RAIL CAR SIDE SCREEN PROTECTOR

Abstract

A protector for a railway car interior, such as an autorack car designed to transport automobiles. The protector is installed on and covers the sidewall of a railway car to provide a barrier between the car and the sidewall to prevent damage to automobiles being transported in the rail car. The protector has two bumpers that are connected to a body and are deflectable to provide expanded zones of protection when contacted by an object. The protector may be provided in different lengths to provide a suitable span of coverage of a railway interior structure when the protectors are arranged adjacently, horizontally along a sidewall of the rail car at suitable heights to provide protection. The outwardly projecting bumpers provide a protective barrier between the automobile, such as a door panel, and the railway sidewall or other structure. A railcar configured with protectors also is provided.

Claims

1. A railcar protector for an interior of a railcar configured to mount to the railcar interior structure, comprising: a) a body configured to mount to the railcar interior structure, the body including a wall; b) at least one bumper having a first end that is attached to the body at a joining location, and a free end; c) wherein the bumper is arcuately configured; and d) wherein the bumper is deflectable in an upward or downward vertical direction relative to the body.

2. The protector of claim 1, wherein the bumper comprises a rolled body portion.

3. The protector of claim 2, wherein the rolled body portion is configured to have a rolled condition which is deflectable upon the receipt of a deflecting force, and wherein said deflectable rolled body portion is biased to return to its rolled condition after being deflected, when the deflecting force is removed.

4. The protector of claim 2, wherein a plurality of bumpers are provided, and wherein each bumper comprises a rolled body portion.

5. The protector of claim 4, wherein each of the plurality of bumpers is connected to the body at a joining location.

6. The protector of claim 4, wherein the rolled body portion of each bumper is configured to have a rolled condition which is deflectable upon the receipt of a deflecting force, and wherein each said deflectable rolled body portion is biased to return to its rolled condition after being deflected, when the deflecting force is removed.

7. The protector of claim 5, wherein said plurality of bumpers comprises a first bumper and a second bumper, and wherein said first bumper has a first zone of coverage and wherein said second bumper has a second zone of coverage.

8. The protector of claim 7, wherein said first bumper connects with said body at a first joining location, and wherein said second bumper connects with said body at a second joining location.

9. The protector of claim 7, wherein said first bumper is deflectable in an at least an upward vertical direction relative to the body, and wherein said second bumper is deflectable in at least a downward vertical direction relative to the body.

10. The protector of claim 7, wherein said first bumper is deflectable to roll into itself and wherein said second bumper is deflectable is deflectable to roll into itself.

11. The protector of claim 7, wherein said first bumper is deflectable upward or downward relative to the joining location, and wherein said second bumper is deflectable upward or downward relative to the joining location.

12. The protector of claim 7, wherein said first bumper is deflectable to deflect in one or more of (i) an upward vertical direction relative to the body when the bumper unrolls, (ii) to roll into itself, and (iii) an upward or downward vertical direction relative to the joining location; and wherein said second bumper is deflectable to deflect in one or more of (i) a downward vertical direction relative to the body, (ii) to roll into itself, and (iii) an upward or downward vertical direction relative to the joining location.

13. The protector of claim 12, wherein the first zone of protection is defined by an area that includes the upward vertical displacement of the first bumper, and wherein the second zone of protection is defined by an area that includes the downward vertical displacement of the second bumper.

14. The protector of claim 13, wherein the protector has a zone of protection that spans between the upward vertical displacement of the first bumper and the downward vertical displacement of the second bumper.

15. The protector of claim 5, wherein the plurality of bumpers includes the first bumper and a second bumper, wherein said first bumper is configured to pivot about the joining location where first bumper first end attaches to the body, and wherein the second bumper is configured to pivot about the joining location where first bumper first end attaches to the body.

16. The protector of claim 1, wherein each bumper has a front surface that spans horizontally along the protector and is disposed forward of the rear wall.

17. The protector of claim 1, wherein the bumper has a leading portion that comprises a horizontal tangent along the rolled body portion that is furthest from the body wall and defines a forward surface.

18. The protector of claim 5, wherein the plurality of bumpers includes a first bumper and a second bumper, wherein the first bumper has a leading portion that comprises a horizontal tangent along the rolled body portion that is furthest from the body wall and defines a first bumper forward surface, and wherein the second bumper has a leading portion that comprises a horizontal tangent along the rolled body portion that is furthest from the body wall and defines a second bumper forward surface.

19. The protector of claim 18, wherein the body wall defines a body wall plane, and wherein each of the first bumper forward surface and second bumper forward surface, is movably deflectable inwardly toward the body wall plane.

