AU680189B2 - Surface rail for composite continuous rail - Google Patents

Description

rV 1 2 ,wI- OPI DATE 27/04/93 AOJP DATE 24/06/93 APPLN. ID 26440/92 PCT NUMBER PCT/US92/07687 i 1111111HIi n lllHll lll II lilIll AU9226440 iNItRNAtiONAL ArrLiCA1i1UlIN ruDl.oni I. JLN'I-\x i11 rliii s.,i iv-..m.ri i'CT) (51) International Patent Classification 5 (11) International Publication Number: WO 93/05981 1/34 Al (43) International Publication Date: 1 April 1993 (01.04.93) (21) International Application Number: PCT/US92/07687 Published With international search report.

(22) International Filing Date: 14 September 1992 (14.09.92) Priority data: 760,658 16 September 1991 (16.09.91) US 894,385 5 June 1992 (05.06.92) US (71)(72) Applicant and Inventor: BRUNING, Donald, Douglas [US/US]; 7137 Carter Trail, Boulder, CO 80301 (US).

(74)Agents: KNEARL, Homer, L. et al.; 3445 Penrose Place, '6 Suite #210, Boulder, CO 80301 (US).

(81) Designated States: AU, CA, JP, KR, European patent (AT, BE, CH, DE, DK, ES, FR, GB, GR, IE, IT, LU, MC, NL, SE).

(54)Title: SURFACE RAIL FOR COMPOSITE CONTINUOUS RAIL 28-s 1 1 i J t 'l 1 1 n 7) Abstract A composite continuous surface rail is constructed by combining a load-bearing support rail (10) divided into segments to allow for thermal expansion with a continuous surface rail (16) that slideably engages the support rail and spans any number of support rail segments. The continuous top or surface rail (16) includes a running rail (16) and an expansion rail The expansion rail (28) is provided to absorb thermal expansion of the running rail (16) while continuing to provide a continuous composite rail surface. The surface rail (16) and/or support rail (10) may be electrified. An electrified running rail and expansion rail will provide an electrified composite rail with electrical continuity.

1- EC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:24 No.008 P.31 IDA0 r 1A n n m IDCA/1Q IL A A f jii A r n^-50n1DrP 14 JC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:18 No.008 P.18 l 87 B02P07PC IPEUS 0 4 MAR 1994 SURFACE RAIL FOR COMPOSITE CONTINUOUS RAIL CROSS REFERENCE TO RELATED PATENTS This application is a Continuation-In-Part of copending patent application Serial No. 07/760,658 filed September 16, 1991, now U.S. Patent No. 5,154,346 issued on October 13, 1992 and entitled "Rail Mounting Clip for Railroad" which is a Division of copending patent application Serial No. 07/569,104 filed August 17, 1990, now U.S.

Patent No. 5,120,910 issued on June 9, 1992 and entitled "Minimum-Joint Electrified Rail System." FIELD OF THE INVENTION This invention relates to continuous surface rails for a railroad. More particularly the invention relates to a composite rail and the composite rail components that make up a rail with a continuous surface.

BACKGROUND OF THE INVENTION A long standing problem with continuous rails in railroad tracks has been the expansion and contraction of long continuous or welded rails. Typically, the entire rail in a continuous rail section is made of steel, steel alloys, brass or aluminum. These materials expand and contract significantly with the changes in temperature.

For example, with a wide range in temperature variations from -20°C to +40 0 C, the expansion or contraction of a continuous steel rail 1 km long can be 0.9 meters. This amount of expansion or contraction will distort or even buckle the track. On straightaways the track will ripple, but the thermal expansion problem is particularly severe on curves. An expanding rail at a curve will push laterally against tie plates and cause the rails in double rail track to spread more than the standard rail AMENDED SHE EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:25 No.008 P.32 PCT/US92/ 07 68 7 is IPEAA SAAMf -A EC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:19 No .OS P.19 pT/1C '07 787 BO2Po7PC 2 IPEUS 0 4 MAR separation. Such spreading of the rails causes derailment of wheeled vehicles running on and guided by the rails.

Of course these problems have been solved in the past by shortening the rail sections and providing enough longitudinal separation at abutment joints in successive rails to absorb the thermal expansion of the rails.

However, such joints are noisy and provide a rough ride.

In addition the separated abutting joints are severe wear points for the rails, and this produces high maintenance cost for the railroad. In addition if the rail is electrified, it is difficult to maintain electrical continuity across the rail section joint from one rail to the next abutting rail.

One solution for the electrical continuity problem in the past has included electrified rail sections that have electrical cables connecting across rail joints as in U.S. Patent 3,813,502. Further, composite rails are known and, for example, include rails shown in U.S.

