RAIL BOOT
20200283963 ยท 2020-09-10
Inventors
Cpc classification
E01B19/003
FIXED CONSTRUCTIONS
International classification
E01B19/00
FIXED CONSTRUCTIONS
Abstract
A flexible rail boot designed to encase a rail. The rail boot includes antenna and a truss, allowing for the storage and release of energy, locking the rail boot in place under the head of the rail after installation. The flexible rail boot may include a corrugated inner surface along the bottom of the base of the rail, compressing and deflecting energy from a train as well as allowing for the passage of water and debris.
Claims
1. A rail boot including an elastomeric material, wherein the rail boot comprises: at least two antennae, wherein the at least two antennae are flexible; at least two trusses each with a first surface in face sharing contact with a rail; a plurality of cells within the at least two trusses; and a patterned inner base surface of the rail boot; wherein a first truss is joined at a first end to a first antenna and at a second end to a base of the rail boot comprising the patterned inner base surface.
2. The rail boot of claim 1, wherein the elastomeric material of the rail boot varies in thickness.
3. The rail boot of claim 2, wherein the thickness of the elastomeric material of the rail boot graduates from 1/10 to 5/16 of an inch.
4. The rail boot of claim 1, wherein the at least two antennae fit below a rail head of a rail.
5. The rail boot of claim 4, wherein the at least two antennae are of a thickness to allow a flangeway filler to additionally fit below the rail head.
6. The rail boot of claim 4, wherein the at least two antennae are in contact with a rail at a top fillet radius of the rail.
7. The rail boot of claim 1, wherein the outside of the truss curves away from the rail.
8. The rail boot of claim 1, wherein an outer surface of the truss is in contact with a support leg of a flangeway filler.
9. The rail boot of claim 1, wherein the elastomeric material of the rail boot is a thermoset elastomer.
10. The rail boot of claim 1, wherein the elastomeric material has a hardness of 20 to 90 Shore A.
11. The rail boot of claim 10, wherein the elastomeric material has a hardness of 60 to 80 Shore A.
12. The rail boot of claim 1, wherein at least one of a corrugation of the corrugated inner surface of the base of the rail boot is rounded.
13. The rail boot of claim 1, wherein the rail boot is held in place against the rail by a release of potential energy.
14. The rail boot of claim 1, wherein the rail boot is thicker at an upper edge of a rail boot base than at a base edge of the rail boot.
15. The rail boot of claim 1, wherein an installed rail boot has a clearance allowance at a bottom fillet radius.
16. The rail boot of claim 15, wherein the clearance allowance between the rail boot and the bottom fillet radius is between 1/64 and of an inch.
17. The rail boot of claim 16, wherein the clearance allowance between the rail boot and the bottom fillet radius is 21/256 of an inch.
18. A rail boot for isolating a rail, the rail boot comprising an extruded thermoset or thermoplastic material, wherein the rail boot comprises: at least two antennae, wherein the at least two antennae are flexible; at least two compressible trusses each of which have a first surface in face-sharing contact with a rail; a plurality of cells within the trusses; and an inner base surface of the rail boot in face-sharing contact with the rail; wherein the outside edge of each compressible truss curves away from the rail.
19. The rail boot of claim 18, wherein the rail boot comprises a plurality of co-extruded thermoset materials.
20. The rail boot of claim 18, wherein the rail boot gradually increases in thickness from the antenna to the base.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0015] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.