20. A method of producing a protector for a railway vehicle interior, comprising: a) forming an extruded body having body with a wall, and a pair of bumpers, each bumper of the bumper pair joining with and extending outwardly from the body wall, and including a first bumper connected to the body wall, and a second bumper connected to the body wall; b) forming said first bumper into a rolled configuration, and forming the second bumper into a rolled configuration; c) maintaining the respective rolled configurations of the first bumper and second bumper to produce respective rolled bumpers which when deflected from their respective rolled configurations, are biased to return to their respective rolled configurations.

21. A railcar configured with one or more levels for transporting automobiles, the rail car comprising: a) one or more wheelsets; b) interior structure comprising a plurality of upstanding posts, sidewalls, a roof, and at least one deck for carrying automobiles; c) an interior space; d) wherein the plurality of upstanding posts are located on each lateral side of the interior space, and wherein the sidewalls are located on each lateral side of the interior space; and e) a plurality of protectors provided on the sidewalls, the protectors comprising a protector having: i) a body configured to mount to the railcar interior structure, the body including a wall; ii) at least one first bumper having a first end that is attached to the body at a joining location, and a free end; iii) at least one first bumper having a first end that is attached to the body at a joining location, and a free end; iv) wherein the first and second bumpers are arcuately configured; and v) wherein the first bumper and second bumper are deflectable in an upward or downward vertical direction relative to the body; f) wherein the protector is mounted to the sidewall with said bumpers disposed horizontally so that the first bumper is positioned at a vertical height that is higher than the vertical height of the second bumper; and g) wherein said bumpers project from the sidewall mounted body into the interior space.

22. The railcar of claim 21, wherein a first arrangement of protectors are provided horizontally along the sidewall at a first vertical position to form a first horizontal zone of protection, and wherein a second arrangement of protectors are provided horizontally along the sidewall at a second vertical position to form a second horizontal zone of protection.

23. The railcar of claim 22, including a plurality of post protectors installed to provide a barrier between the interior space and one or more posts.

24. The railcar of claim 21, wherein said plurality of protectors provided on the sidewalls includes a first plurality of protectors arranged end to end, and a second plurality of protectors arranged end to end.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0025] FIG. 1 is a perspective view of a side screen protector according to an embodiment of the invention, as viewed from the top right.

[0026] FIG. 2A is a side elevation view of the side screen protector of FIG. 1.

[0027] FIG. 2B is a side elevation view of the side screen protector of FIG. 1, taken of the encircled area of FIG. 2A.

[0028] FIG. 3 is a side elevation view of the side screen protector shown in FIG. 2A, illustrated in a condition where the bumpers are deflected from an initial condition, with the initial condition represented in broken lines.

[0029] FIG. 4 is a side elevation view of the side screen protector shown in FIG. 2A, depicting examples of the zones of protection, and showing the protector rolls in deflected positions.

[0030] FIG. 5 is a side elevation view of the side screen protector shown in FIG. 2A, illustrating exemplary force handling conditions to show potential deflections of the bumper rolls.

[0031] FIG. 6 is a perspective view of the side screen protector of FIG. 1 shown installed on a side screen panel of an autorack railway car, the panel being shown in a partial view.

[0032] FIG. 7 is a front elevation view of an exemplary depiction of a fastener useful for installing the protector of FIG. 1 to a structure.

[0033] FIG. 8 is a perspective view of the fastener of FIG. 5.

[0034] FIG. 9A is a perspective view of an exemplary embodiment of an autorack railway car.

[0035] FIG. 9B is a perspective view showing the interior sidewall and floor of an autorack railway vehicle illustrated separate from the other wall and showing the protectors of FIG. 1 installed on the sidewall.

[0036] FIG. 10 is a right side elevation view of an alternate embodiment of a protector according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0037] Protective devices comprising guards for use in an autorack railway vehicle to provide protection for the cargo, typically, automobiles such as cars, trucks and vans loaded into and carried therein are shown and described herein according to preferred embodiments illustrating the invention. Methods for producing the devices and for installing the devices also are provided.

[0038] Referring to FIG. 1, there is illustrated an exemplary embodiment of a protective device according to the invention configured as the side screen protector 110. The protector 110 is shown comprising a body 111 with a body wall 112. A first bumper 113 forms a first protective structure, and a second bumper 114 forms a second protective structure. The first bumper 113 is shown connecting with the body wall 112 at an upper or first joining location 115, and the second bumper 114 is shown connecting with the body wall at a lower or second joining location 116. Although shown spanning the horizontal width of the protector 110, the joining locations 115 and 116 may be discontinuous, providing intermittent connections between the body wall 112 and a joining location 115, 116. According to some embodiments, the joining locations 115, 116 may be coextensive with the respective top edge and lower edge of the body wall 112.

