U.S. patent application number 10/227958 was filed with the patent office on 2003-03-13 for base pad having a leveling system and a method for manufacturing the same.
This patent application is currently assigned to Custom Composites, Inc.. Invention is credited to Mattson, Robert O., Peter, Lawrence A. St..
Application Number | 20030047658 10/227958 |
Document ID | / |
Family ID | 26921910 |
Filed Date | 2003-03-13 |
United States Patent
Application |
20030047658 |
Kind Code |
A1 |
Peter, Lawrence A. St. ; et
al. |
March 13, 2003 |
Base pad having a leveling system and a method for manufacturing
the same
Abstract
The invention provides a support structure for supporting
electrical equipment. The support structure includes a top surface
adapted to have the electrical equipment mounted thereto, and a
level element recessed within a portion of the support structure to
provide a visual indication of whether the top surface is
horizontally oriented.
Inventors: |
Peter, Lawrence A. St.;
(Hubble, MI) ; Mattson, Robert O.; (Chassell,
MI) |
Correspondence
Address: |
Daniel S. Jones
Michael Best & Friedrich LLP
100 East Wisconsin Avenue
Milwaukee
WI
53202-4108
US
|
Assignee: |
Custom Composites, Inc.
Baraga
MI
|
Family ID: |
26921910 |
Appl. No.: |
10/227958 |
Filed: |
August 26, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60315155 |
Aug 27, 2001 |
|
|
|
Current U.S.
Class: |
248/346.01 ;
248/678; 33/379 |
Current CPC
Class: |
H02B 1/50 20130101; F16M
11/22 20130101; H02B 1/011 20130101 |
Class at
Publication: |
248/346.01 ;
248/678; 33/379 |
International
Class: |
B65D 019/00; A47G
029/00 |
Claims
1. A support structure for supporting electrical equipment, the
support structure comprising: a plurality of side walls; a top
surface connected to the plurality of side walls; and a leveling
system for providing a visual indication of whether the top surface
is horizontally oriented.
2. The support structure as claimed in claim 1, further comprising
a base and wherein the plurality of side walls extend generally
upward from the base at an obtuse angle from the base.
3. The support structure as claimed in claim 1, wherein the support
structure is frusto-pyramidical in shape.
4. The support structure as claimed in claim 1, wherein the
leveling system includes a bubble level.
5. The support structure as claimed in claim 1, wherein the top
surface includes a recess and the leveling system includes a bubble
level, the bubble level being positioned within the recess.
6. The support structure as claimed in claim 5, wherein the bubble
level is positioned in the recess such that no part of the bubble
level protrudes above the top surface.
7. The support structure as claimed in claim 1, further comprising
a base flange and a cable opening, the base flange extending out
from a bottom edge of the plurality of side walls, the base flange
framing sides and top of the cable opening such that the cable
opening is an open slot.
8. The support structure as claimed in claim 7, wherein the top of
the cable opening is substantially parallel to the top surface and
includes a recess, the leveling system including a bubble level
that is positionable within the recess.
9. The support structure as claimed in claim 8, wherein no portion
of the bubble level protrudes out of the recess.
10. The support structure as claimed in claim 1, further comprising
a base that includes a recess, the leveling system including a
bubble level that is positionable in the recess such that no
portion of the bubble level protrudes above the base.
11. The support structure as claimed in claim 1, further comprising
a plurality of ribs coupled to and extending generally vertically
along the plurality of side walls.
12. The support structure as claimed in claim 1, further comprising
an opening in the top surface to accommodate electrical connections
to the electrical equipment, the electrical equipment being
supported by the top surface.
13. A support structure for supporting electrical equipment, the
support structure comprising: a top surface adapted to have the
electrical equipment mounted thereto; a recess defined in a portion
of the support structure; and a level element positioned in the
recess such that no portion of the level element protrudes out of
the recess, the level element providing a visual indication of
whether the top surface is horizontally oriented.
14. The support structure as claimed in claim 13, wherein the
recess is defined in the top surface.
15. The support structure as claimed in claim 13, further
comprising a plurality of side walls, a base flange, and a cable
opening, the base flange extending out from a bottom edge of the
plurality of side walls and framing sides and top of the cable
opening such that the cable opening is an open slot.