Patent 2,540,433, Norwegian Patent 70654, and United Kingdom Patent Specification 25t: 43 4. None of these prior designs are directed to handl.ng the thermal expansion in continuous .roCe rails. In all cases the composite rail contains iixedly attached components so that in essence they are a sr.id rail.

Summary of the invention It is an object of this invention to provide a continuous surface rail that does not distort with thermal expansion.

It is another object of chis invention to provide a continuous surfact raill that may be electrified.

'RM ENDED SHEET 0oTO' ~u1 4 ,11 4 -3- The problem of thermal expansion in continuous rails has been solved by fabricating a composite surface rail which effectively eliminates joints between abutting rail sections at the wheel contact surface of the rails.

According to the present invention in a first aspect there is provided a surface rail for mounting on a support rail to form a composite rail with a continuous operative surface, wherein the composite rail has a plurality of the support rails connected end-toend with an expansion joint between each support rail, and each of the support rails has a head with a predetermined cross-sectional shape, said surface rail comprising: a running rail having a length independent of the length of the support rails and 10 having an upper surface for providing the operative surface of the composite rail and for spanning the expansion joints; 0: said running rail having an undersurface shaped to slideably engage the g ,predetermined shape of the head of support rails so that said running rail slides relative to the support rails as the support rails or said running rail expand or contract.

15 According to the present invention in a second aspect there is provided a surface rail apparatus for a composite rail, the composite rail having a support rail for supporting vehicles running on the composite rail, wherein the support rail is divided into longitudinal segments and has an expansion joint between each of the segments of the support rail to absorb thermal expansion of the support rail, said surface rail o, 20 apparatus mounted on the segments of the support rail and comprising: C rail running rail means for spanning the expansion joints in the segments of support rail and providing a continuous surface for contact with vehicles running on the composite rail; and said running rail means having an elongated rail shape which slideably engages 25 the segments of the support rail.

The running surface rail may be of any length and typically would span multiple support rail sections.

Preferably the surface rail embodying the invention comprises an expansion surface rail which is a short surface rail constructed to expand and contract; it is preferably placed between the ends or adjacent running rails. The expansion rail fills the gap between running rails, absorbs thermal expansion of the running rail, and provides surface continuity between running rails. In one preferred aspect of the. invention the head of the support rail is shaped to receive and guide the surface rail. After the support rail slideably engages the surface i rail it serves to guide the more flexible surface rail to the head of the next abutting support rail. The surface rails preferably mate with the support rails in a number of ways. There may be grooves in the top surface of the support rail and matching beads I SR 4 on the under surface of the lN:\LIBTT1J01136:hrW iJ EC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:26 No.008 P 34 PCTIU 2 /0o7 68 ID A I rr- ;1 i ~tII

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EC HANCOCK HL KNERRL TEL:303.447-20?0 Mar 04'94 14:20 No.008 P.21 PCT/US92/ 07 68 7 IPEAJUS 04 MAR 1994 BO2P07PC surface rail. The surface rail bead may have beveled edges that fit between matching counter-beveled edges on the top surface of the support rail. The surface rail may be a box channel shaped to slide over the head of the support rail.

If the composite rail is to be electrified, the support rail and/or surface rail may be made of electrically conductive materials. In one embodiment the support rail is non-conductive while the surface running rail is conductive. The expansion rail may be conductive or insulative depending on whether the rail is in the middle of an electrical control block or at the end of an electrical control block.

BRIEF DESCRIPTION OF DRAWINGS Figure 1 shows a preferred embodiment of the continuous surface composite rail.

Figures 2A, 2B and 2C show a fish plate for connecting abutting support rails.

Figure 3A shows a spring-loaded clip for mounting the support rail on interconnecting ties.

Figure 3B shows a support rail with a conductive surface rail and a second strip which is conductive, the surface rail for providing power to the vehicle and second strip for providing control signals.

Figure 4A shows a conductive support rail having insulating layers to insulate the support rail from the conductive top or surface rail.

Figures 4B and 4C show a preferred embodiment of a rail clip for mounting the rail on ties or a roadbed.

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i AMENDED SHEET -4 ,;r EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:26 No.008 PCT/US92/ 07 687 IDCAlCQ nlA MAD inn') ii EC HANCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:20 No.008 P.22 PQ/S 92 07 6 8 7 Bo2PO7PC 5 IPEA.US 04 MAR 1994 Figure 5 shows a double cylindrical groove and matching bead for attaching the surface rail to the support rail.

Figure 6 shows a support rail head with a cylindrical groove to receive a cylindrical shaped top rail.

Figure 7 shows a support rail head with two continuous surface rails with dovetail beads.

Figure 8 is the bottom view of a surface rail with discontinuous beads at spaced intervals.