[0039] As illustrated in FIG. 1, the first bumper 113 is shown connecting with the body wall 112. The first bumper 113 includes a curved and preferably rolled body portion 121 having a free end 122. The rolled body portion 121 includes a forward surface 123, which provides the leading portion of the bumper 113. According to some preferred embodiments, the device 110 is configured so that the leading portion of the bumper 113 that leads into the cargo space of the railway vehicle preferably comprises a horizontal tangent along the rolled body portion 121 that is furthest from the body wall 112 and defines a forward surface 123. In the embodiment illustrated, the forward surface 123 is shown having a continuous surface, however, according to some alternate embodiments, the rolled body portion 121 may be provided as discontinuous segments, such as, for example, a plurality of adjacently spaced rolled segments. The free end 122 of the first bumper body portion 121 is shown positioned rearward of the forward surface 123. According to some embodiments, the length of the bumper body 121 may be greater and coiled to overlap with itself (e.g., where the wall of the body 121 overlaps itself, or a portion overlaps itself).

[0040] The second bumper 114 is shown configured similar to the first bumper 113 and in the orientation depicted represents a lower bumper, where the first bumper 113 represents an upper bumper. The second bumper 114 is shown connecting with the body wall 112 at the lower or second joining location 116. The second bumper 114 includes a curved and preferably rolled body portion 131 having a free end 132. The rolled body portion 131 includes a forward surface 133, which provides the leading portion of the bumper 114. According to some preferred embodiments, the device 110 is configured so that the leading portion of the bumper 114 that leads into the cargo space of the railway vehicle preferably comprises a horizontal tangent along the rolled body portion 131 that is furthest from the body wall 112 and defines the forward surface 133.

[0041] As illustrated according to a preferred embodiment, the device 110 is shown in FIG. 2A is depicted in a side elevation view showing the bumper pairs 113, 114 in an undeflected condition. The bumper pairs 113, 114 preferably are configured to be rigid but flexible, and are biased to remain in a rolled condition, such as the condition shown in FIG. 2A, until engaged by an object, at which time a roll bumper 113, 114 may deflect. Once the object is no longer engaging the bumper 113, 114, then preferably the bumper 113, 114, having been previously deflected by the object, returns to its undeflected state (FIG. 2A). The body wall 112 is shown having a rear surface 112b that is provided to install on or engage the mounting surface, such as the sidewall of the railway vehicle (e.g., an autorack vehicle).

[0042] Referring to FIG. 3, the device 110 is shown in a side elevation view, with the bumpers 113, 114 in a deflected condition. The protector 110 is illustrated in different deflection positions, represented in broken lines showing the positions of the bumpers 113, 114, as being moved to a deflected position 113, 114. The deflection shows the deflection of both bumpers 113, 114 for purposes of illustration, but a single one of the bumpers 113, 114 may be deflected without the other one of the bumpers 113, 114 being deflected, and/or the bumpers 113, 114 may be deflected by different amounts. The protector 110 is configured to provide an increased expansive zone or zones of protection, as represented by the bumpers 113, 114 being expanded respectively, upward (see bumper 113) and downward (see bumper 114) from their initial conditions (113, 114), to provide protection from contact with the sidewall or other surface. The protection zone or zones is greater than the area that the protector initially covers. For example, the initial zone of protection Z1 is shown to represent the protector with the bumpers 113, 114 in an initial condition. An expanded zone of protection Z2 is shown comprising an area or areas covered when a bumper 113 or 114 or bumpers 113, 114 are deflected. The expanded protection zone Z2 may comprise a first expanded zone Z2a (FIG. 4) corresponding to the deflection of the first bumper 113, and a second expanded zone Z2b (FIG. 4) corresponding to the deflection of the second bumper 114. An expansive zone of protection Z2 provided by the protector 110 is shown in FIGS. 3 and 4. In FIG. 4, the bumpers 113, 114 are illustrated having a deflection that shows maximal or near maximal vertical upward and downward deflection, as represented by the bumpers 113, 114 which are deflected to extreme positions. The positions of the deflected bumpers 113, 114 are shown with the respective free ends 122, 132 being moved to extended positions. As shown also in FIG. 4, an alternate deflection is represented by the broken lines showing 113a and 114a, representing a desired deflection mode where each of the roll bumpers 113, 114 are shown rolling of the profile onto itself, to essentially increase its wall thickness and provide increasing resistance with further deformation. The increase in the wall thickness due to the overlapping, according to some embodiments, may be a doubling of the wall thickness.

