CN108290583B - Rail car bogie roller bearing adapter pad system - Google Patents

Abstract

A railcar truck and adapter pad system (198) between a roller bearing (5) and a side frame pedestal roof (152) of a three-piece railcar truck is disclosed. Many different features of the pad (198) and/or adapter pad interface are configured to improve stiffness characteristics to meet curve-through and high speed performance of a railcar truck.

Description

Rail car bogie roller bearing adapter pad system

Cross Reference to Related Applications

This patent application claims the benefit of united states non-provisional patent application US15/152,860 entitled "railcar truck roller bearing adapter pad system" filed on 12/5/2016 and the benefit of united states provisional patent application US62/161,139 filed on 13/5/2015, which is also a continuation-in-part application of united states patent application US14/585,569 filed on 30/2014, which claims (and, in turn, the patent application also claims) the benefit of united states provisional applications US61/921,961 and US62/065,438 filed on 30/12/2013 and 17/10/2014 17, respectively; also, this patent also relates to U.S. patent applications US14/561,897 filed 12/5/2014, US14/562,005 filed 12/5/2014, and US14/562,082 filed 12/5/2014, which respectively require (and, in turn, the patent also requires) the rights and interests of U.S. provisional applications US61/921,961 and US62/065,438 filed 12/30/2013 and 10/17/2014, respectively. The disclosures of the above-mentioned U.S. patent applications and U.S. provisional patent applications are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to railcar trucks, and more particularly, to roller bearing adapters and adapter pad systems that can improve stiffness, damping, and displacement characteristics to meet curve-through and high-speed performance of a three-piece railcar truck.

Background

Conventional railway freight car trucks used in north america for decades are three-piece trucks comprising a pair of parallel side frames connected by a transversely mounted bolster. The bolster is supported on the side frames by spring groups consisting of a plurality of individual coil springs. The wheelsets of the truck are received in bearing adapters disposed in the front and rear pedestal jaws of the side frames such that the axles of the wheelsets are parallel in a lateral or side position relative to the two rails. The railway car is mounted on the center plate of the bolster, which allows the truck to rotate relative to the car. The spring nest and side frame and bolster clearance stops allow the side frames to move somewhat relative to the bolster along the longitudinal axis, vertical axis, and lateral or side axis.

There has been a long felt need to improve the performance of three-piece trucks. Resistance to lateral and longitudinal loads and truck performance can be characterized by one or more of the following well-known phenomena.

As one side frame moves longitudinally forward relative to the other side frame, a "parallelogram" phenomenon occurs such that the front and rear wheelsets remain parallel to each other, but are not perpendicular to the track, as occurs when a railcar truck encounters a curve. This parallelogram phenomenon of the side frame is also referred to as truck diamond deformation.

"hunting" describes sinusoidal oscillatory longitudinal and transverse movements of the wheel set, which result in a moving side-to-side movement of the rail vehicle body. This sinusoidal motion is a harmonic oscillation due to the conical profile of the wheel set. While the tapered profile promotes natural oscillation of the wheelset, it is also a primary feature that causes the wheelset to produce rolling radius differences and to negotiate curves. When the oscillation reaches the resonant frequency, the oscillation may be dangerous. Hunting is more likely to occur when the trucks are manufactured out of alignment, or are subject to different operating conditions (e.g., wear of the truck components) over time. Hunting is also more likely to occur when the railcar is operating at high speeds. The speed at which the swing is observed to occur is referred to as the "swing threshold".

various methods have been attempted to improve the stability of a standard three-piece truck to prevent parallelogram and hunting, while ensuring that the truck can be formed with the appropriate geometry to accommodate different distances traveled by the wheels on the inside and outside of the curve, respectively. Additional improvements in stiffness, damping and displacement characteristics that can both meet truck sway requirements while also improving the performance of yielding excellent high speed performance and curve passing performance are desired.

disclosure of Invention

This summary is provided to introduce a selection of general concepts in a simplified form that are further described below in the detailed description.

Various aspects disclosed herein relate to a railcar truck, a roller bearing adapter, and an adapter pad.

in one embodiment, provided herein is a roller bearing adapter pad configured for use with a three-piece truck having an AAR standard geometry, the adapter pad configured to engage a side frame pedestal roof. The roller bearing adapter pad may include: a continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous top panel having first and second longitudinal edges; a continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), and a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous bottom panel having first and second longitudinal edges; an elastomeric member located between the top plate and the bottom plate. The first and second lateral edges of the top panel may define an inwardly curved or inwardly angled edge from the outer surface of the top panel to the inner surface of the top panel in side view, and the first and second lateral edges of the bottom panel define an inwardly curved or inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel in side view. The first longitudinal edge of the top panel and the second longitudinal edge of the top panel define an inwardly curved edge or an inwardly angled edge from the outer surface of the top panel to the inner surface of the top panel in a side view, and the first longitudinal edge of the bottom panel and the second longitudinal edge of the bottom panel define an inwardly curved edge and an inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel in a side view. The first lateral edge of the top panel and the second lateral edge of the top panel include curved portions from a top view, and the first lateral edge of the bottom panel and the second lateral edge of the bottom panel include curved portions from a top view. The elastomeric member extends laterally outward beyond the first and second lateral edges of the top and bottom plates, and the elastomeric member extends longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

The first lateral edge of the top plate and the second lateral edge of the top plate may comprise a continuous radius measured from a vertical axis at a center point of the central portion of the top plate in a top view, and the first lateral edge of the bottom plate and the second lateral edge of the bottom plate comprise a continuous radius measured from a vertical axis at a center point of the central portion of the bottom plate in a top view.

The elastomeric member may extend laterally outward at least 0.05 inches beyond the first and second lateral edges of the top and bottom plates, and the elastomeric member may extend longitudinally outward at least 0.05 inches beyond the first and second longitudinal edges of the top and bottom plates. The elastomeric member disposed between the central portions of the top and bottom plates may have a substantially uniform thickness.

In another embodiment, a roller bearing adapter pad system configured for use with a three-piece truck having an AAR standard geometry is disclosed. The roller bearing adapter pad system may include a roller bearing adapter configured to engage a roller bearing, the roller bearing adapter including: the roller bearing includes a crowned top surface, a bottom surface configured to engage the roller bearing, and first and second vertical shoulders projecting upwardly from opposite lateral edges of the top surface. The roller bearing adapter pad system can also include an adapter pad that engages the roller bearing adapter and is configured to engage a side frame of the pedestal roof. The adapter pad may include: a continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), and a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous top panel having first and second longitudinal edges; a continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous bottom panel having first and second longitudinal edges; an elastomeric member disposed between the top plate and the bottom plate. The first and second laterally projecting flanges of the top and bottom plates are integrally disposed over a vertical shoulder of the roller bearing adapter.