Figure 9 shows a mono-rail embodiment where the support rail carries two continuous conductive rails under the support rail overhang.

Figure 10 shows a hanging mono-rail embodiment where the continuous conductive rails are slideably engaged to a vertical portion of the I-beam.

Figures IA and lB show a support rail with a head having a dovetail groove and a foot designed to mate with the tie plates of Figures 16 and 17.

Figures 12A, 12B and 12C show a support rail with a head shaped to slideably engage a box rhannel surface rail and a foot designed to mate with the tie plates of Figures 16 and 17.

Figure 13A is illustrative of surface rails that span multiple joints in support rails and surface rails that are shorter than a support rail.

AMENDED SHEET EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:27 No.008 P.36 PCTUS91 07 68 IPEA/US 0 4 MAR lqq4 ,fc Y c r IE.\d d t r r

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4- 4r t: 4; EC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:20 No.008 P.23 PCUig2 07 68 7 IPEiN US 04 MAR 1994 on rail used between BO2P07PC Figures 138 and 13C show an expansi the surface running rails.

Figure 14 illustrates application of the invention to double rail track.

Figure 15 shows a tie plate that slideably engages the foot of the support rails in Figures 11 and 12 is pinned to the tie plate and tie with fluted pins.

Figures 16A and 16B show a tie plate where the fluted pins are vertically oriented.

Figures 17A and 178 show a tie plate where the fluted pins are oriented at 450 from the vertical.

DETAILED DESCRIPTION OF THE INVENTION One embodiment of the invention is shown in Figure 1.

Support rail 10 is made of electrically non-conductive or insulative material such as poly-carbonate materials, carbon fibers, ceramics, or combinations thereof. Any insulative material that has sufficient structural strength to support a vehicle on the rail may be used.

The top of the support rail 10 contains a notch 12 that runs the length of rail 10. In the preferred embodiment, notch 12 is a dovetail groove. This dovetail groove is designed to receive the dovetail bead 14 of a continuous surface, conductive rail 16 on top of support rail Support rails 10 are abutted end-to-end to form any desired length of rail in a track system. In Figure 1, support rail 10 is joined to abutting support rail 18 at joint 22 by fish plate 20 and a matching counterpart fish plate (not shown) on the other side of rails 10 and 18.

The fish plate brackets are usually bolted together through the body of the support rail with bolts and nuts.

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EC HANCOCK /HL KNEARL TEL:303-447-2070 Mar 0494 14:21 No.008 P.24 PCT/U92 07 68 7 JPEAIiUS D4MAR-15S4 BO2PO7PC7 in a lightrailroad implementation with low loads on the rails, the fish plates are plastic with bolts and nuts molded .as a part of each fish plate. Each molded bolt (see Fig. 2C) has a nub 39 and shaft 38 molded on the fish plate. The nub 39 snapf its through holes 58 in a matching fish plate on the other side of the rail. For example, nubs (not shown) from the opposite-side fish plate pass through holes in rails and snapf it through holes 26 (Fig. 1) in fish plate 20. False nuts 24 are molded into fish plate 20 to simulate real nuts.

The surface rail 16 is attached to both rails 10 and 18 by inserting the dovetail bead 14 into matching dovetail groove 12 in the rails. The flat portion of conductive surface rail 16 rests on the top surface of support rails 10 and 18. The bead 14 of rail 16 riding in groove 12 holds the conductive rail in place. Thus surface rail 16 spans the support rail abutment joint 22 so that relative to a wheeled vehicle or electro-motive device riding on the rail there is no physical discontinuity or electrical discontinuity of the composite continuous conductive rail at joint 22.

The surface rail 16 terminates at some point along the track where it is desirable to end an electrical control zone. In Figure 1, rail 16 terminates where it abuts against floating insulator 28. Insulator 28 thus defines the end of one electric control zone or control block defined by conductive surface rail 16 and the beginning of the next control block defined by conductive surface rail Floating insulator 28 has a dovetail bead 32 to engage K groove 12 in the support rail in the same manner as surface rail 16. Insulator 28 floats on AMENDED SHIEET j

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EC HANCOCK HL KNERRL TEL.:303-44?-2070 Mar 04'94 14:21 No.008 PCIyUS94/ 07 68 7 IPEAIUS 0 4 MAR 11'394 support rail 18 in that it may slid along the top of rail 18. This allows for expansion and contraction of the surface rails due to changes in temperature.

Figures 2A and 2B show an alternative design for the plastic fish plates. Fish plates 34 and 35 are concave relative to the support rail 44 so that a cavity 36 is formed between plates 34 and 35 and the non-conductive support rails.