[0043] Alternatively, the deflections of the bumpers 113, 114 may involve movement of the bumper rolled portion relative to the bumper joining portion, where the bumper 113 may be deflected upward or downward along the joining location. FIG. 5 shows the deflection of the bumper 113 being deflected downward 113. The rolled end of the bumper 113 may roll inward upon itself or may unroll in whole or part when the bumper 113 is deflected upward as shown in FIG. 3, or downward as represented by 113 in FIG. 5. The second bumper 114 is shown in FIG. 5 deflected by rolling into itself, as represented by the broken line position showing bumper 114, and the free end 132 being rolled within the bumper roll 114. Although the bumpers 113, 114 have been illustrated in exemplary deflection positions, each bumper 113, 114 may be deflected to any deflection position, and one bumper 113, 114 may be deflected in a similar deflection manner as the other bumper, or in a different deflection manner than the other bumper 113, 114. The protector 110 is configured to handle multi-directional force loads that are received from different directions, and accommodates the force loads to protect the cargo or other engaging object by responding in the direction to provide further protection to the cargo or other item as the engagement transfers the force. The protector bumpers 113, 114 move in one or more of the directions including unrolling in a vertically upward or downward direction relative to the body, or rolling onto itself, which may be inward, and also moving upward or downward relative to the joining location, where the bumper 113, 114 may move upward or downward from the location where it joins with the body, as well as combinations of one or more of these movements.

[0044] In the protector 110, the front surfaces, including the joining portions 115, 116, the bumper rolls 113, 114, and front surface 112a of the rear wall 112 are provided to form a barrier between the sidewall and an object such as a vehicle door panel, to provide protection over the entire front surface area of the protector 110. Referring to FIG. 4, the protector 110 is illustrated in an expanded condition, where each bumper 113, 114 is deflected to a deflection position 113, 114. The protector body wall 112 and protector bumpers 113, 114, provide a barrier between the sidewall or other structure or surface to which the protector 110 is mounted, and cargo, such as a vehicle door or panel. The protector 110 prevents direct contact with the railcar structure, and therefore eliminates or minimizes an damage in the form of abrasions, paint damage and even denting to the cargo therein. The bumpers 113, 114, are resilient yet rigid to provide some resistance to an engaging object, such as a vehicle door panel. The force imparted on the protector 110 by an engaging object is received by the bumper 113 or 114, or both bumpers 113, 114, and the force is handled by the movement of one or both of the bumpers 113, 114 which handle the force loads and deflect to a partially, fully or substantially fully unrolled condition. The force load is handled by the protector 110 while the protector continues to provide protection, and may increase the coverage of the protection area (upward or downward in the embodiments depicted) to increase the barrier area over which protection is provided.

[0045] As shown in FIG. 4, the protector bumpers 113, 114 are shown in a first condition where they are rolled, and in a second condition where they are unrolled 113, 114 to represent the potential change in position. The bumpers 113, 114 may occupy a range of positions between the initial rolled condition (113, 114) and the expanded condition (113, 114).

[0046] When one of the bumpers 113, 114 is deflected, it may remain in a deflected position while the object is impacting or engaging the bumper 113, 114 (that is, when the force load is no longer applied to the bumper 113, 114 from the engaging object), upon which the bumper 113, 114 then returns to its initial condition (113, 114). Both bumpers 113, 114 may be impacted and deflected, or a single bumper 113 or 114 may be impacted and deflected, depending on the location of the engaging object, and the mounting location of the protector 110.

[0047] According to some embodiments, the protector 110 may be mounted to a railcar structure, such as the sidewall or side screen via the rear wall 112, and, in some embodiments, the rear wall 112 may be configured to provide some flexure at the joining locations 115, 116 or along the wall 112 to increase the resilience of the protector 110.

[0048] The protector 110 is configured to be flexibly constructed so that when one or both of the bumpers 113, 114 is engaged, the bumpers 113, 114 will deflect to undergo a displacement that unrolls, compresses, or moves the bumper 113, 114. The deflection may maximize out when one or both of the respective bumper free edges 122, 132 is substantially vertically oriented (see e.g., FIG. 4). The bumpers 113, 114 also may reach a position when the forces on the bumper cause the bumper to roll into itself, increasing the resistance of the bumper to the receiving force load. The bumpers 113, 114 preferably are resilient and yet suitably rigid so as to protect the vehicle panel from direct or rapid contact with the railway car sidewall. The protector 110 and the bumpers 113, 114 are designed to slow down the motion of a vehicle panel that is moved into engagement with one or both of the bumpers 113, 114. The decrease in the speed of the engaging object also is a feature of the protector 110, which provides a protective surface and structure for the vehicle panel to impact, preferably, eliminating contact with the railcar sidewall or side screen. The protective bumpers 113, 114 also serve to decrease the speed of an impacting object. The protector 110 is configured not only to protect an object, such as a vehicle panel against direct contact with the railway vehicle interior structure (e.g., like a sidewall or side screen), but also to eliminate or greatly reduce any impact, by slowing down or stopping the further motion of the object, such as the vehicle panel.

