ADJUSTABLE ROADWAY SUPPORT SYSTEM FOR RAILWAY GRADE CROSSING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]The present invention claims priority to U.S. Provisional Pat. App. No. 63/737,201, titled “Adjustable Roadway Support System for Railway Grade Crossing”, and further claims priority to U.S. patent application Ser. No. 17/697,585, titled “Roadway Support System for Railway Grade Crossing,” filed Mar. 17, 2022, which claims priority to U.S. Provisional Patent App. No. 63/162,195, titled “Roadway Support System for Railway Grade Crossing,” filed Mar. 17, 2021, each of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002]The present invention relates to an improved roadway support system for railway grade crossings that uses a foundation pile, support brackets and connecting hardware to provide vehicle traffic road support separated from the railroad ballast and track support system. The present invention separates the roadway support system from the track support system so that the roadway support system can last longer and be repaired separately from the track support system. In addition, the roadway support system may further be adjusted quickly and easily to the height of the railway track.

BACKGROUND

[0003]A roadway and railway grade crossing occurs where a railway and roadway intersect at the same level. There are more than 200,000 grade crossings in the U.S., and many require repairs and improvements. U.S. states, not the railroads, are typically responsible for evaluating grade crossing risks and prioritizing grade crossings for repairs and improvements. The crossing design, construction, and maintenance is often a coordinated effort among local, state, Department of Transportation, and railroads. Typically, the decision to install a specific type of crossing is with the state highway authority, not the railroads, and generally requires approval by the Federal Highway Administration. Once installed, the maintenance of grade crossings and their warning devices is generally the responsibility of the railroads.

[0004]Railroads invest heavily in grade crossing maintenance and safety, spending hundreds of millions of dollars each year to maintain crossings. Grade crossing designs currently use various roadway materials, such as asphalt, concrete, wood, rubber, steel, composite materials, and other like materials. All current roadway crossing designs utilize the support system of the railway track, consisting of sub-base materials, ballast, and ties. Specifically, the roadway material is typically placed on the ties and ballast, often connecting or otherwise tying the roadway material to the ties and/or ballast. The weakness in this system stems from the fact that the typical forces from railroad traffic often produces movements in the ties and ballast that in turn significantly degrade the roadway components. The connection between the track support system and the roadway support system often degrades the roadway faster than the railway system, requiring significant costs to repair for both the railroads and the local roadway authority.

[0005]A need, therefore, exists for an improved roadway crossing support structure at roadway and railway grade crossings. Specifically, a need exists for an improved roadway crossing support structure that separates the roadway support structure from the track support structure.

[0006]More specifically, a need exists for an improved roadway crossing support structure that utilizes an independent support system that uses foundation pile, support brackets, and connecting hardware to provide vehicle traffic road support. Indeed, a need exists for an improved roadway crossing support structure that separates the support systems so that the roadway can last longer.

[0007]Moreover, a need exists for an improved roadway crossing support structure that prevents or minimizes degradation of the roadway support structure due to movement of track and ballast due to railroad traffic. Specifically, a need exists for an improved roadway crossing support structure that reduces the cost and allows for easier repair and replacement of roadway support structure.

[0008]Even with the roadway support structure separating from the track support structure, there is a potential for a height differential between the two, due to the track sinking over time caused by the nature of track ballast degrading and vibration from the train loads. This height difference could result in damage to the train or, in extreme cases, even a derailment. A need, therefore, further exists, for a roadway support structure wherein the height may be adjusted to match the height of the track support structure. More specifically, a need exists for modified roadway panels so that the roadway support structure can be adjusted without the need to remove the roadway materials from the support.

SUMMARY OF THE INVENTION

[0009]The present invention relates to an improved roadway support system for railway grade crossings that uses a foundation pile, an adjustable height clamp system and modified roadway panels to provide vehicle traffic road support separated from the railroad ballast and track support system. The present invention separates the roadway support system from the track support system so that the roadway support system can last longer and be repaired separately from the track support system. In addition, the roadway support system is adjustable quickly and easily to the height of the railway track.

