Gauge Plate
A gauge plate insulator includes a body having a first side and a second side positioned opposite the second, with the first side of the body defining a planar surface, and the body defining a first opening and a second opening, and a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members. The leg is positioned between the first and second openings of the body, with the body and leg formed integrally from a fiber-reinforced polymer.
This application claims priority to United States Provisional Application Ser. No. 62/501,327, filed May 4, 2017, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION Field of the InventionThe present invention relates to an insulating joint for use in a rail system to electrically isolate parts of the rail system from each other.
Description of Related ArtA rail system is generally divided into sections or blocks to be able to detect trains which permits more trains to travel on one stretch of track or rail. Each section is electrically isolated from all other sections so that when no train is present in the section, a high electrical resistance can be measured over the parallel railbars in the section. When a train enters a section, the train short circuits adjacent railbars and the electrical resistance drops.
Railbars are generally welded to each other or attached to each other by a steel joint. High performance non-metallic joints are used for electrically isolating two railbars in order to build an electrically isolated section. Switches are insulated in the same way by dividing both the gauge plate and switch rods into two parts and by joining the respective parts with a non-metallic or insulating joint.
Known non-metallic joints are very expensive because of the special high performance material which has to endure high tensile and flexural forces. In addition, a separate insulating plug must be utilized between ends of the gauge plate or switch rod to prevent material buildup of debris which would then cause an electrical short.
U.S. Pat. No. 6,170,756 discloses a prior art gauge plate and switch rod insulator. FIGS. 1-8 of U.S. Pat. No. 6,170,756 are reproduced as
Two parts 10 and 12 are connected to each other by two T-shaped insulating joints or switch plates 16 having T-shaped cross sections. Each insulating joint 16 includes a metallic core encased with an electrically insulating material. Each core is T-shaped with a flat body 17a having a leg or ridge 17b depending therefrom. Likewise, the insulating joint 16 includes a flat body 17c and a depending leg 17d. The depending leg 17d is received within a gap G defined between the first part 10 and the second part 12. Ends of the depending legs 17d abut against each other. Alternatively, it is believed that the metallic core can be a flat plate encased with an electrically insulating material replacing the depending leg or ridge 17b completely with insulating material as shown in
More specifically, the insulating joint 16 includes a steel core 26 with a plurality of holes defined therein through which bolts 20 extend, an insulating layer 28 encasing the steel core 26, and a plurality of bushings 30 provided in the holes.
The steel core 26, not the insulating layer 28, withstands tensile forces applied to the insulating joint 16 through parts 10 and 12. The bushings 30 protect the steel core 26 and the insulating layer 28 from wear caused by the bolts 20. As is evident, the installed T-shaped insulating joint 16 sandwiches ends E and E′ of the two parts 10 and 12 and are secured thereto.
The insulating joint or gauge plate 40 is T-shaped, i.e., has a T-shaped cross section, such that a part of the insulating joint 40 prevents the ends of the first part 42 and the second part 44 from making electrical contact. The insulating joint 40 includes a steel T-shaped core 48, a first electrically insulating layer 50, which encases the core 48, and steel bushings 52. As shown in
All of the insulating joints are made by placing or providing the steel core in a mold and molding around the steel core electrically insulating material, such as polyurethane, rubber, or other polymeric material, thereby forming a T-shaped electrically insulating plate. The metallic core can be flat or T-shaped. The bushings at that time can be cast in place. After the polyurethane hardens, the insulating rail joint is removed from the mold and if the bushings for receipt of fasteners, such as bolts 20 and 56, are not cast in place during molding, they can then be received by the insulating joint holes.
SUMMARY OF THE INVENTIONIn one aspect, a gauge plate insulator includes a body having a first side and a second side positioned opposite the second, with the first side of the body defining a planar surface, and the body defining a first opening and a second opening, and a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members. The leg is positioned between the first and second openings of the body, with the body and leg formed integrally from a fiber-reinforced polymer.
The fiber-reinforced polymer may include at least one of fiberglass-reinforced polyester, fiberglass-reinforced vinyl ester, fiberglass-reinforced polyurethane, and fiberglass-reinforced epoxy. The fiber-reinforced polymer may include at least one of E-class fiberglass and S-class fiberglass.