The first lateral edge of the top plate and the second lateral edge of the top plate may include a curved portion as viewed from a top view, and the first lateral edge of the bottom plate and the second lateral edge of the bottom plate may include a curved portion as viewed from a top view. The first lateral edge of the top panel and the second lateral edge of the top panel may further comprise a continuous radius measured from a vertical axis at a center point of the central portion of the top panel when viewed in a top view, and the first lateral edge of the bottom panel and the second lateral edge of the bottom panel may further comprise a continuous radius measured from a vertical axis at a center point of the central portion of the bottom panel when viewed in a top view.

The first lateral edge of the top panel and the second lateral edge of the top panel define an edge that curves inwardly or angles inwardly from the outer surface of the top panel to the inner surface of the top panel as viewed in side elevation, and the first lateral edge of the bottom panel and the second lateral edge of the bottom panel define an edge that curves inwardly and angles inwardly from the outer surface of the bottom panel to the inner surface of the bottom panel as viewed in side elevation.

the first longitudinal edge of the top panel and the second longitudinal edge of the top panel define an inwardly curved edge and an inwardly angled edge from the outer surface of the top panel to the inner surface of the top panel as viewed in side elevation, and the first longitudinal edge of the bottom panel and the second longitudinal edge of the bottom panel define an inwardly curved edge and an inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel as viewed in side elevation.

The elastomeric member may extend laterally outward beyond the first and second lateral edges of the top and bottom plates, and the elastomeric member may extend longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

The highest strain value may occur inward of the outer edge of the elastomeric member when the top plate is laterally displaced 0.234 inches relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 80% when the top plate is laterally displaced 0.234 inches relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 90% when the top plate is laterally displaced 0.234 inches relative to the bottom plate.

The highest strain value occurs inside the outer edge of the elastomeric member when the top plate is displaced 0.139 inches laterally relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 80% when the top plate is displaced 0.139 inches laterally relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 90% when the top plate is displaced 0.139 inches laterally relative to the bottom plate.

The thickness of the portions of the elastomeric member disposed between the first and second lateral flanges of the top and bottom plates is pre-compressed from a static state.

The roller bearing adapter pad system may also include a first compression gasket disposed between the first lateral flange of the bottom plate and the first vertical shoulder of the roller bearing adapter, and a second compression gasket disposed between the second lateral flange of the bottom plate and the second vertical shoulder of the roller bearing adapter.

A portion of the elastomeric member disposed between the central portions of the top and bottom plates may have a substantially uniform thickness.

In another embodiment, the disclosure herein provides a roller bearing adapter pad configured for a three-piece truck having an AAR standard geometry, the adapter pad configured to engage a side frame pedestal roof. The adapter pad may include: a continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), and a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous top panel having first and second longitudinal edges; a continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region (the first lateral flange having a first lateral edge), and a second lateral flange projecting outwardly from the second upturned region (the second lateral flange having a second lateral edge), the continuous bottom panel having first and second longitudinal edges; and an elastomeric member disposed between the top plate and the bottom plate. The first lateral edge of the top panel and the second lateral edge of the top panel define an edge that curves inwardly from the outer surface of the top panel to the inner surface of the top panel and an inwardly angled edge as viewed in side elevation, and the first lateral edge of the bottom panel and the second lateral edge of the bottom panel define an edge that curves inwardly from the outer surface of the bottom panel to the inner surface of the bottom panel or an inwardly angled edge as viewed in side elevation, and the first longitudinal edge of the top panel and the second longitudinal edge of the top panel define an edge that curves inwardly from the outer surface of the top panel to the inner surface of the top panel or an inwardly angled edge as viewed in side elevation, the first longitudinal edge of the bottom panel and the second longitudinal edge of the bottom panel define an edge that curves inwardly or an inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel as viewed in side elevation . The adapter pad may further include a first compression gasket disposed below the first lateral flange of the bottom plate and a second compression gasket disposed below the second lateral flange of the bottom plate.

The first lateral edge of the top plate and the second lateral edge of the top plate may include a curved portion as viewed from a top view, and the first lateral edge of the bottom plate and the second lateral edge of the bottom plate may include a curved portion as viewed from a top view.

The first lateral edge of the top panel and the second lateral edge of the top panel comprise a continuous radius measured from a vertical axis located at a center point of the central portion of the top panel when viewed in top plan, and the first lateral edge of the bottom panel and the second lateral edge of the bottom panel comprise a continuous radius measured from a vertical axis located at a center point of the central portion of the bottom panel when viewed in top plan. Any point on a lateral edge may have a linear displacement less than or equal to 0.234 when the top plate is rotated 41 milliradians relative to the central position of the bottom plate.

The elastomeric member may extend laterally outward beyond the first and second lateral edges of the top and bottom plates, and the elastomeric member extends longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

The thickness of the portion of the elastomeric member disposed between the first and second lateral flanges of the top and bottom plates may be pre-compressed from a static state.

The elastomeric member disposed between the central portions of the top and bottom plates may have a substantially uniform thickness.

The adapter pad may have an overall longitudinal length of about 6.5 inches to about 8.5 inches, and the adapter pad may have an overall lateral length of about 9 inches to about 11 inches.

The elastomeric member may have a shore a durometer hardness of 65 to 80.

In another embodiment, the disclosure herein provides a roller bearing adapter pad system configured for use with a three-piece truck having an AAR standard geometry. The roller bearing adapter pad system can include a roller bearing adapter configured to engage a roller bearing, the roller bearing adapter having a top surface and a bottom surface configured to engage a roller bearing. The roller bearing adapter pad system can also include an adapter pad engaged with the roller bearing adapter and configured to engage a side frame pedestal roof. The adapter pad may include a top plate, a bottom plate, and an elastomeric member disposed between the top plate and the bottom plate. When a vertical load of 35,000 pounds is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member may provide a longitudinal stiffness of at least 45,000 pounds per inch by longitudinal displacement of the top plate relative to the bottom plate up to 0.139 inches from the central position, a lateral stiffness of at least 45,000 pounds per inch by lateral displacement of the top plate relative to the bottom plate up to 0.234 inches from the central position, and a rotational stiffness of at least 250,000 pounds per inch per radian by rotational displacement of the top plate relative to the bottom plate up to 41 milliradians from the central position. The roller bearing adapter may also include a first compression washer disposed below the first lateral flange of the bottom plate and a second compression washer disposed below the second lateral flange of the bottom plate.

the highest strain value occurs inward of the outer edge of the elastomeric member when the top plate is laterally displaced 0.234 relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 90% when the top plate is laterally displaced 0.234 relative to the bottom plate.

The highest strain value occurs inward of the outer edge of the elastomeric member when the top plate is longitudinally displaced 0.139 relative to the bottom plate. The combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 90% when the top plate is displaced 0.139 longitudinally relative to the bottom plate.

The portion of the elastomeric member disposed between the central portions of the top and bottom plates may have a substantially uniform thickness.

Drawings

FIG. 1A is a perspective view of a standard three-piece truck.

FIG. 1B is an exploded view of a standard three-piece truck.