[0049] According to some embodiments, the rear wall 112 may be flexibly constructed so that the protector 110 may continue to be held on the rail car sidewall (e.g., at the fastening point or locations), even while stresses are placed on the joining locations 115, 116, when the respective bumpers 113, 114 undergo a deflective movement. In the preferred embodiment illustrated, the rear wall 112 is provided having ribbing 112c over its surface. As depicted in the side view in FIGS. 2A and 2B, the ribbing 112c is shown forming a plurality of peaks 112d and valleys 112e. Alternate configurations may be provided for the rear wall 112.

[0050] According to preferred embodiments, each surface of the bumpers 113, 114 is rounded, and the free ends 121, 131 according to preferred embodiments are is disposed so that they are oriented inward or rearward toward the rear wall 112 when the device 110 is installed on a sidewall of a rail car. This minimizes or eliminates the potential for the edges 121, 131 to catch on a structure, such as a vehicle door, or the clothing or tools of personnel loading and unloading the vehicles.

[0051] Preferably, the fasteners used to secure the protector 110 to a sidewall of the rail car (such as the autorack car) are constructed from a non-abrasive material, such as a plastic or nylon or other suitable materials, which if contacted also will not damage the vehicle panel. A fastener (such as for example, the fastener 250 shown in see FIGS. 7 and 8) may be used to secure the protector 110 to the autorack sidewall. The fastener 250 may be a suitable commercially available fastener that is installable by press-fit installation through an aperture 150, 151 in the protector rear wall 112 and into an aperture of the side screen. The protector 110 may be removed by releasing the fastener 250, which can be done by prying, or by squeezing together the fastener legs, or pushing the fastener from the exterior of the sidewall, so that the fastener legs are returned through the sidewall aperture. As illustrated in FIG. 6, the protector 110 is shown installed onto a side screen panel 507 with fasteners 250 mounting the protector 110 on the side screen panel 507.

[0052] The protectors may be produced using any suitable method for their production, including injection molding, extrusion, printing, die cutting, heat treating, and other methods. According to a preferred implementation, a method for production of a protector is provided and involves forming an extruded body using a suitable materials, such as a plastic, nylon, ABS, or other material. The extruded body may be formed as a workpiece having body with a wall, and a pair of bumpers. Each bumper may be provided as a bumper portion, so that the workpiece includes the body portion and one or preferably two bumper portions. The bumper portions may be planar with the body portion when the workpiece is formed, and then may be manipulated by further formation to effect the final configuration of the bumpers, such as the rolled configuration. For example, the formed first bumper portion and second bumper portion may each be rolled and heated, cooled, or subjected to another treatment that will form the bumper roll configuration. The bumper rolls preferably are formed to provide each bumper of the bumper pair joining with and extending outwardly from the body wall, and including a first bumper connected to the body wall, and a second bumper connected to the body wall. The body wall preferably is configured to remain or be formed as a planar or substantially flat structure or portion that can be attached to a mounting surface such as the side screen of a railway car (autorack car). The bumpers preferably are formed into a rolled configuration, and are treated to that they are biased to remain in the rolled configuration, while the body portion to which the roll pairs are joined remains flat. The bumpers are configured so that they maintain their respective rolled configurations of the first bumper and second bumper to produce respective rolled bumpers which when deflected from their respective rolled configurations, are biased to return to their respective rolled configurations. In preferred implementations, apertures may be formed in the body portion to facilitate mounting (e.g., using a fastener to attach the protector to the side screen).