The gauge plate insulator may further include a first fastener configured to be received by the first opening and to secure the body to a first gauge plate member and a second fastener configured to be received by the second opening and to secure the body to a second gauge plate member. The first and second fasteners may each be a buck collar and huck pin. The gauge plate insulator may further include a first washer configured to be positioned between a portion of the first fastener and the body and a second washer configured to be positioned between a portion of the second fastener and the body. The first and second washers may each be a hardened flat washer.
The gauge plate insulator may further include a metallic plate, first and second insulating washers, and first and second insulating bushings, with the metallic plate configured to be received by the first side of the body and defining first and second openings corresponding to the first and second openings of the body. The first insulating washer is configured to be positioned between a portion of the first fastener and the metallic plate, with the second insulating washer configured to be positioned between a portion of the second fastener and the metallic plate. The first insulated bushing may be received within the first opening and configured to receive the first fastener and the second insulated bushing may be received within the second opening and configured to receive the second fastener.
The first opening may include a pair of spaced-apart openings and the second opening may include a pair of spaced-apart openings, with the gauge plate insulator further including a first elongate metallic plate extending between the pair of spaced-apart openings of the first opening, and a second elongate metallic plate extending between the pair of spaced-apart openings of the second opening. The first and second elongate metallic plates may be positioned parallel to the leg. The gauge plate insulator may further include an insulating plate positioned in the first side of the body. The insulating plate may be formed from glass fabric impregnated with epoxy resin.
In a further aspect, a method of manufacturing a gauge plate insulator including a body having a first side and a second side positioned opposite the second, and a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members, includes: impregnating a fiber reinforcement with resin; pulling the fiber reinforcement impregnated with the resin through a forming die to form a profile of the body and leg of the gauge plate insulator; heating the profile to cure the resin; and cutting the profile to a predetermined length.
In a further aspect, a gauge plate insulator includes a pair of laterally spaced, elongated, planar metallic cores, with each of the laterally spaced, elongated, planar metallic cores extending in a first direction, and an electrically insulating material encasing the pair of laterally spaced, elongated, planar metallic cores, with the electrically insulating material defining an insulating member that includes a T-shaped cross section defined by a body of the electrically insulating material and a leg of the electrically insulating material that depends from the body. The depending leg having an elongated dimension that extends in a second direction laterally to the first direction.
Each elongated, planar metallic core may have a first end and a second end with the elongated dimension of the depending leg extending between the first and second ends of each elongated, planar metallic core. The gauge plate insulator may include a plurality of fastener holes, with each fastener hole extending through the body of the electrically insulating member and one of the metallic cores. Each metallic core may include two of the plurality of fastener holes, where one of the two fastener holes of the metallic core is positioned between the elongated dimension of the depending leg and the first end of the metallic core, and the other of the two fastener holes of the metallic core is positioned between the elongated dimension of the depending leg and the second end of the metallic core.
The gauge plate insulator may further include an insulating bushing in each fastener hole. The body of the electrically insulating material may define a pair of plateaus that extend above a surface of the body that faces away from the depending leg, where each plateau encases a surface of one of the metallic cores that faces away from the depending leg and at least a part of a side of the metallic core. A top of the electrically insulating member may form an H-shape.
In a further aspect, a gauge plate insulator includes an L-shaped insulating member having a base configured to be positioned between first and second gauge plate members and a leg extending from the base, a metallic backing plate having a first part configured to engage a first gauge plate member, a second part configured to engage the leg of the L-shaped insulating member, and a third part extending between the first part and the second part of the metallic backing plate and configured to engage a portion of the base of the L-shaped insulating member, a first fastener configured to be received by a first opening defined by the first part of the metallic backing plate to secure the metallic backing plate to a first gauge plate member and a second fastener configured to be received by a second opening defined by the second part of the metallic backing plate and an opening defined by the leg of the L-shaped insulating member, and an insulation plate configured to be positioned between a portion of the second fastener and the second part of the metallic backing plate.
In a further aspect, a gauge plate assembly includes a first gauge plate member having a thick section and a thin section adjacent an end of the first gauge plate member, a second gauge plate member having a thick section and a thin section adjacent an end of the second gauge plate member, with a portion of the thin section of the first gauge plate member overlapping a portion of the thin section of the second gauge plate member, an insulating member positioned between the first and second gauge plate members, at least one fastener extending through an opening extending through the thin sections of the first and second gauge plate members and the insulating member, and an insulation plate positioned between a portion of the at least one fastener and the thin section of the second gauge plate member.
