Patent Abstract:
A railroad crossing gate flasher assembly has a sealed, rodent-proof connection for electrical cables that pass from the foundation to a junction box. A clearance between the bottom of the junction box and the top of the foundation is sealed with a plate to prevent rodents from accessing the cables. The seal plate is mounted to the bolts that extend from the foundation and is leveled after it is inserted onto the bolts. The junction box is lowered onto the seal plate and attached to the same bolts so that the junction box also is level. The seal plate has an opening, coupling and conduit for protecting the cables.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates in general to railroad crossings for automobiles and, in particular, to a sealed, rodent-proof connection between the foundation and utility mast for a railroad gate flasher assembly at railroad crossings. 
     2. Description of the Related Art 
     At railroad grade crossings, train warning systems employ gate flasher assemblies that lower gates to keep roadway traffic off of the rails when trains pass through the crossings. The gates are typically mounted on mast assemblies that are anchored to in-place foundations in the ground. Electrical cables or wiring typically pass underground from a nearby control box, through the foundation, and up into and through a junction box located on top of the foundation to provide power and signals to a gate swing mechanism, warning lights, and bell. 
     In conventional gate flasher assembly designs, there is a clearance required between the bottom of the junction box and the top of the foundation to provide adequate space (e.g., a few inches) to properly level the junction box. The clearance is large enough for small rodents, such as mice, to enter and then climb up into the utility box. The rodents chew the insulation on the exposed electrical wiring and cause damage and electrical shorts in the signal lights and other electrical functions of the gate flasher assembly. To address this problem, railroad companies sometimes use expanding foam insulation to cover the space between the junction box and foundation. Although this practice is workable, an improved solution that permanently and completely seals the junction box and protects the wiring would be desirable to increase the reliability and durability of the gate flasher assembly. 
     SUMMARY OF THE INVENTION 
     Embodiments of a system, method, and apparatus for a railroad crossing gate flasher assembly having a sealed, rodent-proof connection between the foundation and utility mast are disclosed. The crossing gate flasher assembly is mounted on a foundation that is secured to the ground. Electrical cables pass from the foundation up into and through a junction box to power the gate swing mechanism, warning lights, and bell. A clearance between the bottom of the junction box and the foundation is sealed with a plate to prevent rodents from entering the junction box. The sealing plate seals and protects the wiring by preventing rodent infiltration. 
     In one embodiment, the seal plate is mounted to the bolts that extend from the foundation. The seal plate is leveled after it is inserted onto the bolts. The junction box is lowered onto the seal plate and attached to the same bolts. Consequently, the junction box is level because the seal plate has already been leveled. The seal plate has a central opening and electrical conduit extending downward from the opening. The conduit extends below the seal plate and provides a connection point for the electrical conduit that protrudes from underground. When the junction box is mounted to the seal plate and the conduit is coupled to the seal plate, rodents cannot infiltrate the assembly. 
     The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the features and advantages of the present invention are attained and can be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments. 
         FIG. 1  is a schematic drawing of one embodiment of a gate flasher assembly at a railroad crossing and is constructed in accordance with the invention; 
         FIGS. 2 and 3  are side and end views of one embodiment of the gate flasher assembly of  FIG. 1  and is constructed in accordance with the invention; 
         FIGS. 4 and 5  are top and side views of one embodiment of a foundation for the gate flasher assembly of  FIGS. 2 and 3  and is constructed in accordance with the invention; 
         FIGS. 6 and 7  are side and end views of one embodiment of a seal plate assembly for the gate flasher assembly of  FIGS. 2 and 3  and is constructed in accordance with the invention; 
         FIGS. 8 and 9  are enlarged side and end views of one embodiment of the seal plate for the seal plate assembly of  FIGS. 6 and 7  and is constructed in accordance with the invention; and 
         FIG. 10  is an exploded view of one embodiment of a gate flasher assembly constructed in accordance with the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1-10 , embodiments of a system, method and apparatus for a railroad crossing gate flasher assembly having a sealed, rodent-proof connection for a utility mast assembly are disclosed. As shown in  FIG. 1 , one embodiment of a railroad crossing comprises a railroad  11  for trains and a road  13  for roadway traffic  15  that crosses the railroad  11 . One or more railroad crossing gate flasher assemblies  17  are located adjacent to an intersection between the railroad  11  and the road  13 . In the configuration shown, one gate flasher assembly  17  is located on each side of the railroad  11 . A control box  14  is located in the vicinity of the intersection and provides electrical power and control signals to gate flasher assemblies  17  via underground wiring  29 . 