[0010]To this end, in an embodiment of the present invention, a roadway support system for supporting roadway material at a railway grade crossing is provided. The roadway support system comprises: a roadway material panel system connected to a plurality of piles by resting on the shoulder of the pile head and clamped to the pile head by clamp assemblies thereby rigidly connecting the roadway material to the pile.

[0011]In an embodiment, the roadway support system further comprises: a clamping head extending through the roadway material to the pile head through the roadway material cylinders. Thereby rigidly connecting the pile to the roadway material.

[0012]It is, therefore, an advantage and objective of the present invention to provide an improved roadway crossing support structure at roadway and rail grade crossings.

[0013]Specifically, it is an advantage and objective of the present invention to provide an improved roadway crossing support structure that separates the roadway support structure from the track support structure.

[0014]More specifically, it is an advantage and objective of the present invention to provide an improved roadway crossing support structure that utilizes an independent support system that uses foundation pile, support brackets, and connecting hardware to provide vehicle traffic road support.

[0015]Indeed, it is an advantage and objective of the present invention to provide an improved roadway crossing support structure that separates the support systems so that the roadway can last longer.

[0016]More specifically, it is an advantage and objective of the present invention to provide foundation pile, clamping heads and modified roadway panels to provide vehicle traffic road support.

[0017]More specifically, it is an advantage and objective of the present invention to provide an adjustable height system for the roadway material to adjust the height of the road to the rail without removing the panels.

[0018]Moreover, it is an advantage and objective of the present invention to provide an improved roadway crossing support structure that prevents or minimizes degradation of the roadway support structure due to movement of track and ballast due to railroad traffic.

[0019]Specifically, it is an advantage and objective of the present invention to provide an improved roadway crossing support structure that reduces the cost and allows for easier repair and replacement of roadway support structure.

[0020]More specifically, it is an advantage and objective of the present invention to provide foundation pile, clamping heads and modified roadway panels to provide vehicle traffic road support.

[0021]More specifically, it is an advantage and objective of the present invention to provide an adjustable height system for the roadway material to adjust the height of the road to the rail without removing the panels.

[0022]Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0024]FIG. 1 illustrates a perspective cut-away view of a roadway support system for a railway grade crossing in an embodiment of the present invention.

[0025]FIG. 2 illustrates a front cut-away view of a roadway support system for a railway grade crossing in an embodiment of the present invention.

[0026]FIG. 3 illustrates a perspective cut-away view of a roadway support system for a railway grade crossing in an alternate embodiment of the present invention.

[0027]FIG. 4 illustrates a perspective view of a pile used to provide foundation support for the roadway support system of the present invention.

[0028]FIG. 5 illustrates a bolt and nut combination used to tie roadway material to a roadway support system in an embodiment of the present invention.

[0029]FIG. 6 illustrates a close-up view of a nut used in the bolt and nut combination used to tie roadway material to a roadway support system in an embodiment of the present invention.

[0030]FIG. 7 illustrates a perspective of a fully assembled view of a roadway support system with adjustable height system for a railway grade crossing in an embodiment of the present invention.

[0031]FIG. 8 illustrates a front cut-away view of a roadway support system with an adjustable height system for the roadway material of a railway grade crossing in an embodiment of the present invention.

[0032]FIG. 9 illustrates a perspective view of a roadway tray support system for the road material of a railway grade crossing of the present invention.

[0033]FIG. 10 illustrates a perspective view of the adjustable height clamping system for the roadway material assembly with the pile system used to provide for the roadway support system of the present invention.

[0034]FIG. 11 illustrates the clamp head design for external height adjustment tools used to secure the roadway material to the pile support system in an embodiment of the present invention.

[0035]FIG. 12 illustrates a view of the pile head shoulder and clamping system used to tie roadway material to a roadway pile support system in an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0036]The present invention relates to an improved roadway support system for railway grade crossings that uses a foundation pile, support brackets and connecting hardware to provide vehicle traffic road support separated from the railroad ballast and track support system. The present invention separates the roadway support system from the track support system so that the roadway support system can last longer and be repaired separately from the track support system. In addition, the roadway support system may further be adjusted quickly and easily to the height of the railway track.

