RAILROAD SLEEPER AND PROCESS FOR MANUFACTURING A RAILROAD SLEEPER

Abstract

A railroad sleeper (1) for fixation of at least a pair of rails (2,2′) of a railroad network is provided, including a contact surface (3), wherein each rail of the pair of rails (2,2′) is fixed spaced apart from each other, the railroad sleeper (1) being configured by including a hollow sector (4) delimited by association of the contact surface (3) with the anchorage walls (5,5′), thus establishing a free portion (17) adjacent to the anchorage walls (5,5′) and opposite the contact surface (3). An embodiment in which the hollow sector (4) of the railroad sleeper is delimited by a support surface and the process of manufacturing a railroad sleeper is also provided.

Claims

1. A railroad sleeper (1) for fastening of at least one pair of rails (2,2′) of a railroad network, the railroad sleeper (1) comprising a contact surface (3), wherein each rail of the pair of rails (2, 2′) is fixed spaced apart from each other, the railroad sleeper (1) comprising a hollow sector (4) delimited by association of the contact surface (3), thus establishing a free portion (17) adjacent to anchorage walls (5.5′) and opposite the contact surface (3), wherein the contact surface (3) and the anchorage walls (5, 5′) establish an intermediate layer (15) of the railroad sleeper (1), so that: the intermediate layer (15) is manufactured from a polymeric composition comprising a bending module higher than or equal to 5000 Mpa, and wherein at least fixation blocks (10) or metallic plates (22, 22′) are arranged at portions of the hollow sector (4) opposite the point of arrangement of the rails on the contact surface (3).

2. The railroad sleeper (1) according to claim 1, wherein the intermediate layer (15) is manufactured from a composition comprising polypropylene and fiberglass.

3. The railroad sleeper (1) according to claim 1, wherein the intermediate layer (15) is manufactured from a composition comprising polypropylene and 5% to 40% by weight of the composition of fiberglass.

4. The railroad sleeper (1) according to claim 1, wherein a first width (L1) of the railroad sleeper is defined by the distance between the anchorage walls (5,5′), the anchorage walls (5,5′) further comprising support points (7,7′,8,8′) opposite the points of association between the contact surface (3) and the anchorage walls (5,5′), the distance between the support points (7,7′, 8,8′) defining a second width (L.sub.2) of the railroad sleeper (1).

5. The railroad sleeper (1) according to claim 1, wherein the contact surface (3) protrudes beyond the anchorage walls (5, 5′).

6. The railroad sleeper (1) according to claim 4, wherein the association between the contact surfaces (3), anchorage walls (5, 5′) and support (7,7′,8,8′) takes place by means of a segment in curve.

7. The railroad sleeper (1) according to claim 1, further comprising at least a support groove (9), each of the support grooves (9) protruding from the contact surface (3) to the hollow sector (4) of the railroad sleeper (1).

8. The railroad sleeper (1) according to claim 1, wherein the support grooves (9) further protrude from at least one of the anchorage walls (5, 5′) to the hollow sector (4) of the railroad sleeper (1).

9. The railroad sleeper (1) according to claim 1, wherein the anchorage walls (5, 5′) further comprise a plurality of anchorage teeth (12), the plurality of anchorage teeth (12) arranged on the anchorage walls (5, 5′) that are not adjacent the hollow sector (4) of the railroad sleeper (10).

10. The railroad sleeper (1) according to claim 4, wherein the support points (7,7′, 8,8′) are configured as simple support points (7, 7′), wherein the first width (L.sub.1) of the railroad sleeper (1) is equal to the second width (L.sub.2) of the railroad sleeper (1).

11. The railroad sleeper (1) according to claim 4, wherein the support points (7,7′, 8,8′) are configured as double support points (8, 8′), wherein the first width (L.sub.1) of the railroad sleeper is equal to or smaller than the second width (L.sub.2) of the railroad sleeper (1).

12. The railroad sleeper (1) according to claim 11, wherein the double support points (8, 8′) protrude at least out of or into the hollow sector (4) of the railroad sleeper (1), wherein the double support points, when they protrude only into the hollow sector (4), establish the second width (L.sub.2) equal to the first width (L.sub.1) of the railroad sleeper (1).

13. The railroad sleeper (1) according to claim 11, wherein the double support points (8, 8′) protrude out of and into the hollow sector (4) of the railroad sleeper (1).

14. The railroad sleeper (1) according to claim 1, wherein the anchorage walls (5, 5′) are parallel.

15. The railroad sleeper (1) according to claim 1, wherein the anchorage walls (5, 5′) are orthogonal to the contact surface (3).

