray therein.

10. A coupler as claimed in claim 9, wherein the recess is adapted to releasably receive a portion of the first wire portion of the second wire mesh tray therein.

11. A wire mesh tray assembly comprising a first wire mesh tray and a coupler as claimed in any preceding claim, wherein the first engagement element of the coupler is engaged with the first wire portion of the first wire mesh tray and the second engagement element of the coupler is engaged with the second wire portion of the first wire tray.

12. A wire mesh tray assembly as claimed in claim 12, further comprising a second wire mesh tray, wherein the third engagement element of the coupler is engaged with the first wire portion of the second wire mesh tray.

13. A method of engaging a coupler according to any one of claim 1 to 10 with a wire mesh tray, the method comprising: (a) providing a coupler as claimed in any one of claims 1 to 10; (b) providing a first wire mesh tray with a first wire portion and a second wire portion parallel to the first wire portion; (c) engaging the second engagement element of the coupler with the second wire portion; (d) pivoting the coupler about the second engagement element to bring the first wire engagement element and the first wire portion into communication; and (e) applying force to the coupler in a direction towards the first wire portion to engage the first wire engagement element and the first wire portion into engagement with one another.

14. A method according to claim 13, wherein the first wire mesh tray is further provided with a third wire portion opposing the first wire portion and a fourth wire portion opposing the second wire portion, the method further comprising the steps of: (f) providing a second coupler as claimed in any one of claims 1 to 10; (g) engaging the second element of the second coupler with the fourth wire portion; (h) pivoting the second coupler about the second engagement element to bring the first wire engagement element of the second coupler and the third wire portion into communication; and (e) applying force to the coupler in a direction towards the third wire portion to engage the first wire engagement element and the third wire portion into engagement with one another.

15. A method of coupling a first and second wire mesh tray, the method comprising; (a) carrying out the method of claim 14; (b) providing a second wire mesh tray with a first wire portion and a second wire portion opposing the first wire portion; (c) applying force to bring the first and second wire portions of the second wire mesh tray towards one another; (d) aligning the first and second wire portions of the second wire mesh tray with the second wire engagement elements of the first and second couplers, respectively; and (h) releasing the force to bring the first wire portion of the second wire mesh tray into engagement with the second wire engagement element of the first wire mesh tray and the to bring the second wire portion of the first wire tray into engagement with the fourth wire engagement element of the first wire mesh tray.

16. A method as claimed in any one of claims 13 to 16, wherein the one or more couplers is releasable engaged with the one or more mesh wire trays.