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DETAILED DESCRIPTION
[0026] Provided herein is a rail boot that encases a rail, leaving the head and running surface exposed. The rail boot is designed with increased durability as well as rail and flangeway filler retention characteristics, allowing the boot and the flangeway filler to maintain a desired position with regard to the rail after an extended duration of use under real-world conditions, in comparison to previous boot designs. This boot design correspondingly decreases the likelihood of the boot and flangeway filler impeding vehicular/train travel or becoming further degraded due to unwanted vehicular/train interaction with the boot or filler. These characteristics correspondingly increase the boot's lifespan and customer appeal. The rail boot surrounds the neck, web, and base of the rail and locks in place under the railhead. Specifically, the rail boot conforms to the rail profile, increasing (e.g., maximizing) its surface area contact with the rail. The boot's degree of retention on the rail, when installed, is therefore increased, decreasing the chance of undesirable boot deformation and boot-rail misalignment. In some embodiments, the rail boot is of a size and shape to provide sufficient clearance for other flangeway components such as a flangeway filler to lock in place underneath the railhead. This feature drives down the chance of filler misalignment with the rail which may, in some cases, cause filler degradation due to vehicular interaction with the filler. In various embodiments, the flangeway components may have no contact with the rail boot, or may be in contact with any desired part of the rail or rail boot including, but not limited to, the rail boot, the top of the railhead, underneath the railhead, the side of the railhead, the rail web, the rail base, or a combination thereof. The rail boot may be removable or permanently attached to the rail. In some examples, the rail boot may be replaceable without the need for destruction of the surrounding roadway. Consequently, the rail boot's adaptability is expanded, further increasing the boot's customer appeal.
[0027] The rail boot may be constructed of any suitable elastomeric or plastomeric material or combinations therefor. In some embodiments, it is constructed of a material that may store and release mechanical energy by reactive or deflective means. Increasing boot compliance in this manner increases the boot's ability to remain in a desired position once installed and can also increase the boot's installation efficiency, in some scenarios. Such materials include, but are not limited to, one or a blend of flexible elastomers. Suitable elastomeric substrates may include any of the thermoplastic or thermosetting polymer materials known in the art. Non-limiting examples of suitable flexible elastomeric materials include, but are not limited to thermoplastic elastomer, ethylene propylene diene monomer rubber (EPDM), isoprene rubber, nitrile rubber (NBR), styrene-butadiene rubber (SBR), polyisoprene rubber, chloroprene rubber, and silicone, as well as additional natural or synthetic rubber polymers or thermoplastics. In some examples, such rubber polymers have a shore A hardness of 0 to 100, about 20 to about 90, about 60 to about 80 or any fraction thereof. It will be understood, that shore A is durometer scale known in the art which uses a defined spring force and indentor configuration for generation of a hardness measurement.
[0028] The natural or synthetic rubber polymers may be produced by any means generally used. In some examples, the rail boot may be extruded, or if manufactured using a plurality of natural or synthetic rubbers and/or thermoplastics, such materials may be co-extruded. In other examples, it may be cast or molded. The resulting rail boot may be cured or cooled into its finished state by any means generally used. For example, it may be thermoset or flash cured in one or more layers. For example, thermosetting polymers may be vulcanized at temperatures above about 250 F. Forming the polymers in this manner enables the polymer's durability as well as rigidity to be increased, in some cases. In other aspects, thermosetting polymers may be vulcanized at temperatures below about 450 F. In one specific example, thermoplastics may set at temperatures below about 212 F.
[0029] The rail boot generally comprises a base and two sides which lock the rail boot in place under the railhead. In some examples, the rail boot may have antennae that flex during installation and conform to the shape of the rail profile. In some embodiments, the antennae are lodged under the railhead such that sufficient pressure is exerted by the elastomeric material to hold the antennae and hence the rail boot in place. In further embodiments, the pressure exerted by the elastomeric material is sufficient to hold the rail boot in place such that no additional adhesives or hardware are used. In one embodiment, the antennae have lower physical resistance than other parts of the rail boot, allowing for ease of deformation of the antennae to assist in installation of the rail boot. For example, the rail boot may be at its thinnest at the antennae, gradually thickening as it continues down along the rail web. Tapering the antennae in this manner allows the boot's flexion and stiffness to be granularly tuned to facilitate efficient rail installation and, once installed, to be firmly retained against the rail. In one aspect, the rail boot may thin again as it comes in contact with the base angle and/or base edge. In some embodiments, adhesives or caulking such as butyl tape, epoxy, or any useful synthetic or natural rubber base caulking or adhesive and the like may be used to hold the rail boot in place. The adhesives or caulking may be used to permanently bind the rail boot to the rail, or may be merely of sufficient strength to assist in the installation process. In further embodiments hardware such as, but not limited to, clips, tape, zip ties, binders, cords, cables, fasteners, bands, snaps, straps may be used to temporarily or permanently hold the rail boot in place. In additional embodiments, a combination of adhesives and hardware may be used. Such adhesives and hardware may be used on the field side of the rail, the gage side or both.