16. The railroad sleeper (1) according to claim 1, wherein the contact surface (3) is a plane surface.

17. The railroad sleeper (1) according to claim 1, wherein the contact surface (3) and the anchorage walls (5, 5′) further establish an inner wall (13) of the railroad sleeper (1), so that: the inner wall (13) of the railroad sleeper (1) is manufactured from a first polymeric material.

18. The railroad sleeper (1) according to claim 1, wherein the contact surface (3) and the anchorage walls (5, 5′) further establish an outer wall (14) of the railroad sleeper (1), so that: the outer wall (14) of the railroad sleeper (1) is manufactured from a first polymeric material.

19. The railroad sleeper (1) according to claim 1, wherein the contact surface (3) and the anchorage walls (5, 5′) further establish an inner wall (13) and an outer wall (14) of the railroad sleeper (1), so that: the inner wall (13) of the railroad sleeper (1) is manufactured from a first polymeric material; and the outer wall (14) of the railroad sleeper (1) is manufactured from the first polymeric material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] The present invention will now be described in greater detail with reference to an example of embodiment represented in the drawings. The figures show:

[0065] FIG. 1 is a top representation of a railroad network suitable for receiving the railroad sleeper proposed in the present invention, wherein FIG. 1(a) represents a simple railroad network and FIG. 1(b) represents a railroad network of multiple rails;

[0066] FIG. 2 is a representation of the cross section of an embodiment proposed for the railroad sleeper;

[0067] FIG. 3 is an additional representation of the cross section of an embodiment proposed for the railroad sleeper, showing its preferred dimensions;

[0068] FIG. 4 is a representation of the cross section of an additional embodiment proposed for the railroad sleeper;

[0069] FIG. 5 is a representation of the cross section of an additional embodiment proposed for the railroad sleeper;

[0070] FIG. 6 is a representation of the cross section of the structural embodiment proposed for the railroad sleeper shown in FIG. 5, illustrating its preferred configurations;

[0071] FIG. 7 is a representation of the cross section of an additional embodiment of the railroad sleeper proposed in the present invention;

[0072] FIG. 8 is an additional representation of the cross section of the railroad sleeper shown in FIG. 7, illustrating its preferred;

[0073] FIG. 9 is a representation of an additional embodiment proposed for the railroad sleeper proposed in the present invention, this embodiment comprising a support groove;

[0074] FIG. 10 is a representation of an additional embodiment proposed for the railroad sleeper proposed in the present invention, this embodiment comprising a plurality of support grooves;

[0075] FIG. 11 is a representation of an additional embodiment proposed for the railroad sleeper proposed in the present invention, this embodiment comprising a plurality of Anchorage teeth;

[0076] FIG. 12 is a representation of an additional embodiment proposed for the railroad sleeper of the present invention, this embodiment comprising a contact surface protruding beyond the anchorage walls and further disclosing double support points, wherein FIG. 12(a) further discloses a support groove, FIG. 12(b) discloses double support points, FIG. 12(c) discloses a plurality of support grooves, and FIG. 12(d) discloses a plurality of anchorage teeth;

[0077] FIG. 13 is a representation of an additional embodiment proposed for the railroad sleeper of the present invention, this embodiment illustrating the embodiment in which the contact surface does not protrude beyond the anchorage walls and further comprising double support point that protrude into the hollow sector, wherein FIG. 13(a) further discloses a support groove, FIG. 13(b) discloses double support points that protrude into the hollow sector, 13(c) discloses a plurality of support grooves, and FIG. 13(d) discloses a plurality of anchorage teeth;

[0078] FIG. 14 is a representation of the cross section of the structural embodiment proposed for the sleeper illustrated in FIG. 13(c), highlighting its preferred dimensions;

[0079] FIG. 15 is an additional representation of the cross section of a structural embodiment proposed for the railroad;

[0080] FIG. 16 is a representation of the cross section of a structural embodiment proposed for the railroad sleeper, highlighting its inner and outer walls, and an intermediate layer;

[0081] FIG. 17 is a representation of the cross section of an additional embodiment of the railroad sleeper proposed in the present invention, this embodiment further comprising the support surface illustrated in FIG. 17(a), FIG. 17(b) further illustrates a plurality of support grooves, FIG. 17(c) further illustrates a plurality of anchorage teeth, and the protrusion of the support and contact surfaces beyond the anchorage walls, and FIG. 17(d) illustrates a plurality of anchorage teeth.

[0082] FIG. 18 is a profile representation of a railroad network comprising the railroad sleeper proposed in the present invention, further illustrating the fixation blocks;

[0083] FIG. 19 is a representation of the fixation of the railroad sleeper to a fixation block and further making use of a fixation element arranged transversely on the sleeper;

[0084] FIG. 20 illustrates possible structural embodiments for the fixation blocks to be used in conjunction with the railroad sleeper proposed in the present invention;

[0085] FIG. 21 illustrated additional embodiments for the fixation blocks to be used in conjunction with the railroad sleeper proposed in the present invention; and

[0086] FIG. 22 illustrated the fixation of the railroad sleeper proposed in the present invention by means of metallic plates, wherein FIG. 21(a) illustrates the use of a smaller metallic plate as compared to the metallic plate illustrated in FIG. 21(b).

