Insulated rail electrification system

An electrical rail conductor assemblage for an insulated electrification system, including an elongate electrically-conducting rail having a longitudinal groove for receiving a cooperable collector shoe and for guiding it for travel along the rail. The rail has opposite wall portions which border the groove. The wall portions have thin wall sections with rounded longitudinal edges that constitute the mouth of the groove of the rail. The rail is covered by an essentially tubular, insulating, hollow, resilient and rigid cover member enveloping essentially all portions of the rail except for the mouth of the groove thereof. The cover member has a longitudinal cut which registers with the mouth of this groove, and curved, longitudinally-extending snap-on retainer portions that extend along the cut and are adapted to snap over the rounded longitudinal edges of the rail. These retainer portions extend in a circumferential direction through substantially a full semi-circle. The retainer portions further have exterior longitudinal flanges which constitute offset extensions of the opposite wall portions of the resilient cover member, to thus minimize access to the metal of the rail, and reduce the chance of inadvertent electric shock from an electrically live rail.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates generally to rail electrification systems, and more 
particularly to insulating jackets or cover members that surround the 
conductive metal rails of such systems. 
2. Description of the Related Art Including Information Disclosed Under 37 
CFR .sctn..sctn.1.97-1.99 
The following patents are of interest: 
U.S. Pat. Nos.: 
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3,303,294 3,506,099 
3,525,823 
3,649,779 3,902,579 
3,995,725 
3,998,306 4,016,961 
4,106,599 
4,155,434 4,163,485 
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U.S. Pat. Nos. 3,998,306 and 4,016,961 illustrate typical rail 
constructions. Rails of this general type are employed in industrial 
cranes, conveyers, hoists, monorail systems, automated storage and 
retriever systems, and Port Authority Equipment, as well as being used in 
various other applications. 
The constructions disclosed in the patents of the previous paragraph 
feature an electrically conductive rail member (34) preferably constituted 
of aluminum, having spaced flange portions (40) and a web portion (42). A 
flat contact strip (46) is fitted between the flange portions, as shown. 
The contact strip (46) is preferably stainless steel, and is both wear 
resistant and sufficiently electrically conductive so as not to introduce 
significant voltage drop at the contact shoe (16) with which the rail is 
used. 
Such rails are typically suspended by means of mounting clamps (12, 14), 
and an insulating jacket (58) surrounds the rail and provides the required 
electrical isolation between it and the clamps (12, 14). 
Modified rail structures incorporating insulating jackets are illustrated 
in U.S. Pat. Nos. '599; '485; '725; '823; '779; '099; and '294. 
A rail assemblage of a type incorporating a plastic or glass insulating 
hanger is illustrated in U.S. Pat. No. '579. 
U.S. Pat. No. 4,155,434 discloses a 3-phase rail electrification system 
employing an insulating support (22) for mounting a plurality of rails. 
SUMMARY OF THE INVENTION 
The present invention constitutes an improvement over the rail 
constructions noted above in that a more secure retention of the 
insulating jacket or cover member is realizeable, due to a close 
conformity between the inner surface of the jacket or cover member and the 
outer surface of the metal rail, such conformity being obtained by virtue 
of cooperable essentially semi-circular (semi-cylindrical) surfaces on the 
metal rail and cover member, such that the latter hugs and closely 
confines the metal rail at the location of such semi-circular surfaces. 
The improved retention as provided by the invention, minimizes inadvertent 
separation of the cover member from the metal rail, which is particularly 
important where the rail is disposed in a curved path, and where buckling 
of the cover member might otherwise occur. 
The object of the present invention is thus to provide an improved rail and 
cover member which are both simple in their structures, easily assembled 
to one another preferably by means of a snap fit, and thereafter securely 
retained against inadvertent separation. 
A related object of the invention is to provide an improved rail and cover 
member as above set forth, which more effectively hinders inadvertent 
contact with the metal rail by the fingers of an installer or technician, 
at the location of the mouth of the rail, so as to minimize potential 
shock hazards resulting from such inadvertent contact, as by an 
electrically live rail. 
Still another object of the invention is to provide an improved rail and 
cover member of the kind indicated, which is adaptable to conventional 
supporting means, including existing hanger clips, support fixtures, and 
insulators of plastic, glass or the like, all of known configuration. 