Fig. 2 is a perspective view of a roller bearing adapter and adapter pad according to various aspects disclosed herein.

Fig. 3 is a cross-sectional view of a roller bearing adapter, adapter pad, and side frame according to various aspects disclosed herein.

Fig. 3A is a detailed view of a portion of fig. 3.

Fig. 3B is a detailed view of a portion of fig. 3.

Fig. 4 is a perspective view of a roller bearing adapter in accordance with various aspects disclosed herein.

Fig. 5A-5D are perspective views of a roller bearing adapter in accordance with various aspects disclosed herein.

FIG. 6 is a cross-sectional view of the roller bearing adapter of FIG. 4 taken along a centerline.

Fig. 7 is a top view of the roller bearing adapter of fig. 4.

Fig. 8 is a side view of the roller bearing adapter of fig. 4.

Fig. 9 is a front view of the roller bearing adapter of fig. 4.

Fig. 10 is a cross-sectional view taken along line 6-6 of fig. 8.

Fig. 11 is a top view of an adapter pad in accordance with various aspects disclosed herein.

fig. 11A is a cross-sectional view taken along line 11A-11A of fig. 11.

Fig. 11B is a cross-sectional view taken along line 11B-11B of fig. 11.

Fig. 11C is a detailed view of the first upturned region of fig. 11.

Fig. 12 is a side view of a bottom plate of an adapter pad in accordance with various aspects disclosed herein.

Fig. 13A is a top view of an adapter pad in accordance with various aspects disclosed herein.

Fig. 13B is a cross-sectional view taken along the longitudinal line of fig. 13A.

Fig. 13C is a cross-sectional view taken along a longitudinal centerline of a portion of an adapter pad and a roller bearing adapter in accordance with various aspects disclosed herein.

Fig. 13D is a perspective view of an adapter pad with all elastomeric members, including a ground strap, removed in accordance with aspects disclosed herein.

fig. 13E is a perspective view of an adapter pad including a ground strap in accordance with aspects disclosed herein.

Fig. 14 is a schematic diagram depicting lateral force versus displacement of an adapter pad in accordance with various aspects disclosed herein.

Fig. 15 is a schematic diagram depicting adapter pad temperature versus time during loading according to various aspects disclosed herein.

Fig. 16A is a top view of an adapter pad without a top plate in accordance with various aspects disclosed herein.

Fig. 16B is a cross-sectional view of an adapter pad in accordance with various aspects disclosed herein.

Fig. 17A is a top view of an adapter pad in accordance with various aspects disclosed herein.

FIG. 17B is a top view of the adapter pad of FIG. 17A depicting longitudinal displacement.

Fig. 17C is a top view of the adapter pad of fig. 17A depicting lateral displacement.

FIG. 17D is a top view of the adapter pad of FIG. 17A depicting rotational displacement.

Fig. 18 is a schematic view of a method of manufacturing an adapter pad according to various aspects disclosed herein.

Fig. 19 is a perspective view of an elastomeric member of an adapter pad according to various aspects disclosed herein.

Fig. 20A-20C are vertical cross-sectional views of a portion of an adapter pad showing different geometries of a plurality of gaps of the adapter pad in an unloaded configuration, in accordance with various aspects disclosed herein.

Fig. 21A to 21C are schematic views of changes in the geometry of the gap shown in fig. 20A to 20C, respectively, when a load is applied to the adapter pad.

Fig. 22 is a cross-sectional view of a portion of an adapter pad showing a representative arrangement of a plurality of gaps in an elastomeric portion, in accordance with various aspects disclosed herein.

Fig. 23 is a cross-sectional view of a portion of an adapter pad showing a plurality of gaps extending only a partial thickness of an elastomeric layer in accordance with various aspects disclosed herein.

Fig. 24 is a schematic view of a method of manufacturing an adapter pad according to various aspects disclosed herein.

Fig. 25 is a schematic view of a method of manufacturing an adapter pad according to various aspects disclosed herein.

Fig. 25A-25I are perspective views of an adapter pad according to various aspects disclosed herein.

Fig. 26 is a schematic view of a method of manufacturing an adapter pad according to various aspects disclosed herein.

Fig. 27 is a schematic diagram illustrating testing of an adapter pad in accordance with various aspects disclosed herein.

Fig. 28 is a perspective view of an adapter pad in accordance with various aspects disclosed herein.

Fig. 29A is a top view of the adapter pad of fig. 28.

FIG. 29B is a top view of the adapter pad of FIG. 28 showing the various plates in phantom.

fig. 30 is a cross-sectional view taken along a line in the vertical direction of fig. 29A.

Fig. 31 is a detailed view of a portion of fig. 30.

FIG. 31A is a detailed view of another embodiment of a portion of an adapter pad similar to FIG. 31.

FIG. 31B is a detailed view of another embodiment of a portion of an adapter pad similar to FIG. 31.

Fig. 32 is a cross-sectional view taken along line B-B of fig. 30.

Fig. 33 is a detailed view of a portion of fig. 32.

Fig. 33A is a detailed view of another embodiment of a portion of an adapter pad similar to fig. 33.

FIG. 33B is a detailed view of another embodiment of a portion of an adapter pad similar to FIG. 33.

FIG. 34A is a computer screen shot of finite element analysis simulation results showing strain in the elastomer portion as the top plate is laterally displaced relative to the bottom plate in accordance with aspects disclosed herein.

FIG. 34B is a screen shot of a portion of the finite element analysis simulation result of FIG. 34A.

FIG. 35A is a computer screen shot of finite element analysis simulation results showing strain in the elastomer portion as the top plate is longitudinally displaced relative to the bottom plate in accordance with aspects disclosed herein.

FIG. 35B is a screen shot of a portion of the finite element analysis simulation result of FIG. 35A.

Fig. 36A is a perspective view of an adapter pad and a roller bearing adapter in accordance with various aspects disclosed herein.

Fig. 36B is a side view of an adapter pad and a roller bearing adapter in accordance with various aspects disclosed herein.

FIG. 36C is a top view of the adapter pad and roller bearing adapter of FIG. 36A.

3 FIG. 3 36 3D 3 is 3a 3 cross 3- 3 sectional 3 view 3 of 3 the 3 adapter 3 pad 3 and 3 roller 3 bearing 3 adapter 3 of 3 FIG. 3 36 3C 3 taken 3 along 3 line 3A 3- 3A 3. 3

Fig. 36E is a front view of the adapter pad and roller bearing adapter of fig. 36A.

Fig. 37 is a perspective view of an adapter pad in accordance with various aspects disclosed herein.

fig. 38 is a top view of the adapter pad of fig. 37.

Fig. 39 is a bottom view of the adapter pad of fig. 37.

Fig. 40 is a front view of the adapter pad of fig. 37.

Fig. 41 is a rear view of the adapter pad of fig. 37.

Fig. 42 is a side view of the adapter pad of fig. 37.

Fig. 43 is a side view of the adapter pad of fig. 37.