[0087] FIG. 23 illustrated the fixation of the railroad sleeper shown in FIG. 19 by means of metallic plates, wherein FIG. 23(a) 23(b) illustrates segmented plates.

DETAILED DESCRIPTION OF THE FIGURES

[0088] The present invention relates to a railroad sleeper 1 (called also sleeper 1).

[0089] Structurally and with reference to FIGS. 1 to 16, the sleeper 1 proposed in the present invention comprises a hollow sector 4, thus enabling the ballast used in the railroad network to penetrate and be compacted into the sleeper 1, thus increasing the rigidity of the sleeper/ballast assembly.

[0090] FIGS. 1 to 16 illustrate preferred structural embodiments proposed for the railroad sleeper 1, all of them maintaining the characteristic referring to the shaping of the hollow sector 4, as well as to the material (composite) used. The particularities of each embodiment will be discussed hereinafter.

[0091] In reference to FIG. 1, the sleeper 1 proposed is used for fixing at least one pair of rails 2,2′ of a railroad. It should be mentioned that the sleeper 1 is suitable for use in simple railroad networks, provided with only one pair of rails 2, 2′, as shown in FIG. 1(a), or still it may be used at point of the railroad network that comprise a number of rails as shown in 1(b).

[0092] FIG. 1 further makes reference to a contact surface 3 of the proposed sleeper 1, said surface 3 being configured preferably as a plane surface for arrangement of each rail 2, 2′ of the railroad network.

[0093] FIG. 2 illustrates a cross-sectional view of a first structural embodiment of the railroad sleeper illustrated in FIG. 1. One notes the contact surface 3, preferably plane, from which anchorage walls 5 and 5′ protrudes, thus delimiting the hollow sector 4 mentioned before.

[0094] More specifically and with reference to FIG. 2, the hollow sector 4 is delimited from the contact surface 3 and by means of Anchorage walls 5, 5′. Thus, a free portion adjacent to the anchorage walls 5, 5′ is established, opposite the contact surface 3. In other words, the embodiment proposed for the railroad sleeper 1 establishes an inverted-U shape.

[0095] Thus, the free portion 17 should be understood as a (face) bored-through (opened) portion of the hollow sector 4, this portion enabling the ballast of the railroad network to penetrate the railroad sleeper 1, and more specifically of the hollow sector 4.

[0096] The lower portion of the anchorage walls 5, 5′, that is, the portion that supports the sleeper 1 on the soil, is called support points 7, 7′, such support points 7, 7′ being opposite the points of association between the contact surface 3 and the anchorage walls 5, 5′.

[0097] With reference to FIGS. 3 and 4, the anchorage walls 5, 5′ delimit a first width L.sub.1 of the railroad sleeper 1 proposed. As shown in FIG. 3, and considering a preferred thickness E for the sleeper 1, the first width L.sub.1 is delimited by the outermost portions (outer walls) of the anchorage walls 5,5′, that is, the portions that are not adjacent to the hollow sector 4.

[0098] With regard to the support points, they may assume different structural embodiment for the proposed sleeper 1, as shown in FIGS. 2 to 4.

[0099] The embodiment shown in FIGS. 2 and 3 is referred to as simple support points 7, 7′, wherein the contact thickness of the sleeper 1 with the ground is configured as the thickness E itself of the sleeper 1.

[0100] On the other hand, the embodiment shown in FIG. 4 and more specifically in FIG. 4(a) presents double support points 8, 8′, wherein the contact thickness of the sleeper 1 with the ground exhibits dimensions larger than the thickness E of the sleeper 1.

[0101] More specifically, the distance between the support points 7, 7′ shown in FIG. 3 and the support points 8, 8′ shown in FIG. 4 (FIG. 4(b)) define a second width L.sub.2 of the railroad sleeper. Thus, in the embodiment in which the simple support points 7, 7′ are used, the first width L1 has dimensions equal to those of the second width L.sub.2, as shown in FIG. 3.

[0102] On the other hand, in the embodiment in which the double support points 8, 8′ are used, the first width L.sub.1 is smaller than the second width L.sub.2, as shown in FIG. 4, more specifically in FIG. 4(b).

[0103] FIG. 5 illustrate a third embodiment valid for the proposed sleeper 1. In this embodiment, one observes the elements discussed before in the previous embodiments, such as contact surface 3 and anchorage walls 5, 5′.

[0104] The proposal shown in FIG. 5 makes use of simple support points 7, 7′, thus establishing equal dimensions for the first and second widths L.sub.1 and L.sub.2, respectively (as shown in FIG. 6).