As illustrated in end view in Figure 2B, nub 39 of shaft 38 is pressed through a hole in the fish plate by deforming the fish plates 34 and 35 inward as depicted by arrows 33. Fish plates 34 and 35 are identical; when installed, plate 35 is reversed in direction relative to plate 34. Thus, shafts 38 of one plate extend through holes 58 (Fig. 2C) of the other plate. After nub 39 on shaft 38 of fish plate 34 has snapped through the hole in fish plate 35, plates 34 and 35 are held deformed toward the support rail 44. As a result, plates 34 and 35 want to extend in an upward and downward direction, as depicted by arrows 42, against the foot 46 and head 48 of rail 44.

Figure 2C shows details of the fish plate or bracket 34.

Shafts 38 and nuts 40 are molded as a part of plate 34.

The position of the innermost edge of the concave inner surface of plate 34 is illustrated by dashed line 56.

Holes 58 in the plate are tapered to receive the nubs 39 of shafts 38 that snapfit into holes 58. The molded shape of nuts 40 is a matter of choice since they are provided for aesthetics in simulating the appearance of conventional track installation.

Figure 3A illustrates a clip 64 for holding the support rail to a support member or railroad tie 62.

Alternatively, the clip could hold the support rail AMENDED SHEET 0

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EC HANCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:22 No.008 P.26 PCT/US9 07 68 7 BoZpoIpc 9 IPEA/US 04 MAR 1994 directly to the roadbed. Clip 64 has spring tension arms A support rail may be snapped into the clip 64 between the arms 60 as showr Figure 3B and be held by the clip on tie 62 or a road. :d (not shown).

Figure 3B shows a non-conductive support rail 65 and continuous, conductive, surface rail 67 similar to rail 16 in Figure 1. In addition Figure 3B shows a second conductive strip 69 (shown in end view at the end of the composite rail) positioned at the bottom of support rail 65. One or more conductive strips 69 might be used to conduct control signals, such as a radio frequency control signals, down the length of the track.

Conductive strip 69 would be a continuous or minimumjoint strip in the same manner as surface rail 67.

A end view of support rail 65 with surface rail 67 and conductor 69 is shown in Figure 4A. In addition in Figure 4A, the support rail 65 is made of a conductive metal such as steel, brass, aluminum or tin. In this embodiment with a conductive support rail, there must be an insulating layer 67A and 69A between the support rail and surface rail 67 and conductor 69. Insulating layers 67A and 69A are preferably coatings of polycarbonate materials. Plastics such as Vinyl or Teflon might be used.

Also shown in the end view in Figure 4A is a space between the bottom of surface rail 67 and the bottom of the dovetail groove. This space is provided so that a electrical wire might be trapped in the space after passing through a hole (not shown) in the support rail.

Thus the conductive surface rail conductor 67 can receive electrical power from a power source.

A snap in rail clip 64 is shown in Figures 4A, 4, and 4C.

Clip 64 is precast or molded out of flexible poly- AMENDED SHEET j iNTij? EC HANCOCK HL KNEFRL TEL:303-447-2070 Mar 04'94 14:22 No.008 P.27 PCT/92 07 6 8 7 B02P07PC 10 PEUS'0 4 MMR 1994 carbonate materials and has posts 68 with ears 63 that snap fit over the base 46 of support rail 44.

In the detail of Figure 4B, the clip 64 has upstanding posts 68 molded as a single piece with base Upstanding posts 68 have arcuate, vertical-fluted surfaces 66 and ears 63 to hold a rail firmly in place after it is snapped into clip 64. Fluted surfaces 66 would be shaped out of a harder material than the plastic clip and for example might be a metal insert such as steel, brass, or aluminum, molded into the clip. Further the rail base is held in a recessed area 67.

In Figure 4C, there is a top view of clip 64 in Figure 4B. Four posts 68 are shown. Arcuate fluted surfaces 66 are shown by dashed lines. The edges 67A of recess 67 are indicated. Also holes 61 in base plate 65 are provided so that the clip 64 can be fastened to railroad ties or roadbed with nails, spikes or bolts through the holes.

When a rail is pushed down into clip 64, base 65 and posts 68 flex to allow posts 68 to open sufficiently for the base of the rail to slip past ears 63. After ears 63 snap over the base of the rail, the rail is kept from moving vertically and is held in recess 67 by ears 63 applying retentive forces in direction of arrows 63A. In addition the rail is kept from slipping transverse to the direction of the rail by the edges of recess 67 and by retentive forces (in the direction of arrows 66A) from the inner arcuate surfaces 66 of posts 68. The rail is kept from slipping along the length of the rail by the vertical fluted surfaces 66.