Fig. 44 is a perspective view of an adapter in accordance with various aspects disclosed herein.

Fig. 45 is a front view of the adapter pad of fig. 44.

Fig. 46 is a side view of the adapter pad of fig. 44.

Fig. 47 is a rear view of the adapter pad of fig. 44.

Fig. 48 is a side view of the adapter pad of fig. 44.

Fig. 49 is a top view of the adapter pad of fig. 44.

Fig. 50 is a bottom view of the adapter pad of fig. 44.

Detailed Description

In the following description of various exemplary configurations in accordance with the present invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various exemplary devices, systems, and environments in which various aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Moreover, although the terms "top," "bottom," "front," "back," "side," "rear," and the like may be used herein to describe various example features and elements of the invention, these terms are used herein for convenience of description, e.g., based on the example orientations shown in the figures or the orientations during typical use. Further, the term "plurality" as used herein means any number of more than one, either separately or in combination, up to an infinite number, if necessary. Nothing in this specification should be construed as requiring a specific three dimensional orientation to fall within the scope of the invention. Moreover, the reader should understand that the drawings are not necessarily drawn to scale.

In general, aspects of the invention relate to railway car trucks, and railway car truck roller bearing adapters and adapter pads. According to various aspects and embodiments, the railcar trucks and railcar truck roller bearing adapters and adapter pads may be formed from one or more of a variety of materials, such as: metals (including metal alloys), polymers, and composite materials, and the railcar trucks and railcar truck roller bearing adapters and adapter pads may be formed in one of a variety of configurations. It should be understood that the railcar truck roller bearing adapter and adapter pad may comprise components made from several different materials. Further, the components may be formed by a variety of different forming methods. For example, the metal part may be formed by forging, molding, casting, stamping, machining, and/or other known techniques. Additionally, polymeric components (e.g., elastomers) can be manufactured by polymer processing techniques, such as various molding and casting techniques and/or other known techniques.

The various figures in this application illustrate examples of a railcar truck, a railcar truck roller bearing adapter, and an adapter pad in accordance with the present invention. When the same reference number appears in more than one drawing, that reference number will be used consistently in this specification and will refer to the same or similar parts throughout the several views.

As shown in fig. 1A and 1B, a typical railway freight car truck includes an assembly of: two sets of wheel sets 1 (each set of wheel sets comprises two wheels 2), two side frames 4, a bolster 6, two spring sets 8, a friction damping system and four adapters 10. Fig. 1A and 1B illustrate an exemplary truck assembly.

The side frames 4 are disposed longitudinally, for example, in the direction of the rails on which the trucks are located. The bolster 6 is aligned laterally or laterally with respect to the side frames 4 and extends through a middle portion of each side frame 4.

The bolster center plate 12 is a circular portion of the bolster 6 that includes an upwardly projecting lip. The body center plate of the vehicle body is seated in the bolster center plate 12 and serves as a rotation point of the truck and the vehicle body. It is at this juncture that a large portion of the vertical load of the freight car is affected. Typically, the bolster core plate 12 is equipped with wear plates or wear liners so that the bolster castings 6 are protected from wear during the service life of the freight car. In addition, side bearings 14 are provided on the top surface of the bolster 6 at 25 inches from the centerline, which helps to stabilize the vehicle body and prevent the truck from rocking to some extent without changing the type of contact. The type of contact of the side bearing 14 shown in FIG. 1B is not fixed, but is comprised of rollers and a housing.

The bolster 6 rests on top of a spring nest 8, supported below by the spring seats of the side frames. Additional springs, commonly referred to as shock absorbers or side springs 17, may also be included as part of the spring stack and seated on spring seats extending upwardly to the bottom of the friction wedge 16 which may be included as part of the friction damping system.

The friction wedges 16 may be located in recesses at the ends and sides of the bolster 6. The friction wedge pocket of the bolster may be angled relative to the horizontal, typically about 60, to match the sloped surface of the friction wedge. The opposite faces of the friction wedges 16 are generally vertical and contact the so-called cylindrical surfaces of the side frames. The spring force of the damper springs 17 urges the friction wedges 16 against the inclined surfaces of the bolster friction wedge pocket, which react against the vertical cylindrical surface of the side frame.

as the bolster 6 moves up and down due to loads from a freight car seated on the truck, the friction wedges 16 will slide against the cylindrical surfaces, creating column friction damping. This damping can cause energy dissipation, preventing undesirable vibration/oscillation of the freight car as it moves in railway operations. These forces acting between the bolster 6 and the side frame 4 via the friction wedges 16 also tend to prevent the truck from becoming parallelogram geometry in operation. Hard stops (e.g., gibs and rotational stops) help prevent the trucks from becoming extremely parallel in shape. This resistance to parallelogram deformation is commonly referred to as warp stiffness.

As shown in fig. 1A and 1B, the wheel-set 1 of the truck assembly is composed of two wheels 2, an axle 3 and two roller bearings 5. The two wheels are press-fitted on the cam seats of the axle. The journal of the axle extends outside the wheel and provides a mounting surface for the roller bearing 5. The roller bearing 5 is press-fitted on the journal of the wheel shaft. The interface between the roller bearing 5 and the side frame 4 may be constituted by a bearing adapter 7. Typically, railway freight car trucks have been equipped with metal adapters that are precision machined to fit fairly firmly over the roller bearings, while fitting relatively loosely to steel side frame pedestal boxes that enclose the interface between the roller bearings and the side frames. This interface produces a small amount of movement between the wheelset and the sideframe that is controlled by the vertical loads present in the freight car and the frictional forces present between the sliding metal surface at the top of the adapter, referred to as the adapter crown, and the bottom of the steel pedestal roof, which is typically equipped with steel wear plates.

Since the vertical load varies with the cargo weight of the freight car and the rocking motion of the freight car on the bogie, the friction at the metal adapter crowns and the steel pedestal roof wear plates can vary significantly and in conventional bogies is not controlled. Because of the stick-slip nature of metal sliding connections, such metal-to-metal connections require a large wheel-to-wheel force to force the sliding at the interface surfaces. Recent truck designs, such as those conforming to the American Association of Railroads ("AAR") M _976 specification, have incorporated adapter pads at the interface between the steel adapter and the pedestal roof.

Some adapter pad systems have successfully reduced wheelset forces as railcars negotiate curves by allowing lower stiffness compliance between the side frames and the axles. This increased compliance created by the adapter pad also reduces the force required to pull or push the railcar through a curve as required by the M-976 specification, which is incorporated herein by reference. Disadvantageously, these designs reduce the speed at which the freight car resonates during tangential track travel, which may also be described as reducing the swing speed of the freight car. This is disadvantageous because a reduced swing speed limits the operating speed of the train and increases the risk of derailment of the freight cars or damage to the track. Other designs employ quality side frame alignment devices (e.g., crossbeams, frame supports, steering arms, spring blades, yaw dampers, cross braces, or additional friction wedges) to improve swing performance. These systems, commonly referred to as advanced bogie technology, typically increase wheel-to-wheel forces and therefore draw resistance as curves pass. In addition to increasing curve resistance, these designs also increase truck maintenance costs due to the addition of wear components and increased system complexity.