[0105] With a view to potentiate the support of the railroad sleeper 1 proposed in the present invention, there is also, in the embodiment shown in FIGS. 5 and 6, a groove 9 protruding from the contact surface 3 and toward the hollow sector 4 of the railroad sector 4 of the railroad sleeper 1.

[0106] FIG. 7 illustrates an additional structural embodiment for the railroad sleeper 2 proposed, this embodiment making use of the support projections 9 and of the double support points 8, 8′.

[0107] The support groove 9 may protrude through the whole height of the hollow sector 4, as illustrated in the embodiments shown in FIGS. 6 and 7, or, alternatively, the later may protrudes freely from the support base 3 and toward the hollow sector 4, as shown in FIG. 9.

[0108] In an additional structural configure, the support projections 9 further protrudes from at least one of the anchorage walls 5, 5′ and toward the hollow sector 4 of the railroad sleeper 1.

[0109] Such an embodiment is shown in FIG. 10, where one observes that this proposal comprises a support groove 9 protruding from the contact surface 3 and a support groove protruding from the anchorage walls 5 and 5′.

[0110] An alternative structural embodiment for the railroad sleeper comprises the support projections 9 protruding from only the anchorage walls 5, 5′, or still protruding from only one of the Anchorage walls 5, 5′. Further, the number of support projections 9 shown in the figures should not be considered a limitative characteristic of the present invention.

[0111] The proposed railroad sleeper 1 further comprises a plurality of anchorage teeth 12, such anchorage teeth 12 being preferably arranged on at least one of the anchorage walls 5, 5′.

[0112] More specifically, the Anchorage teeth 12 are arranged in the portion of the anchorage walls 5, 5′ not adjacent the hollow sector 4, or still, for a better understanding, the anchorage teeth 12 are arranged on the outer walls of the anchorage walls 5, 5′.

[0113] As can be seen in FIG. 11, the anchorage teeth 12 are configured as recesses (channels) that preferably travel the whole length of the sleeper.

[0114] The anchorage teeth 12 do not interfere in the mechanical characteristics of the sleeper 1, more specifically such teeth 12 provide greater Anchorage of the sleeper 1 to the ballast, enabling the ballast to penetrate into each of the anchorage teeth 12. Additionally, the arrangement of the anchorage teeth 12 further provides saving of material and optimization in the manufacture of the sleeper 1.

[0115] In alternative embodiments, the railroad sleeper 1 might be configured so that the contact surface 3 would protrude beyond the anchorage walls 5, 5′, as shown in FIG. 12 of the present invention. In addition, the anchorage walls 5, 5′ may be parallel or orthogonal to the contact surface (3).

[0116] It is noted that such embodiments make use of double support points 8, 8′, wherein 12(a) illustrates the sleeper 1 comprising a support groove 9 protruding from the contact surface 3 and toward the hollow sector 4. On the other hand FIG. 12(b) illustrates the sleeper without any support groove 9 in its hollow sector 4.

[0117] FIG. 12(c) illustrates the sleeper 1 provided with support projections 9 from the contact surface 3 and also from the Anchorage walls 5, 5′, and, finally, FIG. 12(d) illustrates the sleeper 1 provided with a support groove 9 from the contact surface 3 and also provided with Anchorage teeth 12.

[0118] In the embodiments in which the railroad sleeper 1 comprises double support points 8, 8′, such points 8, 8′ may protrude out of the hollow sector 4 (as shown in FIG. 12), or alternatively such support points 8, 8′ may protrude both out of the hollow sector 4 and into it, as shown in FIG. 13. In another alternative embodiment, the support points 8, 8′ might protrude only into the hollow sector 4. In this case, the second width L.sub.2 of the sleeper would assume a dimension equal to the first width L.sub.1.

[0119] The embodiments shown in FIG. 13 are similar to those of FIG. 12 with respect to the arrangement of the anchorage projections 9. One just observes that in FIG. 13 the contact surface 3 does not protrude beyond the anchorage walls 5, 5′.

[0120] The structural embodiments proposed for the railroad sleeper 1 having been presented, their preferred embodiments are discussed hereinafter.

[0121] The thickness E of the sleeper 1 preferably assumes the value of 2 centimeters (cm), so that values ranging from 1 to 4 centimeters would be acceptable. In the embodiments where the sleeper 1 comprises anchorage teeth 12, such teeth comprise a thickness E.sub.1 ranging from 0.2 to 0.5 cm.

[0122] Thus, and with specific reference to FIG. 11, each of the anchorage teeth 12 is provided with a thickness E.sub.1 (thickness of the Anchorage teeth E1) that preferably range from 0.2 cm to 0.5 cm.