In accomplishing the above objects the invention provides an electrical 
rail conductor assemblage for an insulated electrification system, 
comprising in combination an elongate electrically-conducting metal rail 
having a longitudinal groove for receiving a cooperable collector shoe and 
for guiding the same for travel along the rail, and an essentially 
tubular, insulating, hollow, resilient and rigid cover member enveloping a 
substantial portion of the rail. The rail has opposite wall portions which 
border its groove, these wall portions comprising thin wall sections which 
have rounded longitudinally extending edges that constitute the mouth of 
the groove of the rail. The cover member envelops essentially all of the 
rail except for the mouth of the rail's groove. The rigid cover member has 
a longitudinal cut in its wall throughout its length, the cut registering 
with the mouth of the groove of the rail and bordering two opposite wall 
portions of the cover member which have and which support curved, 
longitudinally-extending snap-on retainer portions that extend along the 
cut of the cover member and are adapted to snap over the rounded 
longitudinal edges of the rail. The retainer portions closely fit the 
rounded longitudinal edges of the rail and extend in a circumferential 
direction through substantially a semi-circle, or half-cylinder. The 
retainer portions have innermost edges of reduced thickness which are 
located inside the groove of the rail, the innermost edges constituting 
oppositely located shoulders which face into the groove of the rail. The 
retainer portions further have exterior longitudinal outwardly projecting 
flanges which constitute laterally offset extensions of the opposite wall 
portions of the resilient cover member that support the retainer portions. 
The arrangement is such that the cover member effectively hugs the 
electrically conducting metal rail, by virtue of the close fit between its 
retainer portions and the rounded longitudinal edges of the rail. There 
results an improved retention of the cover member, and reduced likelihood 
of contact of the rail by the fingers of service or maintenance personnel 
working on the equipment with which the rail is associated. 
Other features and advantages will hereinafter appear.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring first to FIG. 1, there is illustrated an electrically conducting 
rail generally designated by the numeral 10, preferably constituted of 
aluminum and having an elongate metal body 12 with an upper channel 14 for 
securing the rail to a hanger (not shown), which can be of a type similar 
to that of U.S. Pat. No. 4,016,961. The rail has a lower channel in the 
form of a longitudinal groove 16, for receiving a cooperable collector 
shoe (not shown) which also can be of a type illustrated in the above 
identified patent. 
The disclosure of U.S. Pat. No. 4,016,961 is hereby incorporated, by 
reference, in the present application. 
The rail 10 has opposite wall portions 18 which border the longitudinal 
groove 16, a substantially flat contact wear strip 20, preferably 
constituted of stainless steel, for engagement by the contact shoe (not 
shown) with which the rail is to be used. The rail further has thin side 
wall sections 22 which have longitudinal edges 24 that constitute the 
mouth of the groove 16. There is provided an essentially tubular, 
insulating, hollow, resilient and rigid cover member or jacket 26 
enveloping portions of the rail body 12, except at the area at the mouth 
of the groove 16 thereof. The cover member 26 is preferably a rigid PVC 
extrusion, which will not deform substantially under the pressure of a 
clamp, but which can stretch to a certain extent under the action of a 
stretching force. 
The rigid cover member 26 has a longitudinal cut 28 in its wall, throughout 
its length. The cut 28 registers with the mouth of the groove 16 of the 
rail body 12 and is disposed inwardly of two opposite wall portions 30 of 
the cover member 26. 
In accordance with the present invention, the longitudinal edges 24 of the 
rail are rounded in cross-section, and the wall portions 30 of the cover 
member 26 have cooperable curved, longitudinally-extending snap-on 
retainer portions 32 that extend along the cut 28 of the cover member and 
which are adapted to snap over the rounded longitudinal edges 24 of the 
rail body 12. According to the invention, the retainer portions 32 of the 
cover member 26 closely fit these edges 24, and extend in a 
circumferential direction through substantially a full semi-circle or 
half-cylinder, for reasons later explained. The retainer portions 32 of 
the cover member 26 have innermost edges 36 of reduced thickness, which 
are located inside of the groove 16 of this rail body 12, and the 
innermost edges 36 constitute oppositely located shoulders which face into 
the groove 16 of this rail body 12. The retainer portions 32 further have 
exterior longitudinal flanges 38 which constitute laterally and inwardly 
offset extensions of the opposite wall portions 30 of the cover member 26 
that support these retainer portions 32. 
According to the invention, the snap-on retainer portions 32 of the rigid 
cover member 26 closely fit and lock onto the rail 12 and especially by 
virtue of their curved cross sectional configuration by which they extend 
through the semi-circle referred to above. The retainer portions 32 
function as close-fitting hooks which tend to securely hold the cover 26 
to the rail 10, 12 at all times. The two opposite wall portions 30 of the 
cover member 26 can be manually flexed by a separating pressure exerted on 
the exterior flanges 38, thereby to swing the retainer portions 32 out of 
contact with the rail body 12 for facilitating removal of the cover member 
26, should this become necessary. 
