Electrical enclosure, structural assembly, and insert therefor
An insert is for the structural assembly of an electrical enclosure. The structural assembly includes a channel member having a generally flat portion with an aperture and a retaining mechanism, a side sheet coupled to the channel member, and a fastener coupling the channel member to the side sheet. The insert includes a first end portion inserted into the aperture and abutting the side sheet, a second end portion distal from the first end portion, a shoulder portion proximate the second end portion and being engaged by the retaining mechanism, and a tapered portion between the first end portion and the shoulder portion. An axial opening extends through the first end portion, the tapered portion, and the second end portion in order to receive the fastener. Tabs and corresponding notches facilitate proper assembly of the electrical enclosure and the fastener secures the electrical enclosure, once assembled.
1 . An insert for a structural assembly of an electrical enclosure, said structural assembly including a channel member, a side sheet, and a fastener for coupling said channel member to said side sheet, said channel member including an aperture having a retaining mechanism, said insert comprising:
a first end portion structured to be inserted into the aperture of said channel member and to be disposed at or about said side sheet;
a second end portion disposed distal from the first end portion;
a shoulder portion disposed proximate the second end portion and structured to be engaged by said retaining mechanism of the aperture of said channel member; and
a third portion generally extending between the first end portion and said shoulder portion,
wherein said insert includes an axial opening extending through the first end portion, the second end portion, and the third portion, said axial opening being structured to receive said fastener.
2 . The insert of claim 1 wherein said fastener comprises a threaded fastener including at least one of an enlarged head, a washer, and a nut; and wherein said axial opening further comprises a counter-bore coaxial with said axial opening and structured to receive at least one of said enlarged head, said washer, and said nut of said threaded fastener therein.
3 . The insert of claim 1 wherein said retaining mechanism of the aperture of said channel member includes at least one protrusion; and wherein, when said insert is fully inserted within the aperture of said channel member, the first end portion abuts said side sheet and said at least one protrusion engages said shoulder portion in order to retain said insert.
4 . The insert of claim 1 wherein the first end portion has a first diameter; wherein the second end portion has a second diameter; and wherein the second diameter is larger than the first diameter in order that the second end portion engages said channel member at or about the aperture thereof.
5 . The insert of claim 1 wherein the third portion comprises a tapered portion; and wherein said tapered portion forms an angle with respect to said axial opening of between about 5 degrees and about 20 degrees.
6 . A structural assembly for an electrical enclosure, said structural assembly comprising:
a channel member including a generally flat portion having at least one aperture with a retaining mechanism;
a side sheet;
a fastener coupling said channel member to said side sheet; and
an insert comprising:
a first end portion inserted into one of said at least one aperture of said channel member and abutting said side sheet,
a second end portion disposed distal from the first end portion,
a shoulder portion disposed proximate the second end portion and being engaged by said retaining mechanism of said one of said at least one aperture of said channel member, and
a tapered portion generally extending between the first end portion and said shoulder portion,
wherein said insert includes an axial opening extending through the first end portion, said tapered portion, and the second end portion in order to receive said fastener.
7 . The structural assembly of claim 6 wherein said retaining mechanism comprises a generally star-shaped cutout including a plurality of protrusions which engage said shoulder portion of said insert; and wherein when said insert is fully inserted within said one of said at least one aperture and said retaining mechanism engages said shoulder, the second end portion of said insert is substantially flush with respect to said generally flat portion of said channel member.
8 . The structural assembly of claim 6 wherein at least one of said channel member and said side sheet includes a plurality of tabs; wherein at least one of said channel member and said side sheet includes a plurality of corresponding notches; and wherein said tabs are received in said corresponding notches in order to couple the structural assembly together and to facilitate proper assembly thereof.
9 . The structural assembly of claim 6 wherein said structural assembly is a single-stack assembly; wherein said side sheet of said single-stack assembly is a single side sheet; and wherein said channel member of said single-stack assembly includes a pair of channel members coupled to one side of said single side sheet.
10 . The structural assembly of claim 9 wherein each of said channel members includes as said at least one aperture, a plurality of apertures; wherein said insert is disposed within one of said apertures; and wherein said fastener is inserted through said insert and said single side sheet in order to secure said single-stack assembly together.