[0123] Further with reference to FIG. 11, the height hi of each anchorage tooth 12 assumes preferable values from 0.5 to 2.0 cm.

[0124] For any of the embodiments proposed for the railroad sleeper 1, the first width L.sub.1 preferably is equivalent to 24 cm, so that values in the range 18 to 30 cm would be acceptable.

[0125] The embodiments that make use of double support points 8, 8′ (protruding both into and out of the hollow sector 4) establish a second preferred width L2 of 32 cm, so that values in the range 19 to 48 cm would be acceptable, provided that obviously the second width L.sub.2 (double support points) is larger than the first width L.sub.1 (simple support points).

[0126] In the embodiment in which the double support points 8, 8′ protrude only into the hollow sector 4, the second width L2 will assume a value equal to the first width L.sub.1.

[0127] With regard to the width of the double support points 8, 8′, referred to as third width L.sub.3 (FIGS. 4, 8, 11 and 14), the later preferably is equivalent to 6 cm (FIGS. 4, 8 and 11), so that values in the range from 1.5 to 12 cm would be acceptable. In the case of the embodiment shown in FIG. 14, there is a preferred third width L.sub.3 of 10 cm, wherein the range of 2 to 20 cm is acceptable.

[0128] As to the height of the railroad sleeper 1 proposed in the present invention, it is referred to as a first height H and preferably is equivalent, for any of the embodiments proposed, to 19 cm, so that values in the range from 14 to 20 cm would be acceptable.

[0129] In the embodiments that make use of the support groove 9, such an element protrudes from the contact surface 3 at values in the range from 0.5 to 19 cm, thus establishing a height of the Anchorage groove h.sub.3, as shown in FIG. 1. Obviously, the upper limit of this range represents the embodiment in which such a groove extends along the whole height of the hollow sector 4 (FIGS. 5 and 6).

[0130] The width of the anchorage groove, referred to as L.sub.4, assumes preferred values from 0.5 to 3.0 cm.

[0131] For support projections 9 protruding from the anchorage walls 5, 5′, one should reduce the maximum limit of the height h.sub.3 to the value used in the thickness E of the railroad sleeper 1.

[0132] The association of the anchorage walls 5, 5′ with the contact surface 3 and the double support points 8, 8′ may be carried out orthogonally, as shown in previous figures, alternatively it may be carried out by segments in curvature, as in the embodiment shown in FIG. 15.

[0133] The same thing occurs for the embodiment of the support groove 9, which is suitable to be arranged orthogonally with respect to the contact surface 3 and anchorage walls 5, 5′, or alternatively it may be configured from segments in curvature.

[0134] In order for the sleeper 1 to be capable of standing the stresses of its application field, there is the need to use a material having a high elastic module (high rigidity), having also high resistance to impact, resistance to fatigue and high market availability.

[0135] More specifically and in a preferred manner only, the inner wall 13 and an outer wall 14 of the sleeper 1 are manufactured from the first material, preferably a polymeric material and more preferably a pure polymeric material.

[0136] In a further preferred embodiment, the contact surface (3) and the anchorage walls (5, 5′) further establish an inner wall (13) and an outer wall (14) of the railroad sleeper (1), so that the inner wall (13) of the railroad sleeper (1) is manufactured from a first polymeric material; and the outer wall (14) of the railroad sleeper (1) is manufactured from the first polymeric material.

[0137] The inner and outer walls 13, 14 are delimited by the contact surface 3 and anchorage walls 5, 5′, as better shown in FIG. 16.

[0138] In FIG. 16, the outer wall 14 is represented by solid line. On the other hand, the inner wall 13 of the railroad sleeper 1 is referenced by dashed line.

[0139] On the other hand, the inner portion of the walls 13 and 14, referred to as an intermediate layer 15, is preferably made from a composition that preferably, but not exclusively comprises the first material, more preferably a composition of polypropylene with fiberglass, and still more preferably a composition of polypropylene with a fiberglass mass preferably between 5% and 40% (by weight of the composition) and, even more preferably from 33% to 37% by weight of the composition of fiberglass.

[0140] It should be mentioned that the manufacture of the inner wall 13 and the outer wall 14 from the same material used in the manufacture of the intermediate layer 15 (in this case, polypropylene) is just a preferred characteristic of the present invention. Thus, the walls 13 and 14 might be manufactured from a material other than that used in layer 15, as long as obviously it provides the necessary adherence to the piece.

[0141] Such a preferred characteristic in the material of the proposed sleeper 1, wherein the inner 13 and outer 14 walls are preferably made from polypropylene and the intermediate layer 15 is made from a composition of polypropylene with fiberglass, is valid for all the structural embodiments proposed for the railroad sleeper 1, and not only for the embodiment shown in FIG. 16.

