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.

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.