The adapter pad system embodiments described herein may meet the curve passing performance criteria specified by M-976 without reducing the critical swing threshold. The adapter pad system described herein also eliminates the need to add any additional side frame alignment equipment, such as crossbeams, frame supports, steering arms, spring trays, yaw dampers, cross braces, or additional friction wedges, in a standard three-piece truck. The resulting truck system described herein may extend the life of the wheelsets, maintain a higher hunting threshold, improve the durability of the pad system, and minimize wear and forces exerted on the rails.

By way of background, there are many different railcar types and operations available from the north american railway industry that require different truck sizes. Freight cars designed for 70 ton class operation have a Gross Load (Gross Rail Load) of 220,000 pounds, and commonly use 28 inch or 33 inch wheels and 6 inch by 11 inch bearings. The total load for a car designed for a 100 ton class operation is 263,000 pounds, and 36 inch wheels and 6.5 inch by 12 inch bearings are commonly used. The total load for a car designed for a 110 ton class operation is 286,000 pounds and must meet the M-976 performance specification as described above. Such 110 ton cars typically use 36 inch wheels and 6.5 inch x 9 inch bearings. The largest car type commonly used in north america is designed for operations on the 125 ton scale and has a total weight of 315,000 pounds. This car type typically uses 38 inch wheels and 7 inch by 12 inch bearings. Other truck sizes-70 tons, 100 tons and 125 tons are not subject to the same stringent performance standards, and thus no cushion is required so far.

The focus of the present application is on a roller bearing adapter and a matching adapter pad. Embodiments of the adapter and mating adapter pad system disclosed herein can be used with cars designed for 110 ton class operation, and can be extended to be used with trucks for full car load capacities (including 70 ton, 100 ton, 110 ton and 125 ton) and improve the performance of these trucks, including those that do not necessarily comply with the M-976 standard.

One embodiment of an adapter pad system 198 is shown in at least fig. 2 and 3. The adapter pad system 198 may include a roller bearing adapter 199 and an adapter pad 200 configured to be disposed between a wheelset roller bearing or roller bearing 5 and a side frame pedestal roof 152 of a three-piece railcar truck. The side frame may include a first outer side 154 and a second outer side 156. The adapter pad 200 also includes an elastomeric member 360 that supports vertical loads and allows the top plate 220 (which engages the side frame) to move longitudinally, laterally, and rotationally relative to the bottom plate 240 (which engages the roller bearing adapter) with less force than conventional steel-to-steel sliding adapter systems.

In some embodiments, as shown in at least fig. 2-3, when the adapter pad system 198 is installed in a truck system, due to the weight of the railcar and truck components carried by the adapter pad 200, the adapter pad system will be compressed by the constant vertical load created by the weight and ultimately transfer the load to the rail via the wheelsets. While the vertical load applied to the center portion of the adapter pad 200 will naturally vary with different loads of the rail car, it is assumed that for a vehicle having a total load of approximately 286,000 pounds, the corresponding vertical load may be approximately 35,000 pounds per adapter pad.

Tests have determined that the stiffness of the adapter pad 200 can have a significant effect on the performance of the truck system. More specifically, in certain embodiments, it has been determined that truck performance can be improved by improving adapter pad system performance. By increasing the stiffness (measured in force (pounds)/displacement (inches)) of the adapter pad system 198, the performance of the adapter pad system may be improved. Additionally, for example, it has been determined that an adapter pad 200 similar to the embodiments described herein is expected to have an acceptable expected service life (measured as the distance traveled under the load of a truck system including the installed adapter pad 200 whose design service life has been determined to be 100 thousand miles traveled by a railcar) when the stiffness satisfies the following condition: a longitudinal stiffness of at least 45,000 pounds per inch or in a range of about 45,000 pounds per inch to about 80,000 pounds per inch, and/or a lateral stiffness of at least 45,000 pounds per inch or in a range of about 45,000 pounds per inch to about 80,000 pounds per inch, and/or a rotational stiffness (i.e., a stiffness that resists rotation about a vertical axis) of at least 250,000 pounds per foot per arc or in a range of about 250,000 pounds per foot per arc to about 840,000 pounds per foot per arc (all three stiffnesses measured with a vertical load of 35,000 pounds applied to the central portion of the adapter 200). These unique stiffness combinations can maximize the swing threshold speed while still maintaining the curve resistance below 0.40 lb/ton/bow as required by the M-976 specification without the need to employ expensive truck technology, i.e., without the use of cross beams, frame supports, steering arms, spring trays, yaw dampers, cross braces or additional friction wedges to improve performance.

The stiffness of the adapter pad system is quantified by measuring the resistance of the adapter assembly to relative shear displacement of the top plate (which engages the side frame) and the bottom plate (which engages the roller bearing adapter). To determine stiffness, the adapter assembly can be displaced relative to the side frame in multiple directions, e.g., longitudinal (in the direction of rail car travel), lateral (across the rail), yaw (rotating about a vertical axis and coincident with the axle centerline), and vertical (between the side frame pedestal roof and the top surface of the adapter pad). A vertical load of 35,000 should be maintained during the shear stiffness test to simulate a loaded car scenario.

During testing, the force that displaces the top plate relative to the bottom plate may be measured using a load cell attached to the force actuator. Displacement measurements may be collected using displacement sensors, dial gauges, potentiometers, or other displacement measuring instruments. As described in more detail below, the force versus displacement is plotted, and the slope of the hysteresis loop represents the stiffness in the respective direction. The area contained within the loop is proportional to the energy transferred during the load cycle.

Embodiments of the adapter pad system 198 described herein provide thrust plate opening widths and spacings sufficient not to limit the amount of displacement to within AAR values, even when the high stiffness shear pads described herein are used. The adapter design disclosed herein may utilize the target adapter displacement amounts shown in table 1 below.

TABLE 1

embodiments of the adapter pad system 198 having the longitudinal, lateral, and rotational shear stiffness described herein may provide a combination of advantages of high speed stability and low curve resistance for a three-piece truck system. Embodiments of the adapter pad system 198 disclosed herein may increase the warp constraint (warp constraint) of a three-piece truck system as compared to other adapter pad designs. This may result in improved high speed stability. In addition to improvements in high speed stability, embodiments of the adapter pad system 198 described herein may also facilitate longitudinal displacement of the wheelset as it passes through a curve, thereby allowing the front and rear axles of the truck assembly to form an inter-axle yaw angle that is proportional to the curve and that may reduce spoke forces. In general, the adapter pad system 198 will cause the lateral wheelsets to deflect, creating an optimal wheelpath differential when negotiating curves. The stiffness and displacement range of the adapter pad system disclosed herein may allow for optimal inter-axle yaw angle and lateral wheelset offset, resulting in a low spoke force solution through a curve. The reduction in cornering forces and the improvement in high speed stability may help to extend the service life of the wheelsets and rails.