The insulating member may be thicker adjacent to a transition between the thick section and the thin section of the first gauge plate member, and the insulating member may be thicker adjacent to a transition between the thick section and the thin section of the second gauge plate member. The insulation plate may be formed integrally with the insulating member.
For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the example(s) as oriented in the drawing figures. However, it is to be understood that the example(s) may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific example(s) illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments or aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.
With reference to
The depending leg 112 has an elongated dimension that extends in a second direction 118 laterally to the first direction 104. In an example, the elongated dimension of the depending leg 112 extends intermediate the first and second ends 114, 116 of each metallic core 100.
The gauge plate insulator 70 includes a plurality of fastener holes 120. Each fastener hole 120 extends through the body 110 of the T-shaped electrically insulating member and one of the metallic cores 100.
In an example, each metallic core 100 is comprised of two fastener holes 120. One of said two fastener holes 120 of the metallic core 100 is positioned between the elongated dimension 118 of the depending leg 112 and the first end 114 of the metallic core 100. The other of said two fastener holes 120 of the metallic core 100 is positioned between the elongated dimension 118 of the depending leg 112 and the second end 116 of the metallic core 100. An electrically insulating bushing 122 can be included in each fastener hole 120 to electrically insulate metallic cores 100 from the shaft of fasteners (not shown) inserted in said bushings 122.
In an example, the electrically insulating material 106 can be polyurethane, although other suitable materials may be utilized.
Optionally, each metallic core 100 can include an expansion slot 124 that extends between the fastener holes 120 at the first and second ends 114, 116 of said metallic core 100. The optional expansion slot 124 of each metallic core 100 can enable said metallic core 100 to withstand vibration and/or changes in temperature without deformation.
The body 110 of the electrically insulating material 106 can define a pair of optional plateaus 126 that extend above the surface 127 of the body 110 that faces away from the depending leg 112. As can be seen, each plateau 126 encases a surface of one of the metallic cores 100 that faces away from the depending leg 112 and at least part of a side 128 of said metallic core 100. The pair of plateaus 126 are laterally spaced from each other in the second direction 118 and have longitudinal axes that extend in the first direction shown by two-headed arrow 104.
The gauge plate insulator 70 shown in
With reference to
The gauge plate insulator assembly 80 can include a number of fastener holes 148 that extend through gauge plate member 132 and first part 142 of backing plate 140. Each fastener hole 148 can receive the shaft of a Huck pin 150 which can be secured in place via a flat washer 152 and a Huck collar 154 in a manner known in the art.
An insulating plate 156 can be positioned on a surface of second part 144 of backing plate 140 that faces away from plate 130. The gauge plate insulator assembly 80 can also include a number of fastener holes 158 that extend through plate 130, leg 136 of insulator 134, second part 144 of backing plate 140, and insulating plate 156. Each fastener hole 158 can receive the shaft of a Huck pin 150 and can be secured in place via a flat washer 152 and a Huck collar 154.
The gauge plate insulator assembly 80 shown in
The gauge plate insulator assembly 80 shown in
With reference to
Between thin sections 174 and 180 positioned as shown in
An insulating plate or washer 188 can be positioned on a surface of thin section 174 facing away from insulator 170. This example gauge plate can include a pair of fastener holes 190 each of which extends through thin sections 174 and 180, the plate-like portion of insulator 170 therebetween, and through insulating plate 188 for receiving the shaft of a Huck pin 150 which can be secured in place via a flat washer 152 and a Huck collar 154. The gauge plate assembly 80A can optionally include a lifting bale 160 that includes parts 162 that can be received between washers 152 and insulating plate 188. Each fastener hole 190 can receive an insulating bushing 192 to electrically insulate plates 166 and 168 from each other.