[0142] The thickness of one of the inner walls and outer walls 13 and 4 preferably ranges from 0.005 to 0.05 cm, while the thickness of the inner layer 15 may be achieved by subtracting the thickness E of the railroad sleeper by the value of the thickness of one of the inner 13 and outer 14 walls.

[0143] It is important to point out that the use of the composition of polypropylene with fiberglass in the intermediate layer 15 should be considered just a preferred characteristic of the present invention, so that any material (composition) having bending module higher than or equal to 5000 MPa might be used. Finally, one should understand that the bending module should be measured (determined) according to the Standard ISO 178.

[0144] For fixation of the proposed sleeper 1 to the rails 2, 2′, fixation blocks 10 should be arranged in the hollow sector 4 of the sleeper 1. These blocks have the primary function of enabling the installation of the tirefonds and installation of the fixing devices that fasten the rails 2, 2′ to the sleeper. More specifically, such blocks 10 prevent lateral movements of the railroad and should be arranged in the portion of the sleeper 1 that is below the rails 2, 2′, or, in other words, in the portion of the sleeper 1 opposite the point of arrangement of the tracks on the contact surface 3.

[0145] FIG. 18 illustrates a profile view of a railroad network in which the sleeper 1 proposed in the present invention is used. In this figure, one observes the sleeper 1, each of the rails 2, 2′ fixed to the contact surface 3 by means of the support plates 20 and tirefonds 21.

[0146] One further observes in the hollow sector 4 of the sleeper 1, which, when fixed to a railroad network, enables the ballast of the railroad to penetrate the hollow sector 4 and, with the compaction of the ballast in the hollow sector 4, greater rigidity of the ballast/sleeper system will be achieved.

[0147] One further notes in FIG. 18 the fixing blocks 10 arranged below each of the rails 2, 2′, such blocks 10 being configured as solid blocks and may be made from wood, recycled material, concrete, polyethylene, polypropylene, and still may be made from the same material used in the manufacture of the sleeper 1, a composition of polypropylene with fiberglass. In the preferred embodiment, the fixing blocks 10 are made from polyethylene.

[0148] Such fixing blocks 10 may be manufactured by different processes, such as extrusion, intrusion, injection and machining processes that use massive blocks to obtain the final shape of the piece.

[0149] For better fixation of the blocks 10 to the sleeper 1, fixing elements, preferably configured as hexagonal screws 26 might be arranged transversely to the sleeper 1, as preferably represented in FIG. 19. FIGS. 20 and 21 illustrate shapes proposed for the fixing blocks 10. It is important to mention that the structural embodiments proposed for the railroad sleeper 1 enable use of any of the embodiments of the fixing blocks 10.

[0150] The preferred dimensions of each of the proposed fixing blocks 10 are described as follows:

[0151] With reference to FIG. 20(a), it preferably represents a larger base in 60 cm, so that values ranging from 50 to 80 cm would be acceptable.

[0152] The smaller base has a preferred value of about 40 cm, the preferred height is of 15 cm, so that values in the range 13 to 17 cm would be acceptable, and the preferred depth is equivalent to 20 cm, for both the height and the width.

[0153] The preferred values for the fixing block illustrated in FIG. 20(v) are of 15×13×20 (width×height×depth), while for the embodiment shown in FIG. 20(c) there are preferred values of 7.5 cm for the smaller base and 15 cm for the larger base, the preferred depth being of 20 cm and the preferred height being equivalent to 13 cm.

[0154] The proposal illustrated in FIGS. 20(d) and 20(e) disclose fixing blocks 10 made by injection process. One notes that the blocks 10 illustrated in such figures comprise a number of structures 27 designed for supporting loads referring to the arrangement of railroad coaches.

[0155] Thus, the structures 27 combine resistance and lightness and establish a new possibility of arranging the fixing blocks 10. On further notes that the blocks 10 discloses in FIGS. 20(d) and (20(e) further comprises orifices 28 already designed for arrangement of appropriate screws. It should be pointed out that the arrangement and the shape of the structures 27 should not be limited to the embodiments shown in FIGS. 20(d) and 20(e).

[0156] Further, any of the fixing blocks 10 discussed in the present invention and disclosed in FIGS. 20(a), 20(b), 20(c), 21(a) and 21(b) might be made by an injection process, thus configuring a structured block (with the structures 27).

[0157] As to the dimensions of the fixing blocks represented in FIGS. 20(d) and 20(e), one may use preferably the same values already described for the fixing block 10 shown in FIGS. 20(a).

[0158] The structural embodiment of the fixing block shown in FIG. 21(a) has larger base preferably at 60 cm, so that values in the range from 50 to 60 cm would be acceptable, its preferred height being of 15 cm, values between 13 and 17 cm being acceptable, preferred depth being of 20 cm, while the width of each of the bases adjacent the cavity 24 is preferably of 7.5 cm.

