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 flanges that extend outward of the body and are deflectable to provide an expanded zone 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 flanges 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; b) a first flange connected to said body and projecting outward from said body at an angle therefrom; c) a second flange connected to said body and projecting outward from said body at an angle therefrom; d) each first flange and second flange including an engaging edge; e) wherein each engaging edge spans horizontally along the protector.

2. The protector of claim 1, wherein said flanges connect to said body, and wherein said flanges are flexibly configured to move relative to said body.

3. The protector of claim 2, wherein the flanges project forward from said body, and wherein said flanges are deflectable rearwardly and in a vertical direction relative to the body.

4. The protector of claim 1, wherein said first flange is disposed at an upward angle relative to said body and wherein said second flange is disposed at a downward angle relative to said body.

5. The protector of claim 4, wherein each flange comprises a flange connecting wall, wherein the body comprises a body wall, and wherein each said flange makes an inner angle defined by the angle between the flange connecting wall and the body wall, and wherein when the respective flange is engaged by a contacting structure, the inner angle between the respective said flange and the body wall increases.

6. The protector of claim 4, wherein each flange comprises a flange connecting wall, wherein the body comprises a body wall, wherein each said flange makes an inner angle defined by the angle between the flange connecting wall and the body wall, and wherein when a respective one of the flanges is engaged by a contacting structure, the respective inner angles between the respective one of the said flanges and the body wall increases.

7. The protector of claim 1, wherein said body comprises a wall, and wherein said wall has one or more apertures therein.

8. The protector of claim 7, wherein each flange includes a front edge.

9. The protector of claim 8, wherein each flange front edge has an arcuate portion.

10. The protector of claim 1, wherein each said flange includes a front edge and a connecting wall, wherein said connecting wall connects said flange front edge to said body.

11. The protector of claim 1, wherein each said flange includes a front edge, a terminal edge and a connecting wall, wherein said connecting wall connects said flange front edge to said body.

12. The protector of claim 11, wherein said front edge has a first arcuate portion joining with said connecting wall, and a second arcuate portion at the terminal edge thereof.

13. The protector of claim 1, wherein each said first flange and said second flange includes a first deflection locus and a second deflection locus.

14. The protector of claim 13, wherein each said flange includes a front edge and a connecting wall, wherein said flange connecting wall connects said flange front edge to said body, wherein said first deflection locus comprises the joining location where said flange connecting wall joins said rear wall, and wherein said second deflection locus comprises the flange front edge.

15. The protector of claim 14, wherein each said flange front edge is a curved edge.

16. The protector of claim 15, wherein each said flange front curved edge is convex in relation to the front of the flange.

17. 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 flanges, each flange of the flange pair extending from the body wall and including a first flange connected to the body wall and projecting outward from the body wall at an angle therefrom, and a second flange connected to the body wall and projecting outward from the body wall at an angle therefrom; b) the extruded body forming an engaging edge in each of said first flange and said second flange, and wherein the respective engaging edges span horizontally along the protector; and c) cutting one or more apertures in the body wall.

18. 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: i) a body mounted to the railcar sidewall; ii) a first flange connected to said body and projecting outward from said body at an angle therefrom; iii) a second flange connected to said body and projecting outward from said body at an angle therefrom; iv) each first flange and second flange including an engaging edge; v) each of said first flange and said second flange including a connecting wall joining each engaging edge with said body; f) wherein the protector is mounted to the sidewall with said flanges disposed horizontally so that the first flange is positioned at a vertical height that is higher than the vertical height of the second flange; and g) wherein said flanges project from the sidewall mounted body into the interior space.

19. The railcar of claim 18, 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.

20. The railcar of claim 19, including a plurality of post protectors installed to provide a barrier between the interior space and one or more posts.

21. The railcar of claim 18, 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

DETAILED DESCRIPTION OF THE INVENTION

[0031] 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.

[0032] 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 rear wall 112. A first flange 113 forms a first protective structure, and a second flange 114 forms a second protective structure. A first connecting wall 115 and a second connecting wall 116 join the rear wall 112. The first connecting wall 115 is angularly disposed relative to the body rear wall 112 and includes a free end having an engaging surface comprising a front edge 117. The front edge 117 joins the first connecting wall 115 at a joining location 121. The front edge 117 has a terminal edge 118. According to some preferred embodiments, the front edge 117 or a portion thereof is arcuately configured. For example, as shown in FIG. 2, the front edge 117 forms a curved profile at the joining location 121 where the front edge 117 joins the first connecting wall 115. The device 110 preferably has a second flange 114 which is shown configured similar to the first flange 113, but oriented in an opposite direction. The second flange 114 is shown having a connecting wall 116 that joins the rear wall 112. The connecting wall 116 is angularly disposed relative to the body rear wall 112 and includes a free end having an engaging surface comprising a front edge 125. The front edge 125 of the second flange connecting wall 116 joins the front edge 125 at a joining location 130. The front edge 125 has a terminal edge 127, and according to some preferred embodiments, the front edge 125 or portion thereof is arcuately configured.