     In one embodiment, each of the gate flasher assemblies  17  may comprise an arm or gate  19  that is movable between a lower position ( FIG. 1 ) that extends over the road  13  to prevent automobiles  17  from crossing the railroad  11 , and an upper position ( FIGS. 2 and 3 ) that is substantially vertical and does not extend over the road  13 . The gate flasher assembly  17  also comprises a junction box  20  (e.g., a cast housing) having a gate swing mechanism  21  for moving the gate  19 . 
     The gate flasher assembly  17  also comprises warning lights  23  ( FIG. 1 ) and a bell  25  or other audible device. Each of these devices is provided with signals via wiring  29  ( FIGS. 2 and 3 ). As noted previously, the wiring  29  originates from control box  14  and extends underground. When wiring  29  emerges from the ground adjacent gate flasher assembly  17 , it is completely shielded and protected by an electrical conduit  27  that extends from the ground to an interior of the gate flasher assembly  17 . 
     In the illustrated embodiments of  FIGS. 2-5 , each gate flasher assembly  17  also may comprise a foundation  31 . The foundation  31  may comprise upper and lower horizontal plates  33  and a plurality of structural members  35  mounted therebetween. A plurality of bolts  37  (e.g., four shown) extend through bolt holes at an upper end of the foundation  31  (e.g., through upper plate  33 ) and extend upward above the upper end of the foundation  31  and upper plate  33 . In addition, a plurality of nuts  39  are threadingly secured on each of the bolts  37  (e.g., four on each bolt). The nuts  39  are movable relative to the bolts  37  for adjusting a vertical elevation thereof. In one embodiment, each bolt  37  has one nut  39  located below upper plate  33 , and three nuts  39  located above upper plate  33 , such that the upper plate  33  is captured between the first and second nuts  39  on each bolt  37 . 
     As shown in  FIGS. 2 and 3 , the bolts  37  and nuts  39  are used to mount the junction box  20  to the foundation  31 . The junction box  20  has a lower base or flange  22  with bolt holes through which the bolts  37  extend. In one embodiment, the flange  22  is captured between the third and fourth nuts  39  on each bolt  37  as shown. The flange  22  also has an aperture  24  extending through a lower end thereof that permits access into an interior thereof for electrical wiring. 
     Referring now to  FIGS. 2 ,  3  and  6 - 9 , embodiments of the invention also comprise a seal plate  41  located on the foundation  31 . The seal plate  41  has a plate  43  that is mounted to the bolts  37  between, e.g., the third and fourth nuts  39  on each bolt  37 . Thus, the plate  43  directly abuts upper ones of the nuts  39  on the bolts  37  such that the plate  43  is elevated above the top of upper plate  33  by a space or clearance  36  ( FIGS. 2 and 3 ). When leveled, the plate  43  is substantially horizontal and located above the foundation  31 . The seal plate  41  may be leveled by adjustment of the nuts  39  for proper orientation of lights  23  ( FIG. 1 ) on, e.g., gate  19 . Lights  23  should be properly oriented for visibility by the drivers of roadway traffic  15  from a distance D of 500 feet. 
     As best shown in  FIGS. 8 and 9 , the plate  43  has an opening or electrical wiring port  45  that extends therethrough and a pattern of bolt holes  47  that align with the bolt hole pattern formed on flange  22  and upper plate  33  through which the bolts  37  extend. A coupling  49  is aligned with and extends downwardly from the electrical wiring port  45  through a hole  34  ( FIG. 4 ) in upper plate  33 . The hole  34  is sufficiently large to allow articulation of coupling  49  therein when seal plate  41  is leveled. The junction box  20  is mounted on top of and directly abuts the seal plate  41 , such that the junction box  20  is leveled by the leveling of the seal plate  41 . In one embodiment, the junction box includes a removable cover that can be removed without removing the seal plate. 
     The electrical wiring  27  (see, e.g.,  FIGS. 2 and 3 ) extends downward from the junction box  20  through the aperture  24 , the electrical wiring port  45  and coupling  49  of the plate  43 , and within the conduit  27  extending through an interior of the foundation  31 . In this way, the plate  43  and coupling  49  cover the aperture  24  in the junction box  20  to protect the wiring. In addition, a connector  51  is mounted to and located below the coupling  49  of the plate  43 , and the conduit  27  is connected to and located below the connector  51  for protecting the electrical wiring  29 . The conduit  27  extends from the interior of the foundation  31  to an exterior of the foundation  31 . 