[0053] According to some embodiments, the protectors may be produced by extrusion, vacuum forming, or combinations thereof. A sheet or extrusion of material may be positioned on a mold designed to provide the profile and portions of the protector, such as a body or rear wall, and the roll bumpers. The protector may be thermoformed from the sheet material. According to some implementations, the sheet, which may be an extruded or formed sheet, may be positioned on a mold having the form to produce the protector body and bumpers. Heating is applied to the material or sheet on the mold, and the material takes the form of the mold, producing the bumper rolls. The sheet material used to form the protector may be clamped into position on the mold. A suitable heater or heat generating apparatus is used to apply heating to the material on the mold. Some examples of heaters include infra-red elements mounted within an aluminum reflector plate, as well as, quartz heaters, and any suitable heat producing apparatus. Preferably, the heating is done uniformly over the surface of the sheet or material being molded. Multiple heating apparatus may be used to provide uniformity across the material. The production of the protectors also may be facilitated using a process control system which is configured to sense the temperature of the material or sheet during the forming process, and manipulate the process control to increase or decrease temperature. Another step in the process may be an optional air injection if the material should sag, so as to place the material back to a desired position. One or more sensors positioned at locations on the mold may be used to monitor and detect the material condition, so if it should sag or distend from its desired position, the movement is detected, and air is actuated to inject into the sagging area. Once the material is suitably pre-stretched on the mold, a vacuum may be applied to facilitate the further formation of the sheet or material and its conformance to the mold profile. A suitable vacuum pump may be used for drawing the air trapped between the material and the mold. A vacuum pump with a reservoir may be used where capacity is needed. The vacuum is applied while the material is thermally plastic, so that the vacuum can draw the material into engagement with the mold structure, and reduce any air between the material and the mold structure. The formation of the protector rolls may be carried out by thermally forming the roll bumpers on a mold. When the formation of the protector and roll bumpers is made, then the heat is removed, and preferably cooling may be applied to set the material into the configuration desired where the resiliently formed bumper rolls are produced. Cooling apparatus, such as forced or directed air or gasses from nozzles or fans may be used once the part is formed. In some applications, a mist of chilled water may be applied onto the thermoformed sheet, and in some instances both a stream of air or gasses is applied with a water mist. The material may be removed from the mold and cut and finished, for example, to provide mounting apertures, to remove excess material or remove connecting material where adjacent protectors are produced and require separation. Alternatively, one or more portions, such as the roll bumpers 113, 114 (or 213, 214) may be vacuum processed to impart the rolled configuration, and maintain the rolled configuration in the final protector. The methods preferably may extrude the protector to produce an elongated workpiece which is then subjected to processing steps to other features of the protector, such as for example, the roll bumpers and mounting apertures.

[0054] The protector 110 may be provided in different lengths, and protectors 110 may be mounted horizontally adjacent to each other or another protector 110 to provide a horizontal zone of protection along a wall area of the rail car (such as an autorack rail car). The protector 110 provides protection along the horizontal length at the location on the sidewall at which it is installed, and also provided a range of vertical protection along the horizontal length of installation.

[0055] The protector 110 preferably is constructed from material that is suitable to withstand the elements of weather and corrosion. The protector 110 preferably is constructed from materials that if inadvertently contacted will not damage the painted door surface of an automobile, nor transfer any color or material to the vehicle door. In addition, preferably the protectors have longevity and can last for a duration of at least 10 years while remaining full functionality to provide protection. The protectors also are removable, and preferred embodiments provide replaceability for conservation and reuse of materials. Embodiments may be constructed from recycled materials and may themselves be recyclable, and which preferably pose no environmental hazards, nor any harm to the health or safety of personnel installing or operating near the devices.

[0056] Embodiments of the invention also include a railcar configured with one or more levels to receive automobiles therein, and transport automobiles via the rails. The railcar is fitted with the protectors 110 shown and described herein, and may include other protectors (such as post protectors and/or roof rail protectors). The railcars that transport automobiles are often referred to as autorack railway cars, or just simply autoracks, and typically are flat cars that have sidewalls and roof covers installed on them to protect the cargo in the interior space. The railcar also has one or more wheelsets, one or more decks for the automobiles (e.g., single level, bi-level, or tri-level). Automobiles are loaded into the autorack railway car (typically they are driven in) and the autorack transports the automobiles on the railway to a destination. The sidewalls of the autorack car are formed from a panel, such as a screen having apertures therein to which the protectors 110 may be mounted. The autorack car includes a plurality of supporting posts that provide structure to the railway car, and which also support the sidewalls. The railcar interior structure is formed by a plurality of upstanding posts extending from the railcar frame. The railcar has sidewalls and a roof that protect the contents by blocking out debris and some weather elements. The upstanding posts are located on opposite lateral sides of the railcar and the sidewalls are also located on opposite lateral sides. An interior space for receiving the vehicles, and where the one or more decks are located, is provided between the lateral sides of the railway car, with the posts being disposed on each lateral side of the interior space, and sidewalls also being disposed on each lateral side of the interior space. The roof preferably covers the interior space. The protectors 110 of the invention discussed herein, are installed on the railcar interior to provide protection for automobiles to be transported. The protectors 110 are mounted to cover portions of the sidewalls and preferably are installed at pre-determined heights and positions to provide a barrier to unexpected contact with an automobile (e.g., such as a door swinging open). According to preferred embodiments, the protectors are mounted by attaching them to the sidewalls. The protectors 110 provide one or more zones of protection, which are more expansive in coverage than the initial protector area, as the protector bumper portions are deflected and increase the zone or zones of protection above and below the initial installation position of the protector.