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I\ EC HRNCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:23 No.008 P.28 9T 9 /07687 B02P07PC 11 MAR 1994 Figures 5 through 7 illustrate various alternative embodiments for slideably engaging the continuous surface rail on top of the sectional support rail. In Figure the top or surface rail 71 has two rounded beads 70 and 72 for engaging rounded grooves 74 and 76 respectively in support rail 69.

In Figure 6, the support rail 79 has a top surface containing a cylindrical groove 80 with ears 82 and 83.

Continuous conductor 84 has a cylindrical cross-sectional shape. When the conductor 84 is pressed into groove ears 82 and 83 of the groove snap over the conductor.

Conductor 84 has a diameter somewhat greater than the depth of groove 80 so that up to 20% of the diameter of the conductor protrudes above the surface of the support rail. This will insure good electrical contact between the conductive rail member 84 and wheels of an electromotive device drawing electrical power from the rail.

In Figure 7, the support rail 87 has two dovetail grooves 88 and 90 to engage two surface rails 92 and 94 respectively. Top rails 92 and 94 each have a dovetail bead 96 and 98 for engaging dovetail grooves 88 and If surface rails 92 and 94 are conductive, they may be insulated from each other by a ridge 100 on the head of a non-conductive support rail 87.

In Figure 8, an alternative embodiment of the continuous surface rail is shown. In this embodiment, the dovetail bead 102 is discontinuous. The bead need not extend the length of the surface rail. There only needs to be a bead at spaced intervals. Two beads 102 and 104 are shown. The interval between beads should be short enough so that good engagement with the support rail is maintained when the surface rail is slideably engaged into the matching groove in the support rail.

AMENDED SHEET To I EC HRNCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:23 No.008 P.29 Pr?92 07 68 7 B02PO7PC 12 IPENUS 04 mARj994 Figures 9 and 10 illustrate mating of continuous, conductive surface rails to sectional non-conductive mono-rails. The non-conductive mono-rail would be built of strong relatively stiff material to support the weight of the vehicle travelling on the rail. Accordingly, the mono-rail would be in sections which would be assembled to form a track. The surface rails would be flexible and of any length and would span any number of mono-rail sections thereby providing electrical continuity for a predetermined length of track.

In the mono-rail illustrated as an end view in Figure 9, the rail is supported at the base 108 by pylons or a roadbed in cross-section. The electro-motive vehicle rides on the top surface 110 of the mono-rail and carries two electrical conductive wipers or wheels which make contact with conductive surface rails 112 and 114. The continuous surface rails have a dovetail bead 116 and slideably engage matching dovetail groove 118.

In the mono-rail illustrated as an end view in Figure the rail is supported at the top 120 of the I-beam by hanging support 122 in cross-section. The ele.tro-motive vehicle rides on wheels running on the top surfaces 124 and 126 of the base 128 of the I-beam. The vehicle also carries two electrical conductive wipers or wheels which make contact with conductive surface rails 130 and 132.

The continuous conductive surface rails have a dovetail shape and slideably engage matching dovetail grooves 131 and 133 respectively.

In Figures 11A and 11B another embodiment for the support rail is illustrated. Support rail 140 differs from the support rail 10 in Figure 1 in the shape of the foot of the rail. Foot 142 of support rail 140 has its lateral edges shaped to provide a vertical surface 144 and an angular surface 146 oriented approximately 450 from the AMENDED SHEET 44 EC HRNCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:24 No.008 PCT/U9 07 68 7 B0P7C13 IPENUS 0 4 MAR 1994 vertical. The angles of the surfaces are selected so that the foot of the rail 140 will mate with the tie plate shown in Figures 15 to 17. The fastening of the rail to the tie plates and ties will be described in more detail hereinafter in reference to Figures 15 to 17.

The support rail 140 in Figure 11A and 11B has a dovetail groove 148 in the head of the support rail to receive a continuous surface rail 150. Just as in Figure 1, the dove tail 152 on surface rail 150 slideably engages the head groove 148 in support rail 140. The i'urf ace rail may extend for any distance; the length of the surface rail has no relationship to the location of support rail joints except that preferably surface rail joints do not occur at support rail joints.

Support rail 140 in Figure 11A and 11B also has a foot groove 154. Groove 154 might be used to carry a conductive wire. If support rail 140 is made of a flexible material such as Acetal Nylons and polycarbonates, so tha±t it may be shaped to a desired path for a track, groove 154 could receive a stiffening rib (not shown) The rib could be attached to the road bed on which the support rail is mounted.

Figures 12A, 12B and 12C show a support rail 156 similar to rail 140 in Figure 11A except that the head 158 of rail 156 is designed to receive a box channel shaped surface rail 160. Surface rail 160 is laid on top of head 158 and then slideably engaged to the support rail by bending the sides 162 of the channel around the head 158 to produce the composite rail shown in Figure 12C.