[0033] The protector 110 is configured to be flexibly constructed so that when a flange 113, 114 is engaged, the flange 113, 114 will deflect to undergo a vertical and rearward displacement. The deflection may maximize out when one or both of the respective flange terminal edges 118, 127 contact the railway car sidewall. The movement of the flanges 113, 114 upon engagement changes the engagement surface so that the forward facing surface is an area between the front 117 of the flange 113 and the joining location 121 (as per the first flange 113), and similarly for the second flange 114, between the front 125 and joining location 130. According to some embodiments, the rear wall 112 also is flexibly constructed so that the protector 110 may continue to be held on the rail car sidewall (e.g., at the fastening point), while the connecting edges 141, 142 may undergo a slight vertical displacement to further facilitate the vertical displacement of the respective front edges 115, 125 of the flanges 113, 114.

[0034] According to preferred embodiments, each terminal edge 118, 127 is disposed so that it is oriented rearward toward the rear wall 112 (or rearward toward the sidewall when the device 110 is installed on a sidewall of a rail car). This minimizes or eliminates the potential for the edge 118, 127 to catch on a structure, such as a vehicle door, or the clothing or tools of personnel loading and unloading the vehicles. The inturned terminal edge 118, 127 also facilitates the desired movement of the respective flange 113, 114, and provides an engaging edge for contacting the sidewall.

[0035] Referring to FIG. 3, the protector 110 is illustrated in different deflection positions to show the expansive zone of protection Z2 provided by the protector 110. The front surfaces, including the connecting walls 115, 116, the front edges 117, 125, 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. As shown in FIG. 3, each flange 113, 114 makes an inner angle defined along the angle arcs 157, 158 between the respective flange connecting wall 115, 116 and the body wall 112. When a respective flange 113, 114 is engaged by a contacting structure, the inner angle between the respective said flange 113, 114 and the body wall 112 increases (as defined along the arcs 157, 158). The flanges 113, 114 preferably serve as stops to maintain the protector point of contact away from the sidewall or side screen, so even if there is a maximum deflection, and a flange end 118, 127 were to contact a sidewall, the flange front edges 117, 125 may also serve to handle forces and themselves provide a further deflection or resistance, e.g., where the ends 118, 127 may move along the sidewall surface. According to preferred embodiments, the flanges 113, 114 include a first or primary deflection locus and a second or secondary deflection locus, with the first or primary deflection locus comprising the connecting edges 141, 142, and the second or secondary deflection locus comprising the flange front edges 117, 125.

[0036] 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. 6 and 7) 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. 4, 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. The side screen 507 has apertured therein which the leg 251 of the fastener 250 passes to mount the protector 110.

[0037] 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.

[0038] The protector 110 preferably is constructed from material that is suitable to withstand the elements of weather and corrosion. The protectors 110 preferably are 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.

[0039] 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 a zone of protection that is more expansive than the protector area, as the protector portions are deflected and increase the zone of protection above and below the initial installation position of the protector.

[0040] As illustrated in FIG. 2, the protector 110 is shown in an 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 flanges 113, 114 are shown providing an initial or first zone of protection Z1, which is illustrated in FIG. 3 as a zone between the flanges 113, 114. The protector 110 has an expanded zone of protection that expands beyond the protector's initial position. In FIG. 3, the broken line representation of the protector 110 shows the initial protection zone Z1 and installation condition, and static position of the protector 110 and flanges 113, 114. 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 and the force is handled by deflecting the flanges 113, 114 away from the rear wall 112. In the exemplary depiction illustrated in FIG. 3, the protector 110 is moved from a static condition 110 (the broken line representation) to a displaced condition 110 (the solid line representation) which is what takes place when the protector is engaged by an object. The deflection of the flanges 113, 114 is shown taking place in an exemplary depiction in FIG. 3, where the flange deflection movement is represented by the respective deflection arcs 160, 161 (FIG. 3). The flanges 113, 114 and rear wall 112 preferably are made from a material that is strong yet allows deflection and movement of the flanges without cracking or braking through repeated cycles of deflection and return to the initial position (FIG. 2, or 110 position of FIG. 3). 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 flanges 113, 114 and the capacity of the respective flanges 113,114 to move into a wider coverage zone for protection. The flanges 113, 114 are shown in an initial state and position in broken lines, and flanges 113, 114 in solid lines are shown in a deflected position.

[0041] 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 FIG. 3).

[0042] An exemplary embodiment of a railcar 500, configured as an autorack car is depicted in FIGS. 29A and 29B. The railcar 500 is shown to represent an autorack railway car. The railcar 500 is shown in FIG. 29B 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.

[0043] 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 and into an aperture of the side screen wall that is aligned therewith. The fastener cap 252 is larger than the protector apertures 150, 151, so the fastener 250 does not pass entirely through.

[0044] 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 flanges, 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 flanges moving similarly, each flange may react and encounter different forces and therefore there may be skewed or torsional movement of the flanges, and their movements may be independent of each other depending on the force and/or load encountered and handled by each flange.

[0045] 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.

[0046] 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.