[0037]Referring to the figures, FIG. 1 illustrates a perspective cut-away view of a roadway support system 10 in an embodiment of the present invention. The roadway support system 10 comprises a pair of elongated support brackets 12a, 12b, disposed in parallel relation with each other, and further disposed parallel to a pair of railroad rails 14a, 14b. Although shown as a pair of elongated support brackets, it should be apparent that any number of parallel elongated support brackets running parallel with the railroad rails may be utilized.

[0038]The pair of elongated support brackets 12a, 12b may preferably have an inverted U-shape, as illustrated in FIG. 2, but may be any shape apparent to one of ordinary skill in the art, such as cylindrical, rectangular prism, or other like shape. Each of the elongated support brackets 12, 12b generally rests on ties 16 that support the railroad rails 14a, 14b, but are not tied to the ties 16. Generally, the pair of elongated support brackets 12a, 12b float on or above the ties 16.

[0039]A plurality of foundation piles 18 are connected to the pair of elongated support brackets 12a, 12b and are driven downwardly through the ballast, sub-ballast, compacted subgrade, and/or other support materials, and into the earth, as illustrated in FIG. 1, to provide support for the pair of elongated support brackets 12a, 12b and without connection or significant structural support from the ties 16. Therefore, the pair of elongated support brackets 12a, 12b have little, if any, support from the ties and/or ballast, and derive the bulk, if not all, support through the plurality of piles 18 that are driven into the ground.

[0040]The plurality of piles 18 may be connected to the elongated support brackets 12a, 12b via a connection bolt 20 and nut 22 that may be disposed through apertures in the sides of the elongated support brackets 12a, 12b. Thus, the piles 18 may be rigidly connected to the elongated support brackets 12a, 12b, thereby providing the support thereof.

[0041]Roadway material 24 may be disposed atop the elongated support brackets 12a, 12b and may be supported thereby, as illustrated in FIGS. 1 and 2. Bolts 26 may be placed within apertures (not shown) within the roadway material 24 and may extend downwardly through the roadway material 24 and into apertures within the top surface of the elongated brackets 12a, 12b, respectively. The bolts 26 may have a nut 28 on end thereof, as illustrated in FIGS. 5 and 6, that may have a shape that allows the nut 28 to be pre-placed on the bolt 26 prior to dropping down through an aperture in the roadway material 24 and into respective apertures in the top surface of the elongated support brackets 12a, 12b.

[0042]Once disposed therein, the bolt 26 may be turned, which in turn may rotate the nut 28 thereby locking the nut 28 within the apertures of the elongated support brackets 12a, 12b so that the nut 28 may be tightened to the bolt 28. Specifically, as illustrated in FIG. 6, nut 28 have may surfaces 30a, 30b that, when rotated due to tightening of the bolt 26, engages a bottom surface of the top side of the elongated brackets 12a, 12b, thereby preventing the nut from disengaging from the support brackets 12a, 12b.

[0043]The roadway material 24 may be any roadway material useful to holding vehicles driving thereover when crossing the railroad tracks at a grade crossing. The system 10 illustrated in FIGS. 1 and 2 may be particularly useful for steel plates, concrete slabs, composite, blacktop, or combinations thereof.

[0044]FIG. 3 illustrates a roadway support system 40 in an alternate embodiment of the present invention. The roadway support system 40 comprises a plurality of support bracket segments 42 disposed parallel to each other, but roughly perpendicular to railroad rails 44a, 44b. Preferably, each of the support bracket segments 42 may be positioned between ties 46 and may rest on the ballast beneath the ties, or float above the ballast. Generally, the support bracket segments 42 are not connected or tied to the ballast or the ties 46.