[0057] As illustrated in FIGS. 1 and 2A, the protector 110 is shown in a static condition which for example, may be a condition when the protector 110 is installed on a side screen of an autorack rail car. The protector bumpers 113, 114 are shown providing an initial or first zone of protection Z1, which is illustrated in FIG. 3 as a zone between the bumpers 113, 114. The protector 110 has an expanded zone of protection that expands beyond the protector's initial position. In FIG. 3, the solid line representations of the protector bumpers 113, 114 shows the initial protection zone Z1 representing a static position of the protector 110. Upon being engaged by an object, such as, for example, a door panel of a vehicle that the protector 110 is designed to protect, the protector 110 absorbs the force imparted on it from the door panel and the force is handled by the bumpers 113, 114 deflecting, which may be unrolling, moving upward or downward, rolling inwardly, or combinations of these movements. In the exemplary depiction illustrated in FIG. 3, the protector 110 is moved from a static condition 110 (the solid line representation) to a displaced condition (the broken line representation) which is what may take place when the protector is engaged by an object. The deflection of the bumpers 113, 114 is shown taking place in an exemplary depiction in FIG. 3, where the bumper deflection movement is represented by the broken lines, and in FIG. 4 where deflections of the bumpers 113, 114 are represented by broken lines 113 and 114. The protector 110, including preferably the bumpers 113, 114 and rear wall 112 are made from a material that is strong yet allows deflection and movement of the bumpers 113, 114 without cracking or braking when subjected to repeated cycles of deflection and returning to the initial position. The deflection range from the initial deflection zone Z1 is expanded to cover a broader zone of protection, such as the protection zone Z2, represented by the deflection of the bumpers 113, 114 and the capacity of the respective bumpers 113,114 to move from an initial position into a wider coverage zone for protection. The protection zone Z2 may comprise separate expanded protection zones, such as Z2a and Z2b (see, e.g., FIG. 4), which correspond to each respective bumper 113, 114, so that a first expanded protection zone is associated with the first bumper 113 and a second expanded protection zone is associated with the second bumper 114.

[0058] The protector 110 allows for a central mounting of the protector 110 via the rear wall 112 to secure the protector 110 to the sidewall to provide coverage for the initial and expanded zones of protection (see e.g., Z1 and Z2 of FIGS. 3, 4 and 5).

[0059] An alternate embodiment of a prorector 210 is shown in FIG. 10. The protector 210 is viewed in a side elevation depiction. The protector 210 has a pair of roll bumpers 213, 214, which are connected to a rear wall 212, at respective joining locations 215, 216. Each roll bumper 213, 214 has a respective free end, 222, 232. The roll bumpers 213, 214 are illustrated in broken line conditions represented by reference numerals 213, 214, which show the free ends 222, 232 moving away from the side screen wall 610 in the direction of the arrows. The depiction of the free end movement is illustrative of a deflection, although there may be other positions that the free ends 222, 232, and rolls 213, 214 may occupy when there is a force F (see the force arrows in FIG. 10) imparted on the roll bumpers 213, 214, and they are defected. The force may come from a number of different directions, as the depiction of the forces F are for illustrative purposes, and do not represent the angle and direction from which the force may come. The protector 210 is shown in an uninstalled condition. According to some preferred embodiments, the protector rear wall may be forward of the roll bumper rearward portions, as shown in FIG. 10, so that installation of the protector 210 via affixing the rear wall 212 to a surface (such as a side screen) will cause the roll bumpers 213, 214 to deflect. The deflection may be a forward movement or may be a raveling movement (e.g., along the path represented by the broken lines 213, 214). Alternatively, the protector 210 may be mounted to a surface, such as to a side screen with a fastener 250 (see FIGS. 7 and 8), and the roll bumpers 213, 214 may provide tension to maintain the protector 210 in a secure position or condition on the structure. For example, the partial deflection in the mounted position may facilitate further movement of the free ends 222, 232 of the respective roll bumpers 213, 214 toward a closing of circular or arcuate profile, to aid in aligning the profile for proper movement or deflection (such as for example, movement of the free ends 222, 232 along their inward paths 213, 214).