Some adapter pad designs utilize multiple elastomeric layers to reduce shear strain. The multiple layers can significantly increase the thickness of the adapter system and can increase the car height when used in a conventional truck. The increase in car height presents problems in connection with other cars and also raises the center of gravity. Thus, some designs require the use of special non-conventional side frames to minimize the height difference. The embodiments discussed herein may achieve improved dynamic performance without the use of special, unconventional truck components.

Embodiments described herein may be used with Side frames having AAR standard geometries including AAR standard Pedestal geometries and AAR standard thrust plate clearances as described in Association of American railroads Manual of Standards and Recommended Pr acts, Section SII (10/25/2010), Specification S-325(6/ll/2009) - "Side Frame, Na rrow stand-limiting dimensions" (American society of railroads Standards Manual and recommendations, Section SII (10/25/2010), S-325 Specification (6/11 2009), "Side Frame, narrow-limit dimensions"), which is incorporated herein by reference. AAR standard pedestal geometry may be described as including a nominal longitudinal thrust plate spacing of about 7.25-8.25 inches; a nominal thrust plate width of about 3.5-3.75 inches; a nominal longitudinal slit spacing of about 8.88-11.06 inches; and a nominal pedestal roof height of about 5.38-6.89 inches above the centerline of the axle. Embodiments of the adapter pad system 198 disclosed herein may be used with existing and/or standard three-piece truck systems, including truck systems having AAR standard geometries, as described in Association of American Railroads Manual of Standards and Recommanded practices, Section H (l/1/2012) Specification M-924 (2/l/2012) — Journal roller bearing Adapters for Freight Cars "(U.S. railway Association Standards Manual and recommendations, Section H (1/2012) M-924 Specification (2/1/2014)," Journal roller bearing adapter for Freight Cars "), which is incorporated herein by reference. AAR standard thrust plate clearances can be seen in table 1 above to obtain new mold build dimensions. The thrust plate clearance is measured by the distance between the cage section and the roller bearing adapter opening. Standard A AR adapter dimensions may include a nominal longitudinal thrust plate bearing surface spacing of about 7.156-8.656 inches; and a nominal lateral thrust plate opening of about 3.812-4.062 inches. Embodiments of the adapter pad system 198 described herein may also conform to American Association of Railroads ("AAR") M-976 spec locations (AAR Manual of Standard and Recommended Practices, Section D (9/l/2010), Specification M-976(12/19/2013) - "Truck Performance for Rail Cars") (the American Association of Railroads ("AAR") M-976 Specification (AAR standards Manual and recommendations, Section D (9/1/2010), M-976 Specification (12/19/2013), "Truck Performance for railcars"), which is incorporated herein by reference. For example, the adapter pad system 198 disclosed herein may be fitted between the roller bearing 5 and the pedestal roof 152 of an existing truck. Accordingly, the adapter pad system 198 disclosed herein may have an overall height measured between the upper surface of the roller bearing 5 and the pedestal roof 152 of about 1.3 inches or in the range of about 1.1 inches to about 1.5 inches. Although the embodiments described herein are specific to 110T class trucks, the disclosed adapter and matching adapter pad system can also be extended to and improve the performance of trucks for all car capacities (70 ton, 100 ton, 110 ton and 125 ton), including those that do not necessarily conform to the M-976 standard.

fig. 4-10 illustrate a roller bearing adapter 198 in accordance with the disclosure herein. As shown in fig. 4, the roller bearing adapter 199 includes a journal box crown 102. In some embodiments, the pedestal crown or top surface 102 may be a crowned or curved surface such that a central region of the pedestal crown is higher than the lateral edges. Thus, the pedestal crown 102 may be substantially flat in the longitudinal direction and curved in the lateral direction. The pedestal crown 102 may be an AAR standard pedestal crown, but may have a smaller cross-sectional thickness than typical roller bearing adapters. For example, in some embodiments, the roller bearing adapter thickness can be between about 0.6 inches thick (measured along the centerline from bearing surface 117 to journal box crown 102) to about 0.75 inches thick, and in some embodiments, less than about 0.75 inches thick.

As shown in fig. 4-8, the roller bearing adapter 199 may have: an overall height of about 4.83 inches or in the range of about 4 inches to about 6 inches; an overall length of about 9.97 inches or in the range of about 9 inches to about 11 inches; and a total width of about 10 inches or at least 7.5 inches or in the range of about 9 inches to about 11 inches.

The roller bearing adapter 199 can include features for limiting movement of the adapter pad 200 relative to the roller bearing adapter 199. For example, the roller bearing adapter can include a longitudinal adapter pad stop 104. As shown in fig. 4, the longitudinal pad stops 104 may be vertically raised relative to the lateral edges of the pedestal crown 102. The longitudinal adapter pad stop 104 is designed to interface with a slot, groove, or edge of the floor 240 of the adapter pad 200 and can engage the adapter pad 200 such that longitudinal movement of the adapter pad 200 can be limited or controlled at a specified value, but without limiting lateral movement of the adapter pad. Although four longitudinal adapter pad stops 104 are shown in fig. 4, any number or design of longitudinal pad stops may be used, including continuous longitudinal pad stops extending along the entire length of the lateral edges of the pedestal crown 102. Examples of other possible longitudinal stops 104 are shown in fig. 5A-5D. For example, the longitudinal stop 104 may include two bosses on each lateral side, as shown in fig. 5A. The longitudinal stops 104 shown in fig. 5A may interface with protrusions in the bottom plate 240 of the adapter pad 200 that may engage the stops 104 so that longitudinal movement may be limited. Similar to fig. 5A, fig. 5B shows three stops 104 that may constrain the longitudinal movement of the adapter pad 200 relative to the adapter 199 in the same manner.

The longitudinal stop may be incorporated into other portions of the adapter pad. For example, as shown in fig. 5C and 5D, the longitudinal stop 104 may be incorporated into the top surface of the vertical shoulder 106. Similarly, in these examples, the protrusions in the bottom plate 240 of the adapter pad may fit around the stops 104 or bosses and provide a constraint to the longitudinal movement of the bottom plate 240 relative to the top plate 220.

The longitudinal stops 104 may also take on various other combinations of sizes, shapes, and positions to provide the desired motion constraint.