The bending of the sides of the channel surface rail 160 would be accomplished by applying a combination of localized heat and pressure (rollers) to the sides 162 of the channel surface rail. The heat would soften the surface rail and pressure rollers would bend the sides AMENDED SHEET or EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:24 No.008 P.31 BO2PO7PC 14 IPEAUS 04 MAR 1994 around the .head. The surface rail is hooked over the head by this bending operation. The surface rail must remain slideable relative to the head 158 of the support rail 156.

The head 158 has its four corners 164 beveled. In addition the inside corners 166 of the channel 160 are filled to match the beveled corners 164 of the support rail head. This provides more material in the surface rail at the corners of the head in the composite rail; the corners of the surface rail are the points of greatest wear as railway cars ride on the composite rail.

Depending on the application of the continuous composite rails, the support rail may be either a electrically conductive or non-conductive material. Similarly, the continuous surface rail may be conductive or nonconductive. Some examples of support rail material would be steel, aluminum, iron, brass, ceramic, thermo plastics, and thermoset plastics; some examples of surface rail materials would be aluminum, copper, steel, steel alloys, thermo plastics, and thermoset plastics.

If the surface rail is to be electrified, then the support rail should be nonconductive or an insulating layer may be placed between the surface rail and the support rail as shown in Figure 4A.

Figure 13A shows a typical configuration of the continuous composite rail using short support rail segments to illustrate the independence of the length of the surface rail from the joints in the support rail.

Surface rails may span multiple joints in the support rail or may be shorter than a support rail segment. Four support rail segments 170, 172, 174, and 176 abut at joints 171, 173, and 175 respectively. The support rail segments are fastened together with fish plate brackets 177, 178, and 179 (bolts for the fish plate brackets are AMENDED SHEET j EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:25 No.003 P.32 PCT/US92/ 07 68 7 BO2PO7PC 15 IPEMS 04 MAR 134 not shown).. Continuous, surface, running rails 180, 182, 184 and 186 are separated by surface, expansion rails 181, 183, and 185. The running rails and expansion rails all slideably engage the support rail as previously described. The expansion rails are designed to compress or expand longitudinally (along the length of the rail) to absorb expansion of the running rails.

Figures 13B and 13C show the preferred structure for an expansion rail. The structure of the high load-bearing expansion rail 181 is a honeycomb as most clearly seen in the top view in Figure 138. The wall thickness and the material used in the walls 187 of the honeycomb should have sufficient load-bearing strength so that the walls of the honeycomb will transfer the axle weight of the wheeled vehicle riding on the rails to the head of the support rail. At the same time the material should be resilient enough so that if the surface rail contracts after expansion, the expansion rail will expand and continue to provide a continuous surface from a,first running rail to the next successive running rail. The materials used in the expansion rail may be the same as the materials used in the running rail as for example, steel, steel alloys, thermo plastics, and thermoset plastics so long as the material has the necessary strength and resilience.

Figure 13C is an end view of the honeycomb expansion rail in Figure 13B. The honeycomb rail has no top or bottom walls. It does have end walls 188 and may have side walls or the honeycomb may be shaped at the sides of the rail to provide side walls. However, the main structure of the honeycomb rail must be the honeycomb and any exterior walls to the honeycomb must not restrict the expansion/contraction characteristics of the honeycomb structure. If desired to insure mechanical and electrical continuity with the surface running rails, the AMENDED SHEET Bill -i i EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:31 No.008 PCT/US92/ 07 68 7 IPFA/WS A04 MR i QA EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:25 No.008 P.33 PCT/US92/0768 7 lPEANU$ 04MAR 94 BO2P07PC 16 end of the .running rail and the abutting ends 188 of the expansion rail may be welded, fused or bonded.

As shown in the Figure 13A, the dove tail bead on the surface, running, rail has a depth shorter than the depth of the dovetail groove in the head of the support rail.

This is done to reduce friction between the running rail and the support rail so that the running rail may more easily slide in the support rail. The depth 189 of dove tail bead for the expansion rail may be the same as the dovetail bead on the running rail. However for added strength in transferring the load from the top of the expansion rail to the support rail, the depth 189 of dovetail bead on the expansion rail may have the same depth as the depth of the groove in the head of the support rail. In such an implementation, the loadbearing on the top of the honeycomb will be transferred to the bottom of the dovetail groove as well as the top of the support rail head. The added friction between the expansion rail and the support rail does not impede the slideable engagement between the running rail and the support rail.