[0159] Finally, the proposal illustrated in FIG. 21(b) exhibits the same values for the larger base, height and depth as the values of the embodiment 21(a) and a preferred width of 15 cm for each of the smaller bases adjacent the cavity 24. One should mention that the above-mentioned dimensions were given by way of example, without entailing any limitation of the present invention.

[0160] Alternatively to the use of the fixing blocks 10, one may fixe the sleeper 1 by means of the already existing cast-iron plates 25 and still by means of the metallic plates 22 (preferably made of steel) fixed to the existing plates (plate 25) by means of conventional fixing element 23, such as screws, press washers and nuts.

[0161] Such fixing form is illustrated in FIG. 22, wherein FIG. 22(a) shows metallic plates 22 of smaller size as compared to that represented in FIG. 22(b). The embodiment shown in FIG. 22(b), being arranged completely between the rails of the railroad network, ends up increasing the strength of the sleeper 1. It is further pointed out that the number of metallic plates 22 used should not restrict the number shown in FIG. 22.

[0162] In addition to the structural embodiments proposes for the railroad sleeper 1, where one establishes the hollow sector 4 and its free portion 17, the present invention also proposes the shaping of a railroad sleeper 1′ further comprising a support surface 3.′

[0163] Said support surface 3′ is opposite the contact surface 3 and adjacent the Anchorage walls 5 and 5′. In this way, the hollow sector 4 of the railroad sleeper 1′ is delimited from the association of the contact surface 3 with the support surface 3′ and by means of the anchorage walls 5, 5′. Thus in the embodiments shown in FIG. 17, the sleeper 1′ does not comprise the free portion 17, since its hollow sector 4 is delimited also by the support surface 3.′

[0164] It should be pointed out that the other characteristics and embodiment proposed for the railroad sleeper 1 comprising the free portion 17 are also valid for the embodiment of the railroad sleeper 1′ shown in FIG. 17 and that comprises the support surface 3′.

[0165] For example, in the railroad sleeper 1′ provided with the support surface 3′, is reference to the inner 13 and outer 14 walls is valid, as well as the use of the material and composition already mentioned when describing the railroad sleeper 1. Further, the reference to the use of the support blocks 10 is also valid for this embodiment. In this regard, FIG. 23 illustrates additional possibilities of fixing the railroad sleeper 1′, wherein metallic plates 22′ are used (the number of metallic plates 22′ does not restrict the number represented in the figures). The comment already made in FIGS. 22(a) about the increase in the strength of the sleeper 1 is also valid for the representation of FIGS. 23(a).

[0166] Further, as one observes in the embodiment shown in FIG. 7(b), the railroad sleeper 1′ comprises support projections 9, which protrude from at least one of the contact surfaces 3, support surface 3′ and Anchorage walls 5.5′.

[0167] Further, as observed in FIG. 17(c), the contact surface 3 may protrude beyond the Anchorage walls 5, 5′, together with the support surface 3′ proposed in this embodiment.

[0168] One observes in FIGS. 17(c) and 17(d) the proposal of arranging the Anchorage teeth 12, just as proposed before for the embodiment of the railroad sleeper 1 in which its hollow sector 4 does not comprise the support surface 3.′

[0169] In the embodiment shown in FIG. 17, the simple support points 7, 7′ should be understood as the proposal in which the contact surface 3 and the support surface 3′ do not protrude beyond the Anchorage walls 5, 5′, as shown in FIGS. 17(a), 17(b) and 17(d).

[0170] On the other hand, the double support points 8, 8′ should be understood as the proposal in which the contact surface 3 and the support surface 3′ protrudes beyond the Anchorage walls 5, 5,′ just as the embodiment proposed in FIGS. 17(c).

[0171] In summary, except for the difference in the shaping of the hollow sector 4, the railroad sleeper 1′ comprises all the characteristics mentioned before for the railroad sleeper 1.

[0172] It is important to mention that the embodiments illustrated in the figures of the present invention are preferred embodiments for the railroad 1,1′.

[0173] Thus, considering both the railroad sleeper 1 provided with a free portion 17 and the railroad sleeper 1′ with the support surface 3′, it is acceptable to propose an embodiment that is not explicitly shown in the figures presented, but that uses combinations of the characteristics set forth in the figures.

[0174] For example, considering the embodiment shown in FIG. 17, it would be acceptable to propose a structural embodiment for the railroad sleeper 1′ that makes use of the Anchorage teeth 12 and of the support projections 9, even if the figures do not explicitly illustrate such an embodiment.

[0175] The structural forms proposed for the railroad sleeper 1, 1′ of the present invention are obtained preferably by an extrusion/co-extrusion process. Such a process is carried out by means of a conventional extruding machine, provided, for example, with a feed point, thread cannon, matrix, calibrator and velocity reducer.

