Molded Railroad Composite Cross Tie Unit

Abstract

A molded composite cross tie and two molded, non-metallic composite tie plates are molded into a single molded railroad composite cross tie unit. The molded railroad composite cross tie unit is fully assembled and ready for laying a ballast and accepting railroad track. The molded, non-metallic composite tie plates are molded with a cant onto which railroad track may be laid. The railroad track is secured by either traditional spikes or screws. When secured by screws, holes are molded with thread that is compatible with the screws used to hold the railroad track in place. One molded, non-metallic composite tie plate is molded into each end of the molded composite cross tie. The separation between the two molded, non-metallic composite tie plates is determined by the gauge of the railroad track.

Claims

1. A molded railroad composite cross tie unit comprising a molded composite cross tie and two molded, non-metallic composite tie plates, a. wherein the molded composite cross tie and the molded, non-metallic composite tie plates are constructed of a polymer or composite with high tensile strength, high compressive strength, high shear strength, and high resistance to wear and friction; b. wherein the molded composite cross tie is non-wooden; c. wherein the molded railroad composite cross tie unit supports rails for a railroad, with the rails comprising an upper surface on which train wheels ride, and a rail base; d. wherein the molded, non-metallic composite tie plates comprise an outer shoulder, an inner shoulder, and a center section, where the outer shoulder and the inner shoulder are separated by a distance approximately equal to the width of the rail base; e. wherein the center section of the molded, non-metallic composite tie plate is tapered so that the higher side is nearer the outer side of the molded, non-metallic composite tie plate; f. wherein the gauge for the molded railroad composite cross tie unit is that required by the railroad company; g. wherein the molded composite cross tie has two ends; h. wherein one molded, non-metallic composite tie plate is integrated into each end of the molded composite cross tie; i. wherein the molded, non-metallic composite tie plates are positioned between about 0.3 and 1.0 inch above the surface of the molded composite cross ties; j. wherein the molded, non-metallic composite tie plates have an outer end and an inner end, where the inner end is located toward the center of the molded railroad composite cross tie unit and the outer end is located away from the center of the molded railroad composite cross tie unit; k. wherein for each molded, non-metallic composite tie plate an outer shoulder and an inner shoulder are formed with a separation approximately equal to the width of the rail base; and l. wherein a plurality of holes is molded into the molded, non-metallic composite tie plates.

2. The molded railroad composite cross tie unit as in claim 1 where the molded composite cross ties are between 8-10 feet in length, 8-10 inches in width and about 3 to 10 inches in thickness.

3. The molded railroad composite cross tie unit as in claim 1 where the plurality of holes is threaded with diameters and thread designed to accept screws with matching thread configuration.

4. The molded railroad composite cross tie unit as in claim 1 where the plurality of holes is not threaded.

5. The molded railroad composite cross tie unit as in claim 1 where the composite is a hard, non-metallic material with a tensile strength of a minimum of 100,000 psi.

6. The molded railroad composite cross tie unit as in claim 1 where the composite is selected from the group consisting of linen phenolic, nylon, acrylic polymer, polyimide, glass epoxy, polystyrene, and polybenzimidazole.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 depicts a top view of a railroad track with the molded railroad composite cross tie units in place.

[0016] FIG. 2 depicts a top view of the molded railroad composite cross tie unit including the molded composite cross tie with two molded, non-metallic composite tie plates.

[0017] FIG. 3a depicts a side view of the molded, non-metallic composite tie plate located at the left outer end of the molded composite cross tie.

[0018] FIG. 3b depicts a side view of the molded, non-metallic composite tie plate located at the right outer end of the molded composite cross tie.

[0019] FIG. 4 depicts a side view of the molded railroad composite cross tie unit.

[0020] FIG. 5 depicts a rail base attached to the molded, non-metallic composite tie plate.