16. The support structure as claimed in claim 15, wherein the top
of the cable opening is substantially parallel with the top surface
and wherein the recess is defined in the top of the cable
opening.
17. The support structure as claimed in claim 13, further
comprising a base flange that is substantially parallel to the top
surface, the recess being defined in the base flange.
18. The support structure as claimed in claim 13, wherein the level
element includes a bubble level.
19. The support structure as claimed in claim 18, wherein the
bubble level includes a longitudinal axis that is substantially
parallel to the top surface when the bubble level is positioned in
the recess.
20. The support structure as claimed in claim 13, further
comprising a plurality of side walls coupled to the top surface and
a plurality of ribs coupled to and extending generally vertically
along the plurality of side walls.
21. The support structure as claimed in claim 13, further
comprising an opening in the top surface to accommodate electrical
connections to the electrical equipment, the electrical equipment
being supported by the top surface.
22. A method of manufacturing a support structure for supporting
electrical equipment, the method comprising: providing a mold for
the support structure, the mold including a recess-defining
protrusion; introducing a molding material into the mold; curing
the molding material into the shape of the support structure within
the mold and forming a level recess in the support structure around
the recess-defining protrusion; removing the support structure from
the mold; and inserting a level element into the level recess.
23. The method as claimed in claim 22, wherein providing a mold
further includes integrally forming the recess-defining protrusion
with the mold.
24. The method as claimed in claim 22, wherein providing a mold
further includes providing a capsule and mounting the capsule to
the mold to define the recess-defining protrusion.
25. The method as claimed in claim 24, wherein providing a capsule
further includes positioning a flat surface of the capsule against
the mold and spacing a round surface of the capsule away from the
mold, the round surface of the capsule being complementary to the
level element shape.
26. The method as claimed in claim 24, wherein mounting the capsule
further includes affixing the capsule within the mold with an
adhesive.
27. The method as claimed in claim 22, wherein inserting a level
element further includes inserting a level element into the level
recess such that no portion of the level element protrudes out of
the level recess.
28. The method as claimed in claim 22, wherein providing a mold
includes forming the recess-defining protrusion out of
aluminum.
29. The method as claimed in claim 22, further comprising applying
a release agent to the mold after providing a mold and prior to
introducing a molding material.
30. The method as claimed in claim 29, further comprising applying
a gelcoat over the release agent prior to introducing the molding
material.
31. The method as claimed in claim 22, wherein introducing a
molding material into the mold further includes introducing a
molding material into the mold with a chopper gun.
32. The method as claimed in claim 22, further comprising placing a
plurality of ribs into the molding material after introducing the
molding material into the mold and prior to completion of the
curing step.
33. The method as claimed in claim 22, further comprising
compressing the molding material in the mold to ensure the molding
material is substantially uniform and to remove air bubbles from
the molding material.
34. The method as claimed in claim 22, wherein introducing a
molding material further includes introducing fiberglass, resin,
and a catalyst into the mold.
35. The method as claimed in claim 22, wherein inserting a level
element into the level recess further includes inserting a bubble
level into the level recess.
Description
SUMMARY
[0001] The present invention provides an electrical equipment
support structure including a plurality of side walls, a top
surface connected to the plurality of side walls, and a leveling
system for providing a visual indication of whether the top surface
is horizontally oriented.
[0002] The present invention also provides a support structure that
supports electrical equipment. The support structure includes a top
surface adapted to have the electrical equipment mounted thereto, a
recess defined in a portion of the support structure, and a level
element positioned in the recess such that no portion of the level
element protrudes out of the recess. The level element provides a
visual indication of whether the top surface is horizontally
oriented.
[0003] The present invention further provides a method of
manufacturing a support structure for supporting electrical
equipment. The method includes providing a mold having a
recess-defining protrusion, introducing a molding material into the
mold, curing the molding material into the shape of the support
structure within the mold and forming a level recess in the support
structure around the recess-defining protrusion, removing the
support structure from the mold, and inserting a level element into
the level recess.
[0004] Other features and advantages of the invention will become
apparent to those skilled in the art upon review of the following
detailed description, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a base pad embodying the
invention.
[0006] FIG. 2 is a sectional view along line 2-2 in FIG. 1.
[0007] FIG. 3 is a cut-away perspective view of a level recess of
the base pad.