As shown in fig. 4-8, the roller bearing adapter 199 also includes a vertical shoulder 106. The vertical shoulder 106 may be vertically elevated relative to the longitudinal edge of the pedestal crown 102. The vertical shoulder 106 is designed to improve the bending strength of the adapter 199 and minimize twisting of the adapter 199 under the higher forces exerted by the adapter pad 200. By minimizing distortion of the adapter pad 200 under load, the vertical shoulder 106 may improve load distribution on the roller bearing component and may extend bearing life. Vertical shoulder 106 is designed to interface with a slot, groove, edge, or surface of bottom plate 240 of adapter pad 200 such that lateral movement of bottom plate 240 is limited or controlled to a specified value. In addition to limiting floor movement, in some embodiments, the vertical shoulders can provide vertical support to the laterally projecting flanges 116, 118 of the adapter pad 200. For a 6.5 inch by 9 inch adapter, vertical shoulder 106 may extend laterally to 10 inches wide and vertically about 1 inch above a standard pedestal crown. In some embodiments, the upper surface of the vertical shoulder 106 may be located up to about 0.75 inches or up to about 3 inches above the pedestal crown 102. The vertical shoulder may also be up to about 8 inches in the longitudinal direction. The vertical shoulder may be cast integral with the adapter and used on standard adapters for 70T, 100T, 110T or 125T grade operations. Although continuous vertical shoulders are shown, any number of vertical shoulders may be used. The vertical shoulder may be at least 0.5 inches wide.

The roller bearing adapter 199 may also include features such as vertical shoulders 106 to improve the bending strength or cross-sectional moment of inertia of the adapter 199 to minimize twisting of the adapter 199 at higher forces applied by the adapter pad 200. For example, for the embodiment shown in fig. 4 and 6-10, and more particularly for the embodiment shown in fig. 8 and 10, the cross-section of the adapter 199 may be taken approximately through the longitudinal center of the roller bearing adapter 199, as shown in fig. 8 and 10. As shown in fig. 10, a central Y-axis 108 may extend in a vertical direction through a lateral center of adapter 199. The central Z-axis 110 may extend in a lateral direction about 5.2 inches above the central axis of the axis 111, or in a range of about 5.0 inches and 5.5 inches. The cross-sectional moment of inertia I Z-Z at the center of the adapter about the center Z-axis 110 for the cross-section shown in FIG. 10 may be about 1.4in⁴Or from about 1.0 to about 2.0in⁴Within the range of (1). About a central Y-axis 108 of the cross-sectionThe cross-sectional moment of inertia I y-y at the center of the adapter may be about 86.8in⁴Or from about 50 to about 100in⁴Within the range of (1). Adapter designs that do not employ a vertical shoulder have a significantly lower area moment of inertia through the lateral cross-section. For example, an adapter design without a vertical shoulder 106 at the same lateral centerline cross-section as shown in FIG. 10 may have about 0.2in about the central Z-axis⁴And may have about 32.9in about the central Y axis⁴The moment of inertia of. The resulting lower moment of inertia compared to the disclosed adapter may result in lower stiffness and higher stress of the adapter under similar loading configurations and possibly reduced roller bearing performance.

The roller bearing adapter 199 may be made of one or more different types of steel alloys having suitable strength and other performance characteristics. For example, roller bearing adapter 199 may be made from ASTMA-220 grade, A-536 grade cast iron, or from ASTMA-148 grade, A-126 grade, A-236 grade, or A-201 grade cast or forged steel. In some embodiments, the entire roller bearing adapter 199 is formed from a single, unitary member (cast, machined, pressed, or other suitable metal forming operation).

Turning now to the adapter pad 200 of the adapter system 198, it is configured to be disposed between, and engageable with, the roller bearing adapter 199 and the side frame pedestal roof 152 of the side frame 4. As shown in fig. 11-11C and primarily in fig. 11A, adapter pad 200 generally includes an upper member or top plate 220 having an inner surface 222 and an outer surface 224, a lower member or bottom plate 240 having an inner surface 242 and an outer surface 244, and an elastomeric member 360 disposed along a portion of adapter pad 200 between inner surface 222 of top plate 220 and inner surface 242 of bottom plate 240. Adapter pad 200 includes a central portion 210 disposed below the lower surface of pedestal roof 152, wherein plates 220, 240 each have a respective central portion 226, 246. The adapter pad 200 also includes first and second upturned regions 212, 214 and first and second lateral flanges 216, 218. The top plate 220 has corresponding first and second upturned regions 228, 230 projecting upwardly from opposite edges of the central portion 226 of the top plate 220, a first lateral flange 232 projecting outwardly from the first upturned region, and a second lateral flange 234 projecting outwardly from the second upturned region 230. Similarly, the bottom panel 240 has corresponding first and second upturned regions 248, 250 projecting upwardly from opposite edges of the central portion 246 of the bottom panel 240, a first lateral flange 252 projecting outwardly from the first upturned region, and a second lateral flange 254 projecting outwardly from the second upturned region 250. As shown in fig. 3, when the truck system is assembled, the lateral flanges 216, 218 are disposed laterally outboard of the pedestal roof 152 and the central portion 210 is disposed below the pedestal roof 152. The first and second upturned regions 212, 214 are disposed between the central portion 210 and the respective first and second lateral flanges 216, 218 and provide a transition therebetween.

Turning first to the central portion 210, in some embodiments it may consist essentially of three components, including a central portion 226 of the top plate, a central portion 246 of the bottom plate, and an elastomeric member 360 disposed therebetween. As described above, the adapter pad 200 is disposed between the side frame pedestal roof 152, which generally has a substantially flat horizontal engagement surface, and the roller bearing adapter 199, which may generally have a curved or crowned top. As shown in fig. 11A and 12, a central portion 246 of the bottom plate 240 may have a curved lower surface 244 such that the outer surface 244 generally conforms to the curve or crown of the adapter 199. More specifically, in some embodiments, the edges 261, 262 of the central portion 246 facing the central portion 246 can have a thickness greater than the thickness at the center of the central portion 246. For example, as shown in fig. 12, the thickness at the center of the center portion 246 may be about 0.15 inches or in the range of about 0.06 inches to about 0.35 inches, while the thickness at the edges 261, 262 may be about 0.26 inches or in the range of about 0.15 inches to about 0.5 inches.

In some embodiments, the central portion 226 of the top plate 220 may include a substantially horizontal and parallel outer surface 224 and inner surface 222, as shown in fig. 11A. The thickness of the central portion 226 of the top plate 220 may be about 0.28 inches or in the range of about 0.15 inches to about 0.4 inches. In such a system, the thickness of the elastomeric portion 360 may be substantially similar throughout the central portion 210, which may improve performance characteristics in some embodiments.

It has been found that in some cases, an elastomeric portion having a uniform thickness can have certain advantages. For example, in certain embodiments, if the plurality of elastomeric layers have the same length and width dimensions in all components, the linear heat shrinkage along the length and width of the pad may be constant. For example, in some embodiments, during the molding process, the rubber forming the elastomeric member may be injected into the mold at about 300 degrees fahrenheit, and then may be cooled to room temperature. Linear thermal contraction perpendicular to the shear plane may be related to part thickness "T", temperature change, and coefficient of thermal expansion. During cooling, uneven elastomer thickness can lead to uneven shrinkage. Uneven shrinkage can result in residual tensile stresses in the final cooled area that can adversely affect fatigue life.