DETAILED DESCRIPTION OF THE INVENTION

[0021] A top view of a railroad with molded railroad composite cross tie units (10) placed along railroad tracks (70) is displayed in FIG. 1. The molded railroad composite cross tie units (10) are perpendicular to the rails (60). The molded railroad composite cross tie unit (10) is comprised of a molded composite cross tie (15), with a first end and a second end; a first molded, non-metallic composite tie plate (20) integrated into the first end of the molded composite cross tie (15) and a second molded non-metallic composite tie plate (21) integrated into the second end of the molded composite cross tie (15).

[0022] The molded railroad composite cross tie unit (10) depicted in FIG. 2 comprises the molded composite cross tie (15), the first molded, non-metallic composite tie plate (20) and the second molded, non-metallic composite tie plate (21). The first molded, non-metallic composite tie plate (20) comprises an outer end (50), a center section (30), and an inner end (51). The second molded, non-metallic composite tie plate (21) comprises an outer end (55), a center section (32), and an inner end (56). The same composite material is used for both the molded, non-metallic composite tie plates and the molded composite cross tie.

[0023] FIG. 2 shows that there are four holes (22) associated with each of the molded, non-metallic composite tie plates.

[0024] Also shown is a first outer shoulder (26) and a first inner shoulder (27) as part of the first molded, non-metallic composite tie plate (20). The first outer end (50) is tapered up towards the first outer shoulder (26). The first outer shoulder (26) is perpendicular to the surface of the molded composite cross tie (15). The first inner end (51) is tapered up from the molded composite cross tie (15) towards the first inner shoulder (27). The first inner shoulder (27) is perpendicular to the surface of the molded composite cross tie (15). In between the first outer shoulder (26) and the first inner shoulder (27) is the center section (30), which is tapered down from the first outer shoulder (26) to the first inner shoulder (27).

[0025] Also shown in FIG. 2 is a second outer shoulder (29) and a second inner shoulder (28) as part of the second molded, non-metallic composite tie plate (21). The second outer end (55) is tapered up towards the second outer shoulder (29). The second outer shoulder (29) is perpendicular to the surface of the molded composite cross tie (15). The second inner end (56) is tapered up from the molded composite cross tie (15) towards the second inner shoulder (28). The second inner shoulder (28) is perpendicular to the surface of the molded composite cross tie (15). In between the second outer shoulder (29) and the second inner shoulder (28) is the second center section (32), which is tapered down from the second outer shoulder (29) to the second inner shoulder (28).

[0026] FIG. 3a depicts a tilted view of the first molded, non-metallic composite tie plate (20). Shown more clearly is the taper of the first outer section (50) and the first inner section (51). The first outer shoulder (26) and the first inner shoulder (27) are parallel to each other, and both are perpendicular to the surface of the molded composite cross tie (15). The taper of the first center section (30) is also shown.

[0027] FIG. 3b depicts a tilted view of the second molded, non-metallic composite tie plate (21). Shown more clearly is the taper of the second outer section (55) and the second inner section (56). The second outer shoulder (29) and the second inner shoulder (28) are parallel to each other, and both are perpendicular to the surface of the molded composite cross tie (15). The taper of the second center section (32) is also shown.

[0028] FIG. 4 depicts the molded railroad composite cross tie unit (10). Also shown are holes (22) molded into the molded railroad composite cross tie unit (10) in the molded, non-metallic composite tie plates, (20) and (21). The molded holes (22) may be threaded or straight edges depending on the manner to be used to attach rails) to the molded railroad composite cross tie unit (10).

[0029] FIG. 5 depicts the attachment of a rail (60) to the first molded, non-metallic composite tie plate (20). The other rail would be attached to the second molded, non-metallic composite tie plate (21) in the same manner. The rail (60) has an upper surface on which a train wheel rides and a base (80) which is attached to the molded, non-metallic composite tie plate (20) by screws (65) in this embodiment. The holes (22) are molded into the molded, non-metallic composite tie plate (20). In another embodiment the holes (22) are short holes, between about 0.5 inches and 1.5 inches, and not threaded, where standard railroad spikes are driven into the molded non-metallic composite tie plates.