The expansion rails may be electrically conductive or non-conductive. If the surface rail is conductive, the expansion rails would be nonconductive at the end of electrical control blocks. Within an electrical control block the expansion rail would be conductive to provide electrical continuity from one running rail to the next running rail. They would then perform the dual function of compensating for thermal expansion in the surface V 30 rails and insulating abutting surface rails so as to form electrical control blocks in the rail system. The expansion rail will be insulative if formed from thermo plastic or thermoset plastics. It will be conductive if formed from conductive metals or plastics plated with conductive metals.

AMENDED SHEET EC HANCOCK /HL KNEARL, TEL:303-447-20?O Mar 04'94 14:26 No.003 P.34 17PCTUS92 07 68 7 B02P7PC17IPEAC& 0 4 MA1 ;994 Each surface rail would normally span many support rail segment'joints, but the surface rails may be of any length.. Figure 13A illustrates a surface, running rail 182 that spans two joints 171 and 173. Figure 13A also illustrates a running rail 184 that is shorter than a single support rail segment 174 whereby there are two expansion rails 183 and 185 between joints 173 and 175.

Figure 14 shows two rail track implemented with the composite rails of the present invention. Support rail segments 190 are the same length and positioned on ties 192 so that abutting joints 194, 196, 198, and 200 for one rail of the track are offset respectively from abutting joints 201, 203, 205, 207, and 209 for the other rail. Running rail 210 spans joints 203, 205, 207, and 209 and is supported by more than three support rail segments 190. Similarly surface running rail 212 spans joints 194, 196 and 198. on the other hand running rail 215 is shorter than one segment and positioned as shown in Figure 14 does not span any joints.

All surface rails slideably engage the support rail segments to slide relative to the support rail when the surface rails expand or contract due to thermal expansion. The slideable engagement also facilitates installation of the surface rails on the support rail segments. Expansion rails 214 in Figure 14 are resilient and expand or contract to absorb thermal expansion of the surface rails. The expansion rails have the same crosssectional shape as the running rails and may also be conductive or non-conductive if the running rails are electrified.

F) While the track in Figure 14 illustrates a preferred embodiment for two rail track, it will be appreciated by one skilled in the art that ties and support rail segments could be preassem.kled in a different RAi AMENDED SHEET

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EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:26 No.008 PCT/US92/07 687 SBo 7PC IP EAUS 04 MAR 1994 B02P07PC 18 configuration. In preassembled two rail track the ends of the support rail segments would be aligned. The joints between abutting and parallel support rails would then be aligned rather than offset as shown in Figure 14.

This configuration would allow quick installation of parallel support rails on a roadbed. The two rail track would be finished by adding the continuous surface running rails and expansion rails.

The tie plates for fastening the support rails of Figures 11-14 to the ties are shown in Figures 15-17. Figure shows an assembled composite rail from Figure 11A in cross-section fastened in tie plate 220 on tie 222. Tie 222 is notched so that tie plate 220 is recessed in the notch in the tie. Fluted pins 224 and 226 pass through holes in tie plate 220 and holes in clamping shoes 228 and 230 and are driven into tie 222. Thus pins 224 and 226 fasten the rail to the tie plate and the tie plate to the tie.

Pins 224 and 226 are fluted so as to engage the edge of the foot of the support rail 140 as the pins are driven into the tie. Pin 224 is oriented at 450 to the vertical and its flutes deform and engage 450 surface 146 at the edge of the foot of support rail 140. Pin 226 is oriented vertically and its flutes deform and engage the vertical surface 144 at the edge of support rail foot.

Since the pins engage the support rail foot, they tend to hold the support rail firmly against motion along the direction of the rail.

Figures 16A and 16B are top and side views of the tie plate with the holes for spikes oriented vertically.

Spikes 232 are shown in Figure 16B. Figures 17A and 17B are top and side views of the tie plate with the holes j for spikes 234 oriented at 450 from the vertical. In both embodiments the tie plates 231 and 233 are designed AMENDED SHEET EC HRNCOCK HL KNERRL TEL:303-447-2070 Mar 04'94 14:27 No.008 P.36 PCT/US92/ 07 68 7 IPEAUS 04 MAR 1994 BO2P07PC 19 for use with four spikes. In tie plate 231 holes 235 through the clamp shoes 239 and tie plate are oriented vertically. In tie plate 233 holes 237 through clamp shoes 240 and the tie plate are oriented 45° from vertical. In addition to the holes for spikes 232 and 234, each of the tie plates also has four holes 236 to receive spikes (not shown) for holding the tie plates 231 and 233 to ties.