     In another embodiment, the invention may comprise a railroad crossing gate flasher assembly having a foundation adapted to be located adjacent to an intersection between a railroad for trains and a road for automobiles. A junction box is mounted to the foundation and has a gate that is movable between upper and lower positions. Electrical wiring extends downward through an aperture on a lower end, and the junction box is above and spaced apart from the foundation. 
     A seal plate is positioned between the foundation and the junction box and has a plate with an electrical wiring port and a coupling extending downwardly therefrom. A connector is mounted to and located below the coupling, and a conduit is connected to and located below the connector. The electrical wiring extends from the aperture and through the electrical wiring port, coupling, connector and conduit for protecting the electrical wiring from the junction box to an exterior of the foundation. In one embodiment, the coupling, connector and conduit extend through an interior of the foundation, and the conduit extends from the interior of the foundation to the exterior of the foundation. 
     The railroad crossing gate flasher assembly may further comprise warning lights, a bell, and a gate swing mechanism for moving the gate, the warning lights, bell and gate swing mechanism being provided with electrical power and signals by the electrical wiring. The plate may be leveled above the foundation for leveling the junction box and is substantially horizontal. For example, the plate may be leveled on bolts extending through an upper end of the foundation, and nuts on each of the bolts that are movable relative to the bolts for leveling the plate. 
     In still another embodiment, the invention may comprise a complete railroad crossing having a railroad for trains, and a road for vehicular traffic (e.g., automobiles) that crosses the railroad and forms an intersection therebetween. A warning system is located at the intersection for alerting drivers of automobiles of trains in a vicinity of the intersection. The warning system comprises a gate flasher assembly and a control box for distributing electrical power and control signals to the gate flasher assembly via electrical wiring. The gate flasher assembly may comprise a foundation and a junction box mounted to the foundation with the electrical wiring extending downward through an aperture on a lower end, the junction box being above and spaced apart from the foundation. 
     A seal plate is positioned between the foundation and the junction box and comprises a plate having an electrical wiring port with a coupling extending downwardly therefrom, a connector mounted below the coupling, and a conduit mounted below the connector, such that the electrical wiring extends from the aperture and through the electrical wiring port, coupling, connector and conduit for protecting the electrical wiring from the junction box to the control box. 
     In yet another embodiment, a utility mast assembly comprises a foundation, a plurality of bolts extend through an upper end of the foundation and extending upward above the upper end of the foundation. A plurality of nuts are on each of the bolts, and the nuts are movable relative to the bolts for adjusting their vertical elevation. A seal plate is located on the bolts and directly abuts upper ones of the nuts on the bolts. 
     The seal plate comprises a flat plate that is substantially horizontal and located above the upper end of the foundation and which is leveled by adjustment of the nuts. The plate has an electrical wiring port that extends therethrough, and a pattern of bolt holes through which the bolts extend. A coupling is aligned with and extends downwardly from the electrical wiring port away from the plate. A junction box is mounted on top of and directly abutting the seal plate. The junction box has a pattern of bolt holes that align with the pattern of bolt holes in the plate and through which the bolts extend, and electrical wiring extending downward through an aperture on the lower end of the junction box, the electrical wiring port and coupling of the plate, and an interior of the foundation, such that the plate and coupling otherwise cover the aperture in the junction box. 
     In still another embodiment, the invention may comprise a utility mast assembly having a utility mast that extends in a vertical direction above ground with a junction box at a lower end thereof. The junction box includes a bottom aperture through which electrical wires extend up into the utility mast. As illustrated in the various drawings, an in-place foundation is adapted to be preassembled and buried in the ground to form a foundation for supporting the utility mast in the vertical direction. 
     A seal plate is positioned between the foundation and the junction box, and is attached to the foundation with a gap therebetween so that the seal plate can be leveled relative to the foundation. The seal plate also is attached to the junction box and comprises a plate having an electrical wiring port with a coupling extending downwardly therefrom, a connector mounted to and located below the coupling, and a conduit connected to and located below the connector. The electrical wiring extends from the aperture and through the electrical wiring port, coupling, connector and conduit, such that the seal plate, coupling and connector form a rodent-proof seal between the junction box and the conduit. The junction box may include a removable cover that can be removed without removing the seal plate. 
     While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.

Technology Classification (CPC): 4