[0045]As with the support system 10, described above, the support bracket segments 42 may be tied to the earth via piles 18 that are driven through the ballast, sub-ballast, compacted subgrade, and any other track support fill material. The piles 18 may be connected to the support bracket segments 42 via bolts and nuts, as described above. Likewise, roadway material 48 may be disposed on a top side of each of the support bracket segments 42, and the bolts 26 and nuts 28, as described herein, may be used to tie the roadway material 48 to the support bracket segments 42. This embodiment may be useful when the road material comprises solid timbers that run parallel to the railroad rails 44a, 44b, as shown in FIG. 3.

[0046]Preferably, the piles 18 comprise a rod 50 with a helical plate 52 disposed near a first end 53 thereof so that the same may be rotated via a rotating driver into the ground, as illustrated in FIG. 4. An aperture 54 may be disposed near a second end 55 so that the piles 18 may be attached to the elongated support brackets via the nut 20/bolt 22 combination through the sides of the support brackets, as illustrated in FIG. 2.

[0047]Thus, the roadway material 24, 48, as shown and described herein, may be tied to elongated support brackets or support bracket segments, which may in turn be supported via piles driven into the earth. Therefore, if railroad traffic on the rails causes pitching or heaving of the tracks, ties, ballast, and/or other support material, the roadway material will generally remain undisturbed, thereby decreasing degradation thereto, and allowing the roadway material to enjoy longer life and less costly repairs.

[0048]In an alternate embodiment of the present invention, an improved roadway support system for railway grade crossings may use a modified foundation pile, adjustable height clamping system and redesigned roadway material panels to provide vehicle traffic road support separated from the railroad ballast and track support system. The present invention separates the roadway support system from the track support system so that the roadway support system can last longer and be repaired separately from the track support system. The alternate embodiment of the present invention provides an adjustable height system to adjust the height of the road to match the height of the rail that may change over time.

[0049]Referring to the figures, FIG. 7 and FIG. 8 illustrates a perspective view of a fully assembled roadway support system in an embodiment of the present invention. The roadway support system comprises a roadway material panel 101 mounted on a plurality of pile supports 102 with adjustable clamping assemblies 103.

[0050]The roadway material panels may comprise a support tray 105, or support structures imbedded into the material, with a plurality of cylinders 106 for the clamping assemblies 103, as illustrated in FIG. 8 and FIG. 9. The roadway material panels may be constructed with concrete, asphalt, rubber, timber or other materials as selected for roadway traffic. The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations.

[0051]The clamping support assembly 103 may comprise a clamp head 107 attached to a pile head 108 using a plurality of bolts 109 and nuts 111, as illustrated in FIG. 10, to provide support for the roadway material assembly and secures the roadway material 104 to the piles 102. Therefore, the roadway material 104 may preferably derive the bulk, if not all, support through the plurality of piles 102 that may be driven into the ground.

[0052]The clamp head 107 may contain a square socket 113, bolt through holes 112 and square shaft 110 as illustrated in FIG. 10 and FIG. 11. The clamp head 107 may secure the roadway material panels 101 to the piles 102 through the bolt through holes 112 using the bolts 109 through to pile head threaded bolt holes 116 and nuts 111. The square shaft 110 may preferably be inserted into the pile head 108 square socket 115, as illustrated in FIGS. 10-12 .

[0053]The pile head 108 contains a pile shoulder 114 as illustrated in FIG. 12. The roadway material support tray 105 or imbedded support structure with cylinders 106 may preferably rest on the pile shoulder 114. The pile shoulder 114 may contain a radius feature to compensate for the installation angle tolerance of the piles 102, to achieve proper alignment of the panels with the track. Thus, the piles 102 may be rigidly connected to the roadway material panels 101 thereby providing the support thereof.

[0054]Once assembled, the clamp head 107 may be turned using an installation tool (not shown), inserted into the clamp head square socket 113, which in turn may rotate the pile 102 via the clamp head square shaft 110 and pile square socket 115. Thus, turning the clamp head 107 may preferably turn the shaft of the pile 102 and adjust the height of the pile 102 up or down and, in turn, adjust the height of the roadway panel up or down.

[0055]It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to “the invention” are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.