[0030] The molded composite cross tie (15) is between 8 and 10 feet in length, 10 inches to 13 inches wide, and 7 inches to 10 inches thick. At about 33 to 39 inches from the center toward the ends of the molded composite cross tie (15), the surfaces (51) and (56) of the molded composite cross tie (15) merge into the molded, non-metallic composite tie plates (20) and (21), where the surface gradually increases to a height of about 0.4 inches to 0.7 inches above the surface elevation of the molded composite cross tie (15). The inner shoulders (27) and (28) are formed when the elevation of the surface abruptly decreases by about 0.2 inch to about 0.3 inch on the outer sides of the elevated surfaces (51) and (56). At about 10 to 20 inches from the ends of the molded composite cross tie (15) toward the center of the molded composite cross tie (15), the surfaces (50) and (55) of the molded composite cross tie (15) merge into the molded, non-metallic composite tie plates (20) and (21), where the surface gradually increases to a height of about 0.4 inches to 0.7 inches above the surface elevation of the molded composite cross tie (15). The outer shoulders (26) and (29) are formed when the elevation of the surfaces (50) and (55) abruptly decreases by about 0.2 inch to about 0.3 inch. The first center section (30) of the first molded, non-metallic composite tie plate (20) is between the shoulders (26) and (27). The second center section (32) of the second molded, non-metallic composite tie plate (21) is between the shoulders (28) and (29). Center sections (30) and (32) are canted toward the middle of the molded non-metallic composite ties plates (20) and (21) to help keep the train on the rails. These center sections (30) and (32) are the parts of the molded, non-metallic composite tie plates (20) and (21) that are under the rails (60).

[0031] The cant of the center sections (30) and (32) of the molded, non-metallic composite tie plates (20) and (21) is between 1.1 degrees to about 2.8 degrees, but more preferably between about 1.3 degrees and 1.8 degrees.

[0032] The width of the center sections (30) and (32) of the molded, non-metallic composite tie plates (20) and (21) is designed to fit the width of the base of the rail (80) and is typically between 4 inches and 7 inches.

[0033] The length of each molded, non-metallic composite tie plate, (20) and (21), is between 14 inches and 18 inches. The width of each molded, non-metallic composite tie plate, (20) and (21), is between 5 inches and 10 inches. The distance between the first molded, non-metallic composite tie plate (20) and the second molded, non-metallic composite tie plate (21) is determined by the gauge of the rail. The standard US gauge is 4 feet, 8.5 inches, and thus the distance from the first inner shoulder (27) and the second inner shoulder (28) is between 4 feet 4 inches and 4 feet 1 inch. The gauge may be adjusted to comply with other gauges, which are well known in the industry.

[0034] In one embodiment, the molded railroad composite cross tie unit (10) is formed without metal jackets to hold spikes. Starter holes (22) are molded into the molded, non-metallic composite tie plates (20) and (21), into which spikes may be used to hold the rail in place.

[0035] In another embodiment, the molded railroad composite cross tie unit (10) is formed with four threaded steel jackets (22) molded into the molded, non-metallic composite tie plates (20) and (21. Two threaded steel jackets (22) are located on the front side of the molded, non-metallic composite tie plates (20) and (21), and two threaded steel jackets (22) are located on the back side of the molded, non-metallic composite tie plates (20) and (21). Threaded screws are sized to fit within the threaded steel jackets (22) located in the molded, non-metallic composite tie plates (20) and (21). The threaded screws hold the rail in place.

[0036] The composite used to form the molded railroad composite cross tie unit (10) was a stiff polymer or other stiff composite with high tensile strength, typically higher than 100,000 psi. The polymer or composite exhibited high compressive strength, high shear strength, and excellent resistance to wear and friction. The polymer or composite was selected from the group consisting of linen phenolic, nylon, acrylic polymer, polyimide, glass epoxy, polystyrene, and polybenzimidazole.