11 . The structural assembly of claim 6 wherein said structural assembly is a double-stack assembly; wherein said side sheet of said double-stack assembly is a single side sheet; wherein said channel member of said double-stack assembly includes first and second pairs of channel members; wherein said first pair of channel members is coupled to one side of said single side sheet; and wherein said second pair of channel members is coupled on another side of said single side sheet, opposite said first pair of channel members.
12 . The structural assembly of claim 11 wherein each of said channel members includes as said at least one aperture, a plurality of apertures; wherein the apertures of said first pair of channel members generally align opposite the apertures of said second pair of channel members; wherein said insert is disposed within one of the apertures of said first pair of channel members and another insert is disposed within a corresponding one of the apertures of said second pair of channel members;
and wherein said fastener is inserted through said insert of said first pair of channel members, through said single side sheet, and through said other insert in order to secure said double-stack assembly together.
13 . An electrical enclosure comprising:
a first frame;
a second frame disposed opposite and distal from said first frame; and
a structural assembly interconnecting and supporting said first frame and said second frame, said structural assembly including a channel member having a generally flat portion with at least one aperture and a retaining mechanism, a side sheet coupled to said channel member, a fastener coupling said channel member to said side sheet, and an insert comprising:
a first end portion inserted into one of said at least one aperture of said channel member and abutting said side sheet,
a second end portion disposed distal from the first end portion,
a shoulder portion disposed proximate the second end portion and being engaged by said retaining mechanism of said channel member, and
a tapered portion generally extending between the first end portion and said shoulder portion,
wherein said insert includes an axial opening extending through the first end portion, said tapered portion, and the second end portion in order to receive said fastener.
14 . The electrical enclosure of claim 13 wherein said insert generally extends between said side sheet and said generally flat portion of said channel member in order to provide rigidity to said electrical enclosure.
15 . The electrical enclosure of claim 13 wherein said retaining mechanism comprises a generally star-shaped cutout including a plurality of protrusions which engage said shoulder portion of said insert; and wherein when said insert is fully inserted within said one of said at least one aperture and said retaining mechanism engages said shoulder portion, the second end portion of said insert is substantially flush with respect to said generally flat portion of said channel member.
16 . The electrical enclosure of claim 13 wherein said first and second frames each include an edge member; wherein at least one of said channel member, said side sheet, and said edge member includes a plurality of tabs; wherein at least one of said channel member, said side sheet, and said edge member includes a plurality of corresponding notches; and wherein said tabs are received in said corresponding notches in order to couple said structural assembly together and to said first and second frames, and to facilitate proper assembly of said electrical enclosure.
17 . The electrical enclosure of claim 13 wherein said structural assembly is a single-stack assembly; wherein said side sheet of said single-stack assembly is a single side sheet; wherein said first and second frames include edge members; and wherein said channel member of said single-stack assembly comprises a pair of said edge members of said first and second frames, which are coupled to one side of said single side sheet.
18 . The electrical enclosure of claim 17 wherein each of said edge members includes as said at least one aperture, a plurality of apertures; wherein said insert is disposed within one of said apertures; and wherein said fastener is inserted through said insert and said single side sheet in order to secure said single-stack assembly together.
19 . The electrical enclosure of claim 13 wherein said structural assembly is a double-stack assembly; wherein said side sheet of said double-stack assembly is a single side sheet; wherein said first and second frames include edge members; wherein said channel member of said double-stack assembly includes first and second pairs of channel members; wherein said first pair of channel members comprises said edge members of said first and second frames, which are coupled to one side of said single side sheet; and wherein said second pair of channel members is coupled to another side of said single side sheet, opposite said edge members.
20 . The electrical enclosure of claim 19 wherein said channel members and said edge members include as said at least one aperture, a plurality of apertures; wherein the apertures of said edge members generally align opposite the apertures of said second pair of channel members; wherein said insert is disposed one of the apertures of said edge members and another insert is disposed within a corresponding one of the apertures of said second pair of channel members; and wherein said fastener is inserted through said insert of said edge members, through said single side sheet, and through said other insert in order to secure said double-stack assembly together.