[0008] FIG. 4 is a perspective view of a capsule of the base pad
mold.
[0009] FIG. 5 is a partial sectional view of the capsule and a
mold.
[0010] FIG. 6 is a partial sectional view of the mold, the capsule,
a portion of the base pad, and a chopper gun.
[0011] FIG. 7 is a perspective view of an alternative construction
of the base pad.
[0012] FIG. 8 is a perspective view of an alternative construction
of the base pad.
DETAILED DESCRIPTION
[0013] FIG. 1 illustrates a molded support structure or base pad 20
used to support electrical equipment 24 (shown in phantom). The
electrical equipment 24 may be, for example, transformers,
switchgears, sectionalizing cabinets, meters, splice connections
and is typically used by electric, cable, telephone, and similar
utilities. The invention may also be embodied in other types of
electrical equipment support structures, including, but not limited
to box pads, groundsleeves, boxes with removable covers, vaults,
and foundations. The base pad 20 includes an integrally-molded base
or base flange 28 that provides stability to the base pad 20 and
the equipment 24 mounted to the base pad 20.
[0014] Integrally-molded side walls 36 extend generally up from the
flange 28 at a generally obtuse draft angle from the horizontal
flange 28. In this regard, the base pad 20 is generally
frusto-pyramidical in shape. The frusto-pyramidical shape
facilitates removal of the base pad 20 from a mold (discussed in
greater detail below), and also stacking and storage of multiple
base pads 20. The side walls 36 may alternatively extend vertically
up from the flange 28 and not at an obtuse angle to give the base
pad 20 a more cubic shape. The side walls 36 include
molded-in-place ribs 40 that provide extra strength to the base pad
20, therefore allowing the base pad 20 to be molded with less
material. The ribs 40 protrude from and extend along the side walls
36. The ribs 40 initiate near the flange 28 and terminate near the
top of the side walls 36.
[0015] Cable openings 44 are defined in the side walls 36 at a
bottom portion of the pad 20. The cable openings 44 communicate
with a cavity 48 defined by the side walls 36. The cable openings
44 have side walls 52 extending generally vertically up from the
flange surface 28, or at an angle thereto to facilitate molding,
and a top wall 56 that is generally parallel to the flange 28. The
top wall 56 connects the side walls 52 to each other. The openings
44 are therefore open, downwardly-facing slots framed on three
sides by the side and top walls 52, 56.
[0016] The base pad 20 also includes a top surface 60
integrally-molded with the side walls 36. The top surface 60 is
generally parallel to the flange 28 and includes an aperture 64
communicating with the cavity 48. The top surface 60 further
includes threaded inserts 68 for mounting the equipment 24 to the
base pad 20, and also includes level recesses 72 for receiving
levels 76.
[0017] Referring to FIGS. 2 and 3, the level recesses 72 are
defined in the top surface 60, but do not penetrate all the way
through to the cavity 48. In this construction, two level recesses
72 are shown, but any number of level recesses 72 can be molded
into the pad 20 to achieve the same result. It is preferable to at
least have two level elements or levels 76 to determine the
orientation of the top surface 60 with respect to horizontal. The
recesses 72 are large enough for a level 76 to fit into, and deep
enough to ensure that the level 76 does not protrude significantly,
if at all, above the top surface 60 of the base pad 20. The
so-recessed levels 76 are protected from impact that may shear a
non-recessed level off the top surface 60.
[0018] In the illustrated embodiment, the level 76 is a bubble
level and includes a cylindrical shell 80 containing fluid 84 and
an air bubble 88 therein. The shell 80 includes two spaced apart
lines 92 circumferencing the shell 80 and defining two parallel
planes. The level 76 has a longitudinal extent along an axis 94 and
the air bubble 88 settles between the two lines 92 when the
longitudinal extent is horizontally-oriented along the axis 94.
Although the bubble level is illustrated and described herein, any
type of level element can be used and still be within the spirit
and scope of the present invention, such as, for example any level
element that utilizes natural phenomenon, such as gravity, to
operate and determine horizontallity of the level element.
[0019] The base pad 20 is used as follows. A hole is dug into the
ground in a desired location for the base pad 20. The base pad 20
is then placed in the hole, such that the flange 28 contacts the
ground and the side walls 36 extend upward to or above the ground
level. Cables from the electrical equipment 24 can extend through
the cable openings 44. The base pad 20 is then checked for
levelness by looking at the levels 76 mounted to the base pad
20.