Vertical or non-vertical orientation of spike holes in the tie plates depends on the forces the rail will be subject to. Vertical orientation provides most resistance to vertical force from the rail. Non-vertical orientation provides more resistance to horizontal force from the rail but less resistance to vertical force from the rail. Tie plate 220 in Figure 15 used a combination of vertical and non-vertical spike holes. One skilled in the art will appreciate that depending on the horizontal and vertical forces on the rail and the materials used for the rail, tie plates, and ties, other angular orientations of the spike holes may be selected.

While a number of preferred embodiments of the invention have been shown and described, it will be appreciated by one skilled in the art, that a number of further variations or modifications may be made without departing from the spirit and scope of my invention.

AMENDED

SHEET

AT ,0

Claims (11)

1. A surface rail for mounting on a support rail to form a composite rail with a continuous operative surface, wherein the composite rail has a plurality of the support rails connected end-to-end with an expansion joint between each support rail, and each of the support rails has a head with a predetermined cross-sectional shape, said surface rail comprising: a running rail having a length independent of the length of the support rails and having an upper surface for providing the operative surface of the composite rail and for spanning the expansion joints; said running rail having an undersurface shaped to slideably engage the predetermined shape of the head of support rails so that said running rail slides relative to the support rails as the support rails or said running rail expand or contract. AMENDED SHEET rN OZ wills AMENDED SHEET EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:28 No.008 P.38 PCI' 92 07 68 7 B02P07PC 21 IPEWS 0o MAR 199

2. The surface rail of claim 1 wherein said undersurface of said running rail has opposing first and second surfaces; said first surface is positioned relative to the second surface to slideably engage a constricted cross-sectional shape in the head of the support rails whereby said running rail will slide along the length of the support rail but is otherwise constrained on the head of the support rail.

3. The surface rail of claim 2 wherein the cross- sectional shape in the head of said support rail is a dovetail groove, and: said first and second surfaces of said undersurface are lateral walls of a dovetail bead on said undersurface.

4. The surface rail of claim 1 wherein the predetermined shape of the head of the support rail is substantially rectangular, and said undersurface is a box shaped channel with interior walls slideably engaging exterior walls of the ipport rail head. The surface rail of claim 1 wherein said running rail is fabricated from an electrically non-conductive material.

6. The surface rail of claim 1 wherein said running rail is fabricated from an electrically conductive material. AMENDED SHEET EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:28 No.008 P.39 PCTUS92 07 68 7 IPEA'S 04 MAR 7994 B02P07PC

7. The surface rail of claim 6 further comprising: an insulating layer on all surfaces of the running rail that contact the support rails.

9. The surface rail of claim 1 wherein said surface rail further comprises: an expansion rail for adjusting to the expansion or contraction of said running rails slideably engaging the support rails. The surface rail of claim 9 wherein said expansion rail is fabricated as a honeycomb structure, said structure having honeycomb walls oriented to transfer the load from the upper surface of said expansion rail to the head of the support rail. AMENDED SnEET 0 i -i EC HANCOCK HL KNEARL TEL:303-447-2070 Mar 04'94 14:29 No.008 PCT/US92/ 07 68 7 BO2PO7PC 23 IPEAU 0 4 4

13. Surface rail apparatus for a composite rail, the composite rail having a support rail for supporting vehicles running on the composite rail, wherein th" support rail is divided into longitudinal segme -ts -nd has an expansion joint between each of the segments of the support rail to absorb thermal expansion of the support rail, said surface rail apparatus mounted on the segments of the support rail and comprising: running rail means for spanning the expansion joints in the segments of support rail and providing a continuous surface for contact with vehicles running on the composite rail; and said running rail means having an elongated rail shape which slideably engages the segments of the support rail.

14. The surface rail apparatus of claim 13 further comprising: a plura-ity of said running rail means, each of said running rail means slideably engaging at least one of the segments of the support rail; expansion rail means, between each of said running rail means, for providing a continuous surface between adjacent running rail means and for adjusting to expansion or contraction of said running rail means; said expansion rail means having a rail shape for slideably engaging the segments of the support rail and a length sufficient to absorb the expansion of adjacent running rail means. AMENDED SHEET RA4/I Lrnc~ |i r -24- The surface rail apparatus of claim 14 wherein; said running rail means is electrically conductive; and said expansion rail means is electrically conductive for continuing electrical continuity between adjacent running rail means.

16. The surface rail apparatus of claim 14 wherein; said running rail means are electrically conductive; and said expansion rail means are electrically non-conductive for insulating adjacent running rail means from each other.

17. The surface rail apparatus of claim 13 further comprising: S, 10 a plurality of said.running rail means, each of said running rail means slideably S engaging at least one of the segments of the support rail. C 18. A surface rail substantially as hereinbefore described with reference to Sc the accompanying drawings. S Dated 17 April, 1997 Donald Douglas Bruning Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON c a I t t i i u i il