It is to be noted that by the invention, the cover member 26 closely fits 
the exterior of the rail body 12 to enable the assemblage of cover member 
26 and rail body 12 to be flexed as a unit without separation of the cover 
member 26 from the rail body 12 when the assemblage is formed into a 
curved configuration as in FIG. 4. The exterior flanges 38 of the cover 
member 26 have first and second sets of shoulders 40, 42 extending along 
their free edges, the shoulders of said sets being disposed in 
back-to-back relation to each other. 
Another embodiment of the invention is shown in FIG. 2, wherein like 
components have been assigned similar numbers with the addition of the 
suffix "a". There is illustrated a modified metal rail 10a, comprising a 
formed sheet metal body 12a, having an integral flat slide contact surface 
20a, and juxtaposed longitudinally-extending edges 22a, forming a groove 
16a to receive a contact shoe (not shown). By the invention, the rail body 
12a has rounded longitudinal edges 24a which border the groove 16a in the 
rail, and a cover member designated 26a is provided. The cover member 26a 
has a longitudinal cut 28a in its wall throughout its length. The cut 28a 
registers with the mouth of the groove 16a of the rail body 12a and 
borders two opposite wall portions 30a of the cover member 26a. 
By the invention, the wall portions 30a of the cover member have cooperable 
curved, longitudinally-extending snap-on retainer portions 32a that extend 
along the cut 28a of the cover member 26a and are adapted to snap over the 
rounded longitudinal edges 24a of the rail body 12a. The retainer portions 
32a of the cover member 26a closely fit these edges 24a, and extend in a 
circumferential direction through substantially a semi-circle, as in the 
first embodiment. The retainer portions 32a of the cover member 26a have 
innermost edges 36a of reduced or tapered thickness, which are located 
inside of the groove 16a of the rail body 12, and the innermost edges 36a 
constitute oppositely located shoulders which face into the groove 16a of 
the rail body 12a. The retainer portions 32a further have exterior 
longitudinal flanges 38a which constitute laterally and inwardly offset 
extensions of the opposite wall portions 30a of the cover member 26a that 
support the retainer portions 32a. 
Still another embodiment of the invention is shown in FIG. 3, wherein like 
components have been assigned similar numbers with the addition of the 
suffix "b". There is illustrated a rail 10b with body portion 12b having a 
configuration similar to that of FIG. 1, including a flat contact strip 
20b, and a semi-rigid cover member 26b having retainer portions 32b with 
edges 36b that extend along a cut 28b of the cover member 26b and which 
snap over the rounded longitudinal edges 24b of the rail body 12b. At the 
lowermost ends of the flanges 38b, there are coextensive transverse 
shoulders 44 extending inward and terminating in upwardly extending 
flanges 46, the free longitudinal edges of which face the inside of the 
groove 16b of the rail body 12b. 
The arrangements of FIGS. 1, 2 and 3 all result in an especially snug 
retention of the cover member on the metal rail body, even when the rail 
is disposed along a curved path as indicated in either FIG. 4 or FIG. 5. 
The cover member effectively hugs the rail by virtue of the cooperable 
semi-circular engaging surfaces on the longitudinal edges of the rail body 
and on the retainer portions 32, 32a, 32b, respectively of the cover 
member 26, 26a, 26b, respectively. 
In all of the disclosed embodiments, the spacing between the exterior 
longitudinal flanges 38, 38a, 38b, respectively is preferably sufficiently 
small to prevent access to all portions of the conducting rail body 12, 
12a, 12b, respectively by the fingers of operating personnel and/or 
service technicians, thereby minimizing the possibility of inadvertent 
shock from an electrified rail. The stiffness of the cover member is 
chosen so that little yielding will occur under manual pressure, as of a 
type which would be applied to the cover member adjacent its cut, by the 
fingers of such personnel. An important safety feature is thus provided by 
the present invention, minimizing potential shock hazards which otherwise 
might be present during maintenance or test of an installed rail system of 
this type. 
The disclosed rail conductor assemblages are thus seen to constitute an 
important advance and improvement in the field of rail electrification 
systems. 
Variations and modifications are possible without departing from the spirit 
of the invention. 
Each and every one of the appended claims defines an aspect of the 
invention which is separate and distinct from all others, and accordingly 
it is intended that each claim be treated in this manner when examined in 
the light of the prior art devices in any determination of novelty or 
validity.