[0020] FIGS. 4-6 illustrate a process for molding the level
recesses 72 integrally with the base pad 20. A mold 96 is used for
forming the base pad 20 and includes a recess-defining protrusion.
The recess-defining protrusion can be integral with the mold 96 or
it can be a separate component affixed to the mold 96. In the
illustrated embodiment, the recess-defining protrusion is a capsule
100 that is separate from the mold 96 and is affixed thereto (e.g.,
with an adhesive). The first step is to mount capsules 100 to the
mold 96 in locations where the level recesses 72 are desired.
[0021] The capsules 100 are preferably aluminum because of the
durability and long life of aluminum, but other capsule materials
can be used, such as, but not limited to fiberglass, clay, other
metals, and any other material that would withstand the molding
process. Each capsule 100 has a flat bottom surface 101 and a
rounded top surface 102. The flat bottom surface 101 contacts the
mold 96, while the round top surface 102 is spaced from the mold
96. The round top surface 102 of the capsules 100 give the level
recesses 72 a round bottom, so that the cylindrical levels 76 lie
evenly in the level recesses 72. The flat bottom surface 101 can be
affixed to the mold 96 to ensure that the capsule 100 does not move
during the molding process. The flat bottom surface 101 can be
affixed to the mold 96 with an adhesive that will withstand the
molding process.
[0022] The second step is to apply a release agent 104 to the mold
96 and capsules 100, which facilitates removal of the base pad 20
upon completion of the molding process. A polyester gelcoat 106 is
applied to the mold 96 and capsules 100 after the release agent
104. Typically, the gelcoat 106 is given about thirty minutes to
cure, but periods may vary depending on the gelcoat and curing
conditions.
[0023] The gelcoat stage is followed by the lamination stage, in
which a chopper gun 108 reels in strands of continuous roving
fiberglass and cuts it into workable fibers approximately two
inches long. The chopper gun 108 also pumps in the resin
(polyester, vinyl ester or a blend plus fillers), which is combined
with the fiberglass and a catalyst at the spray tip. The mixture is
sprayed over the cured gelcoat 106 to a desired thickness
(preferably 3/8"). During this stage the ribs 40 are added by hand.
Production workers use rollers and brushes to compress the
lamination to ensure the fiberglass is uniform and to remove any
air bubbles. Alternatively, the compression may be done
automatically by a machine. The base pad 20 is allowed to cure
(approximately sixty minutes) and is removed from the mold 96.
Lastly, the base pad 20 is trimmed with a grinder and the threaded
inserts 68 are drilled.
[0024] Although a preferred molding process has been described, any
molding process can be used to create the level recesses 72 and
still be covered under the scope of the present invention. Such
alternative molding processes include, but are not limited to, male
molds, matched metal compression molding fiberglass systems,
compression molding, injection molding, and vacuum molding. Also,
materials other than fiberglass can be used to make the base pad 20
and still be within the spirit and scope of the present invention.
Such alternative materials include, but are not limited to,
plastics, concrete, polymer concrete, and fiberglass reinforced
concrete.
[0025] Referring to FIG. 7, an alternative construction of the base
pad 20 having a leveling system is illustrated. Parts that are the
same as those of FIGS. 1-6 are given the same reference numbers. In
this construction, the base pad 20 has leveling recesses 72 defined
in the top walls 56 of the cable openings 44. The level recesses 72
are deep enough to ensure that the levels 76 do not protrude above
the top walls 56 of the cable openings 44.
[0026] Referring to FIG. 8, another alternative construction of the
base pad 20 having a leveling system is illustrated. Parts that are
the same as those of FIGS. 1-6 are given the same reference
numbers. In this construction, the base pad 20 has leveling
recesses 72 defined in the flange 28 of the base pad 20. The level
recesses 72 are deep enough to ensure that the levels 76 do not
protrude above the flange 28.
[0027] Although particular constructions of the present invention
have been shown and described, other alternative constructions will
be apparent to those skilled in the art and are within the intended
scope of the present invention. Thus, the present invention is to
be limited only by the following claims.
* * * * *