[0030] The thickness of the rail boot may be constant or variable. In some embodiments, the thickness is graduated. The thickness may affect the amount of pressure or force that may be captured and released by one or more portions of the rail boot. For example, in one embodiment the rail boot may be thinner at the base edge of the rail, improving the clearance of the encased rail for insulators. In further embodiments, the rail boot antenna and/or rail boot truss may be thinner than other parts of the rail boot, allowing for ease of installation. The rail boot antenna and rail boot truss may be of the same or different thicknesses. In additional embodiments, the base of the rail boot may be the thickest portion of the boot. The variability of thickness may range up to about 800% from one portion of the boot to another. In some embodiments, the thickness variation between the thinnest and thickest part of the boot may be about 500%. For example, in one embodiment, the thickness may be between about 1/10 inch () to , 1/10 to 5/16, 1/16 to 5/16, or fractions thereof. However, other rail boot dimensionalities have been envisioned.
[0031] The rail boot may be constructed so that the antennae may yield to installation stress allowing for ease of installation. Once installed, the antennae exert pressure against the bottom head angle, holding the rail boot in place under the railhead. As the rail boot descends along the web of the rail, it may form a multi-cellular truss comprising one, two, three, four, five, six, seven, eight, nine, ten or more cells on one or both sides of the rail. The cells may independently be the same or different shapes and may contain the same or different volumes of space. In some embodiments, the walls of the cells are the same thickness all around. In other embodiments, the portion of the cells that sits against the rail web may be thinner than other parts of the cells. In additional embodiments, the elastomeric material of the walls between the cells may be thinner than elastomeric material of the walls of other parts of the cells. In some embodiments, one or more trusses may curve away from the rail. Such a curvature may allow the rail boot to slide past, along, or compress to allow for other components of the rail system to be installed in conjunction with the rail boot. In some examples, the structure of the truss or trusses allows it to be compressed in order for other components of the rail system to be installed. In one aspect, such compression allows for installation of other components of the rail system without disturbing the surrounding roadway. In other aspects, the rail boot may be installed as the rail system is built.
[0032] In one example, a truss allows for compression and deflection of stored energy to provide a vertical resistive force to maintain tension between the railhead and the rail boot antenna. The tension may enable a relatively high level of (e.g., maximum) contact between the rail boot and the profile of the rail. The tension created under the railhead and at the base radius of the rail creates pressure at both top and bottom ends of the truss, flexing it slightly at the truss centerline and forcing the rail boot into contact with the surface web of the rail with an inward horizontal force.
[0033] In a further embodiment, the flexibility and energy storage properties of the truss may be replaced by using a material with high levels of density such as a co-extruded or dual durometer thermoplastic elastomer, synthetic rubber polymer, or other semi or ridged substrate.
[0034] In some embodiments, the rail boot fits snugly along the web and around the bottom of the rail. In other embodiments, there may be a slight gap or clearance allowance at the bottom fillet radius between the rail and the rail boot. For example, such a gap may be between about 1/64 of an inch () to about or any fraction thereof. In some examples, it may be 21/256 at the base web radius between the rail boot and the rail. In some embodiments, this space allows for additional compression when horizontal installation force is applied, creating vertical resistive force to provide sufficient tension between the rail head and the rail boot antennae, allowing for increased (e.g., maximum) contact of the rail boot with the profile of the rail.
[0035] While the rail boot may be of variable or constant thickness, in some embodiments the rail boot may be thinner at the base edge, allowing for increased clearance for rail insulators or other rail installation components.
[0036] The interior of the bottom of rail boot against the rail may be uniform or corrugated. Such corrugations may be of any shape desired. In some embodiments, they may be angular, rounded, ridged, fluted, grooved, channeled, ribbed, or any of the like, alone or together, sufficient to generate an irregular surface. In some embodiments, the corrugation may be in a pattern. While the corrugation may serve any purpose desired, in some embodiments such corrugation may allow for the removal of liquid or debris that may build up along the rail, increasing the longevity of the rail. In additional aspects, the corrugation may allow for compression and deflection of energy as the train passes over the rail.