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In this example, each fastener hole 190 also extends through the portion 194 of insulator 170 that replaces insulating plate 188 in the example shown in
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The gauge plate assembly 80H shown in
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A plurality of fastener holes 218 extends through plates 130 and 132, insulating plate 210, and metallic plate 216. An insulating bushing 220 can be received in each fastener hole 218, at least in the portion of fastener hole 218 defined by metallic plate 216, to isolate the shaft of the Huck pin 222 projected through the fastener hole 218 from metallic plate 216. Each Huck pin 222 can be secured in its respective fastener hole 218 via an insulating washer 224 received on the shaft of Huck pin 222 and in contact with a surface of metallic plate 216 opposite insulating plate 210, a flat washer 226 disposed on a side of insulating washer 224 opposite metallic plate 216, and a Huck collar 228 received on the threaded end of the shaft of the Huck pin 222 on a side of flat washer 226 opposite insulating washer 224. An optional lifting bale 160, including parts 162, can be provided, with each part 162 sandwiched between an insulating washer 224 and a flat washer 226. In the illustrated example, insulating washers 224 are square or rectangular. However, this is not to be construed in a limiting sense.
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Because the pair of plates 230 are spaced from each other, the insulating washers 224 shown in
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The reinforcing fiber may be provided from a reinforcement supply 280, which may include rovings of fiber or rolls of fiber mat. Before and/or after the reinforcing fiber is impregnated with the resin, the reinforcing fiber may undergo a preforming process 282 to preform the reinforcing fiber to prepare the reinforcing fiber for the forming process. After the fiber reinforcement is impregnated with the resin, the method may include applying a surfacing veil 284 to the fiber reinforcement. The forming and heating step 274,276 may occur simultaneously with a heat source being provided as the fiber reinforcement and resin pass through the forming die, although other suitable arrangements may be utilized. As noted above, the method 270 includes pulling 286 the fiber reinforcement through a forming die, which may be accomplished using any suitable pulling system, such as a caterpillar-style system or reciprocating system. The cutting step 278 may be accomplished via a cut-off saw, although other suitable arrangements may be utilized.
Although the method 270 is described in connection with the insulating plate 210, the method 270 may be utilized in connection with other components and elements of the present application.
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Moreover, the gauge plate insulator 90 of
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The foregoing examples have been described with reference to the accompanying figures. Modifications and alterations will occur to others upon reading and understanding the foregoing examples which are provided for the purpose of illustration and are not to be construed in a limiting sense. For example, while the use of Huck pins and Huck collars is disclosed, the use of any other suitable and/or desirable fastener arrangement in replacement of a Huck pin/Huck collar combination is envisioned. Accordingly, the foregoing examples are not to be construed as limiting the disclosure
Claims
1. A gauge plate insulator comprising:
- a body having a first side and a second side positioned opposite the second, the first side of the body defining a planar surface, the body defining a first opening and a second opening; and
- a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members, the leg positioned between the first and second openings of the body, wherein the body and leg are formed integrally from a fiber-reinforced polymer.
2. The gauge plate insulator of claim 1, wherein the fiber-reinforced polymer comprises at least one of fiberglass-reinforced polyester, fiberglass-reinforced vinyl ester, fiberglass-reinforced polyurethane, and fiberglass-reinforced epoxy.
3. The gauge plate insulator of claim 1, wherein fiber-reinforced polymer comprises at least one of E-class fiberglass and S-class fiberglass.
4. The gauge plate insulator of claim 1, further comprising a first fastener configured to be received by the first opening and to secure the body to a first gauge plate member and a second fastener configured to be received by the second opening and to secure the body to a second gauge plate member.
5. The gauge plate insulator of claim 4, wherein the first and second fasteners each comprise a huck collar and huck pin.
6. The gauge plate insulator of claim 4, further comprising a first washer configured to be positioned between a portion of the first fastener and the body and a second washer configured to be positioned between a portion of the second fastener and the body.
7. The gauge plate insulator of claim 6, wherein the first and second washers each comprise a hardened flat washer.
8. The gauge plate insulator of claim 4, further comprising a metallic plate, first and second insulating washers, and first and second insulating bushings, the metallic plate is configured to be received by the first side of the body and defines first and second openings corresponding to the first and second openings of the body, the first insulating washer configured to be positioned between a portion of the first fastener and the metallic plate, the second insulating washer configured to be positioned between a portion of the second fastener and the metallic plate, the first insulated bushing received within the first opening and configured to receive the first fastener and the second insulated bushing received within the second opening and configured to receive the second fastener.
9. The gauge plate insulator of claim 1, wherein the first opening comprises a pair of spaced-apart openings and the second opening comprises a pair of spaced-apart openings, the gauge plate insulator further comprising a first elongate metallic plate extending between the pair of spaced-apart openings of the first opening, a second elongate metallic plate extending between the pair of spaced-apart openings of the second opening, the first and second elongate metallic plates positioned parallel to the leg.