[0176] The structural embodiment of the extruding machine do not represent the preferred aspect of the present invention, so that extruding machines known from the prior art may be used to shape the railroad sleeper 1, 1,′ proposed.

[0177] On the other hand, determined parameters and extrusion-process steps should be followed for correct shaping of the sleeper 1, 1′, such parameters and steps being discussed hereinafter.

[0178] Generally speaking, during the extrusion process, one should permit compaction of the composition (structure that forms the sleeper 1,1′) used within the calibrator of the extruder and homogenous cooling of the whole thickness of the piece.

[0179] The process proposed comprises the initial step of adding the composition used (preferably polypropylene with fiberglass) to the feeder of the extruding machine and then regulate temperature parameter of the head (melting zone) to meet the characteristics of the material.

[0180] Concomitantly with the above step, one should add the first pure polymeric material (pure polypropylene, without fiberglass) to an extruding machine and melt it.

[0181] Then, one should add in the extruding machine, at the same time (at the same head), the (pure) molten polypropylene together with the composition of polypropylene with fiberglass.

[0182] After this, one should coat the composition of polypropylene with fiberglass with pure polypropylene, thus establishing a structure with the arrangement of the inner 13 and outer 14 walls in pure polypropylene and the intermediate layer 15 in polypropylene and fiberglass. Thus one establishes a structure similar to the extrusion process known as ABA, in which the first layer (layer A) consists of a determined material (in this case, pure polypropylene), the intermediate layer (layer B) consists of another material, in this case a composition of polypropylene with fiberglass, and the third layer consists again of the material A, pure polypropylene.

[0183] It should be pointed out that the manufacture of the inner 13 and outer 14 walls from the same material used in making the intermediate layer 15 (in this case, polypropylene) is just a preferred characteristic of the present invention. Thus, the walls 13 and 14 might be made from a material other than that used in the layer 15, as long as obviously it provides the necessary adherence to the piece.

[0184] Following the description of the proposed steps, after melting the structure within the cannon and the screw of the extruding machine, the molten structure is extruded within the matrix, said matrix having the main function of shaping the structure to a desired shape.

[0185] Subsequently, the structure, upon coming out of the matrix, passes through calibrator provided with a water-based cooling system. Said cooling system aims at keeping the molten structure in its final shape, besides aiding in cooling the piece.

[0186] Upon coming out of the calibrator, the piece gets into a system for controlling the velocity of the extruding machine, thus limiting the flowrate of the process and enabling compaction of the structure within the calibrator, thus preventing bubbles and loss of material. Finally, the molten structure) is cut into a desired size.

[0187] It is important to point out that the use of the composition of polypropylene with fiberglass in the intermediate layer 15 should be considered only as a preferred characteristic of the process described, so that any material (composition) having a bending module higher than or equal to 5000 MPa might be used.

[0188] Additionally, the composition of polypropylene with fiberglass preferably used comprises, preferably, fiberglass in the range from 5% to 40% by mass, and more preferably from 33% to 37% by mass of fiberglass.

[0189] Depending on the desired shape for the railroad sleeper 1, 1′, the calibrator of the extruder may be configured as a calibrator with or without vacuum. On calibrators without vacuum, one proposes a preferred length from 0.3 to 0.5 meters, while on a calibrator with vacuum, one proposes a preferred length between 1 and 4 meters and vacuum of the cooling chamber from 0 to 0.4 bar.

[0190] It is pointed out that a calibrator without vacuum should be preferably used for shaping the railroad sleeper 1 whose hollow sector 4 is delimited by the free portion 17.

[0191] On the other hand, a calibrator with vacuum is preferably used in shaping the sleeper 1′ whose hollow sector 4 is delimited by the support surface 3.′

[0192] Additionally, the following preferred parameters for the extruding machine are proposed: [0193] temperature of the extruder preferably ranging from 220° C. to 250° C.; [0194] amperage of the extruder ranging from 25 to 350 A; [0195] pressure of the head preferably ranging from 15 5 to 70 bar; [0196] velocity of the extruding machine (velocity of the line) ranging from 0.1 to 0.5 meters/minute; [0197] rotation of the screw preferably ranging from 10 to 45 rotations per minute (rpm); [0198] productivity of the extruding machine preferably ranging from 0.1 to 0.8 k/meter;

[0199] Although the process of shaping the railroad sleeper 1, 1′ has been referred to as an extrusion process, one should understand that such a characteristic is just a preferred embodiment of the present invention, so that other processes might be used for structural shaping of the proposes sleeper 1, such as an intrusion, injection or pultrusion process.

[0200] A preferred example of embodiment having been described, one should understand that the scope of the present invention embraces other possible variations, being limited only by the contents of the accompanying claims, which include the possible equivalents.