[0037] Those skilled in the art will recognize that it is common within the art to describe devices and/or processes in the fashion set forth herein, and thereafter use standard engineering practices to integrate such described devices and/or processes into larger systems. That is, at least a portion of the devices and/or processes described herein can be integrated into a railway system via a reasonable amount of experimentation.
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[0040] The rail boot 100 may be constructed of any suitable material. In some embodiments, it is constructed of an elastomeric material with sufficient elasticity such that the rail boot 100 may be compressed to install the rail boot 100 around the rail and the release of stored energy from the compression may be used to hold the rail boot 100 in place around a rail. In this way, the rail boot is made more compliant to reduce the likelihood of the boot separating or otherwise exhibiting misalignment with the rail. Such an elastomeric material may be electrically conductive or non-conductive. As shown in
[0041] While the rail boot may be used on any type of rail, a cross-section of an illustrative rail on which a rail boot may be installed is shown in
[0042] Turning to
[0043] A gap 304 between the base edge radius and rail boot is shown. The gap 304 may be of any distance that allows for enough flex for the antenna to compress and seal the rail boot against the web. In some embodiments, the gap 304 may be between about 1/64 to about or any fraction thereof. However, other gap dimensions have been contemplated. Further, in some embodiments, the corrugations 122 increase the release of sand or debris in the event of a flood or buildup of condensation at the base of the rail, increasing the lifespan of the rail.
[0044] As shown in
[0045] As shown in more detail in
[0046] In the perspective view of
[0047] Turning to
[0048] In some embodiments, support leg 706 may be in contact with the second surface 306 of the truss. In other aspects, the support legs such as extended support leg 708 may be longer than the standard profile to assist in locking the rail boot 100 in place. In some examples, the field side flangeway filler may have a compression point 714, which aids in installation of the flangeway filler between the boot and the roadway. Installation time may be decreased when the filler includes the compression point feature. In additional aspects, a bolt such as U-bolt 710 may be used to reduce gaping in the field side flangeway filler 704 and gage side flangeway filler 702. In one example, the U-bolt 710 may be constructed out of stainless steel, reducing the likelihood of rust build-up on the bolt. The flangeway filler, in such an example, is made more robust and can be more easily disassembled for component repair or rearrangement, for instance. However, the U-bolt may be constructed out of other materials, such as carbon steel, in other examples. Both material properties and cost considerations may be taken into account when selecting the material construction of the U-bolt as well as the other flangeway filler and rail boot components, in some cases.
[0049] Further, in one example, rebar 750 may be included in the flangeway filler 704. The rebar 750 may extend longitudinally along the filler and may be designed to connect with a corresponding bore in an adjacent filler section. In some instances, the rebar may be coated with epoxy to provide corrosion resistance. However, the epoxy coating may be foregone, in other instances, due to cost, for example.
[0050] The rail boot 100 may have constant or variable thickness. In some embodiments, the rail boot 100 may be thinner from the bottom fillet radius 214 through the base angle 218 and over the base edge allowing for increased contact and installation efficiency of rail insulators rail insulators 712.
[0051] While the compressive force in the cells in the truss keep the boot upright and in place, in some embodiments, an adhesive can be placed along the inside 716 of the rail boot. The adhesive may be placed along the entire inside of the rail boot 100 or may be placed in strategic places such as along the portion of the rail boot 100 in contact with the web 212 of the rail 200. In this way, the boot may be more securely coupled to the rail, thereby decreasing the likelihood of unwanted boot movement relative to the rail.
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[0054] References to one embodiment or an embodiment do not necessarily refer to the same embodiment, although they may. Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to. Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words herein, above, below and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application. When the claims use the word or in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list.
[0055] The foregoing described aspects depict different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively associated such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as associated with each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being operably connected, or operably coupled, to each other to achieve the desired functionality.
[0056] While a preferred embodiment of the present invention has been illustrated, those skilled in the art will recognize that many modifications and variations are possible in accordance with the above teachings without varying from the spirit and scope of the invention. It is to be understood that such modifications and variations are within the spirit and scope of the present invention as set forth in the following claims.