[0060] An exemplary embodiment of a railcar 500, configured as an autorack car is depicted in FIGS. 9A and 9B. The railcar 500 is shown to represent an autorack railway car. The railcar 500 is shown in FIG. 9B without the wheelsets, and without coupling apparatus which are standard components of a railcar that are commercially available and known, and shows the exposed interior portion and a base or floor (which is a single floor shown, while an autorack may have multiple levels, such as two or three levels, depending on the vehicle cargo being transported. In addition, the railcar interior is shown for illustrative purposes, and the heights, levels and positioning of the protection devices and shown in exemplary placements, and depending on the number of levels, post locations, and relative spacing and heights from the floor level and/or the anticipated location of the door swing, could be different than the locations shown. A plurality of protectors 110 are shown installed on the autorack railcar 500 to provide suitable protection at the desired placement level or position. Placements of the protectors 110 may not represent the actual level or levels of the height position of the protection devices when installed in the autorack, but rather give examples or approximations of the levels where protection may be installed and shows the versatility of the protectors and system of the invention to provide protection at a number of suitable locations and positions. The protectors 110 also may have different lengths and different numbers and arrangements may be used, other than the number and arrangement shown. The railcar includes a base that serves as a floor or bed 501 and has a pair of upstanding end posts 502, 503, and, in the embodiment depicted, includes a plurality of upstanding intermediate support posts, for example the posts 504, 505. A second or third elevated floor also may be provided (though not shown). A sidewall 506 is shown, and may be configured from a plurality of panels 507, 508, 509 that are mounted to the posts, such as the posts 502, 503, 504, 505, and, in some embodiments also the base 501. The sidewall panels 507, 508, 509 preferably are screen panels, also known as side screens, that have a series or plurality of apertures therein 511. As discussed herein, the protectors of the invention mount to the autorack car 500, and preferably secure to the sidewalls 506, such as to the sidewall panels 507, 508, 509, and more particularly to the apertures 511 shown provided at a number of locations on the panels 507, 508, 509. The protectors 110 may be installed on the panels 507, 508, 509. The protectors 110 may be used in arrangements with other protectors, such as the protectors 550 shown covering a portion of the posts 504, 505 to provide protection from inadvertent contact by cargo, such as an automobile door. The protectors 110 are shown in the autorack configuration to provide protection along the sidewall 506, while the autorack car 500 also includes other protectors (such as the post protectors 550) which protect against contact with the posts.

[0061] The protectors 110 may be installed by securing the protector with a fastener, such as the fastener 250. The fastener shaft 251 preferably is inserted into an aperture 150, 151 of the protector 110 (preferably in the rear wall 112) and into an aperture of the side screen wall that is aligned therewith. The fastener cap 252 is larger than the protector apertures 151, 152, so the fastener 250 does not pass entirely through. Although the protector 110 is shown with two apertures, preferred embodiments may contain a plurality of apertures, such as those 150, 151 spaced apart to provide alternate mounting arrangements for facilitating mounting and positioning, and to limit or prevent lateral shifting of the protectors 110 when mounted on the side screen wall 506.

[0062] The protectors provide a barrier between the automobile and the interior rail car structures. The protectors may be installed to cover a sidewall, and provide a protective surface or structure between the sidewall and an automobile in order to limit damage caused by an automobile door that may swing out, which, instead, may contact the protector. According to preferred embodiments, the autorack is configured with a plurality of protectors which are disposed at heights suitable to protect the automobiles from direct contact with the sidewall by providing a protective barrier between the automobile door and the sidewall. According to preferred embodiments, the protector has a resilient surfaces, such as the rolled bumpers, that are designed to absorb shock and forces to prevent damage to the paint finish and/or structure of an automobile, such as the automobile door that is swung open toward a sidewall. The autorack may include protectors that have different lengths (which, for example, may be mounted horizontally along the sidewall), so that the height above the floor or floor level at which protection is required can be accommodated. Protectors may be installed at different heights to provide protection at different vertical heights along the sidewall, provides one or more zones of protection vertically as well as horizontally along the sidewall. Also, while described and shown in conjunction with the bumpers moving similarly, each bumper may react and encounter different forces and therefore there may be skewed or torsional movement of the bumpers, and their movements may be independent of each other depending on the force and/or load encountered and handled by each bumper.

[0063] The protectors shown and described preferably are constructed from a suitable material which may be a polymer having resistance to heat, cold and extreme weather conditions, as well as corrosion and UV radiation. The protectors shown and described herein may be injection molded, and/or extruded, or produced using a combination of extrusion and injection molding. In addition, the apertures may be formed using a suitable process, such as dies, cutters, punches, or other suitable devices and procedures.

[0064] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. Numerous other changes, substitutions, variations, alterations and modifications may be ascertained by those skilled in the art and it is intended that the present invention encompass all such changes, substitutions, variations, alterations and modifications as falling within the spirit and scope of the appended claims.