10. The gauge plate insulator of claim 1, further comprising an insulating plate positioned in the first side of the body.
11. The gauge plate insulator of claim 10, wherein the insulating plate comprises a glass fabric impregnated with epoxy resin.
12. A method of manufacturing a gauge plate insulator comprising a body having a first side and a second side positioned opposite the second, and a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members, the method comprising:
- impregnating a fiber reinforcement with resin;
- pulling the fiber reinforcement impregnated with the resin through a forming die to form a profile of the body and leg of the gauge plate insulator;
- heating the profile to cure the resin; and
- cutting the profile to a predetermined length.
13. A gauge plate insulator comprising:
- a pair of laterally spaced, elongated, planar metallic cores, each of the laterally spaced, elongated, planar metallic cores extend in a first direction; and
- an electrically insulating material encasing the pair of laterally spaced, elongated, planar metallic cores, the electrically insulating material defining an insulating member that includes a T-shaped cross section defined by a body of the electrically insulating material and a leg of the electrically insulating material that depends from the body, the depending leg having an elongated dimension that extends in a second direction laterally to the first direction.
14. The gauge plate insulator of claim 13, wherein:
- each elongated, planar metallic core has a first end and a second end; and
- the elongated dimension of the depending leg extends between the first and second ends of each elongated, planar metallic core.
15. The gauge plate insulator of claim 14, further including a plurality of fastener holes, wherein each fastener hole extends through the body of the electrically insulating member and one of the metallic cores.
16. The gauge plate insulator of claim 15, wherein each metallic core is comprised of two of the plurality of fastener holes, wherein one of the two fastener holes of the metallic core is positioned between the elongated dimension of the depending leg and the first end of the metallic core, and the other of the two fastener holes of the metallic core is positioned between the elongated dimension of the depending leg and the second end of the metallic core.
17. The gauge plate insulator of claim 15, further comprising an insulating bushing in each fastener hole.
18. The gauge plate insulator of claim 13, wherein the body of the electrically insulating material defines a pair of plateaus that extend above a surface of the body that faces away from the depending leg, wherein each plateau encases a surface of one of the metallic cores that faces away from the depending leg and at least a part of a side of the metallic core.
19. The gauge plate insulator of claim 13, wherein a top of the electrically insulating member forms an H-shape.
20. A gauge plate insulator comprising:
- an L-shaped insulating member having a base configured to be positioned between first and second gauge plate members and a leg extending from the base;
- a metallic backing plate having a first part configured to engage a first gauge plate member, a second part configured to engage the leg of the L-shaped insulating member, and a third part extending between the first part and the second part of the metallic backing plate and configured to engage a portion of the base of the L-shaped insulating member;
- a first fastener configured to be received by a first opening defined by the first part of the metallic backing plate to secure the metallic backing plate to a first gauge plate member and a second fastener configured to be received by a second opening defined by the second part of the metallic backing plate and an opening defined by the leg of the L-shaped insulating member; and
- an insulation plate configured to be positioned between a portion of the second fastener and the second part of the metallic backing plate.
21. A gauge plate assembly comprising:
- a first gauge plate member having a thick section and a thin section adjacent an end of the first gauge plate member;
- a second gauge plate member having a thick section and a thin section adjacent an end of the second gauge plate member, a portion of the thin section of the first gauge plate member overlapping a portion of the thin section of the second gauge plate member;
- an insulating member positioned between the first and second gauge plate members;
- at least one fastener extending through an opening extending through the thin sections of the first and second gauge plate members and the insulating member; and
- an insulation plate positioned between a portion of the at least one fastener and the thin section of the second gauge plate member.
22. The gauge plate assembly of claim 21, wherein the insulating member is thicker adjacent to a transition between the thick section and the thin section of the first gauge plate member, and wherein the insulating member is thicker adjacent to a transition between the thick section and the thin section of the second gauge plate member.
23. The gauge plate assembly of claim 21, wherein the insulation plate is formed integrally with the insulating member.
Type: Application
Filed: Apr 30, 2018
Publication Date: Nov 8, 2018
Inventors: Steven D. Singleton (Sarver, PA), W. Thomas Urmson, JR. (Valencia, PA), Ronald K. Junk (Cabot, PA), John W. Mospan (Pittsburgh, PA)
Application Number: 15/966,398