Referring further to fig. 11-11C, and primarily to fig. 11C, in some embodiments, the first and second upturned portions 228, 230 of the top plate 220 can include outer planar portions 228a, 230a (only the first upturned region is shown in fig. 11C) and inner planar portions 228d, 230 d. In some embodiments, the planar portions 228a, 230a and 228d, 230d may extend at an angle Δ relative to a plane P extending along the outer surface 224 of the central portion 226. In some embodiments, the angle Δ may be an obtuse angle, and in some embodiments, the angle may be in the range of about 95 degrees to about 115 degrees, such as 105 degrees or any other angle within this range. In embodiments in which the first upturned portion 212 and/or the second upturned portion 214 includes a clamp, as described in more detail below, the planar surface may surround one or both sides of the clamp, or may be alternating with respect to the clamp. The first and second upturned portions 228, 230 of the top plate 220 can also include lower curved portions 228b, 230b and 228e, 230e that form transitions between the central portion 226 and the planar portions 228a, 230a and 228d, 230 d. Similarly, the first and second upturned portions 228, 230 of the top plate 220 can also include upper curved portions 228c, 230c and 228f, 230f that form transitions between the lateral flanges 232, 234 and the planar portions 228a, 230a and 228d, 230 d. The upper or lower curved portions 228b, 230b, 228e, 230e, 228c, 230c, 228f, and 230f may be formed to have a constant curvature and/or a varying curvature. The bottom plate 240 may include similar planar portions and similar upper and lower curved regions. In some embodiments, the upturned regions 212, 214 may not include a planar portion and may be formed to have a constant curvature and/or a varying curvature.

Referring additionally to fig. 11A, the first and second lateral flanges 216, 218 may extend laterally outboard of the side frame 4 and be disposed at a different vertical height or plane than or above the central portion 210 disposed below and in contact with the pedestal roof 152. Accordingly, the first and second lateral flanges 216, 218 are disposed in a vertically elevated position relative to the central portion 210. The first and second lateral flanges 216, 218 may provide more room for the elastomer and, as discussed below, may increase the stiffness of the adapter pad. In some embodiments, as shown in fig. 13B, the outer surface 244 of the first and second lateral flanges 252, 254 of the bottom plate 240 may be about 0.92 inches or in the range of about 0.25 inches to about 2 inches above the outer surface 244 of the lowermost edge of the bottom plate 240. In some embodiments, the first and second lateral flanges 216, 218 may include planar and horizontal outer surfaces 224, 244, which may be parallel to the outer surface 244 of the central portion 226. In some embodiments, the outer surfaces 244 of the first and second lateral flanges 252, 254 of the bottom plate 240 may rest on the vertical shoulders 106 of the roller bearing adapter 199. In other embodiments, outer surfaces 244 of first and second lateral flanges 252, 254 of bottom plate 240 do not contact vertical shoulder 106. Moreover, in other embodiments, the outer surfaces 244 of the first and second lateral flanges 252, 254 of the bottom plate 240 may indirectly contact the vertical shoulder 106 through another piece (such as a compression shim). As will be discussed in more detail below, in some embodiments, the lateral flanges 216, 218 of the adapter pad may each share approximately 10% to 30% of the vertical force from the pedestal roof 152 when the vertical force is applied to the central portion 210 of the adapter pad.

While at least the embodiment of the adapter pad 200 shown in fig. 11-13 includes the upturned portions 212, 214 and the lateral flanges 216, 218, these portions need not be included in all embodiments. In some embodiments, the central portion 210 may be used without the lateral flanges 216, 218 and/or without the upturned portions 212, 214, but such designs may impact performance. In one embodiment, the lateral flanges 216, 218 may extend from a central portion without upturned portions and without degrading performance characteristics. Similarly, in some embodiments, the lateral flanges may extend outside of the central portion, but in the same plane as the central portion. In other embodiments, the adapter pad 200 may include an upturned portion that can be connected to a lateral flange.

The top plate 220 may be made of one or more different types of alloys having suitable strength and other performance characteristics. For example, the top panel 220 may be made of ASTM A36 steel sheet or steel having strengths comparable to or higher than those specified in ASTM A-572. In some embodiments, the entire top plate 220 is formed from a single unitary member (cast, machined, pressed, rolled, stamped, forged, or other suitable metal forming operation). In some embodiments, the top plate 220 may be formed of a material having a constant thickness throughout. In other embodiments, the top plate 220 has a variable thickness. For example, in some embodiments, the lateral flanges 232, 236 of the top plate 220 can have a thickness that is greater than or less than the thickness of the central portion 226. Similarly, as previously described, the bottom plate 240 may have a constant or varying thickness. In some implementations, one, some, or all of the corners 233 of the top plate 220 can be curved.

In some embodiments, the outer surface 226 of the top plate 220 may receive a coating of elastomeric material 265, which may be the material that contacts the pedestal roof 152. As described elsewhere herein, the elastomer layer 265 can provide damping and calibrated flexibility to the pad, as well as provide a compressible surface to minimize wear between the adapter pad 199 and the pedestal roof 152. The elastomeric coating 265 may be formed to have a flat outer surface that conforms to the geometric profile of the steel portion of the top plate 220, and may have a uniform thickness along the entire top plate 220, or in other embodiments, a uniform thickness in discrete portions of the pad (e.g., a uniform thickness in the central portion 210, a uniform thickness (which may or may not be the same) on one or both of the upper lateral flanges 232, 234, a uniform thickness (which may or may not be the same) on one or both of the upturned portions 228, 230, etc.).

During use, heat may be generated in the adapter pad 200 by friction of the pad 200 and sliding relative to the side frame pedestal roof 152 and/or relative to the bearing adapter 199; and/or by hysteresis damping of the elastomeric member 360 of the adapter pad 200. These heat sources may cause an increase in the temperature of the adapter pad, which may result in reduced durability and stiffness.

In some embodiments, the first and second lateral flanges 216, 218 may include upper and lower surfaces that are exposed to air outside the side frame that is enclosed at the pedestal area (when the adapter pad is installed within the truck pedestal). The exposed surfaces can easily allow heat to dissipate from the adapter pad (which acts as a heat sink) during operation of the rail car, and can allow net heat to flow from the central portion 210 of the adapter pad 200 toward the lateral flanges 216, 218. As will be readily appreciated, heat is generated within the adapter pad 200 during operation of the railcar for various reasons, such as friction generated against relative translation or rotation between the adapter pad 200 and the side frame and between the adapter pad 200 and the bearing adapter 199, as described below. Additionally, because the adapter pad 200 is in surface-to-surface contact with the side frame 4 and the bearing adapter 199, the adapter pad 200 can receive heat generated elsewhere and transferred to the adapter pad 200. In addition, the annular damping of the elastomer part also generates heat. The heat must eventually be removed to avoid a significant increase in the temperature of the components of the adapter pad 200, thereby extending the useful life of these components and reducing possible design constraints that may be necessary when the adapter pad 200 (or portions of the adapter pad 200) are operated continuously at higher temperatures without removing heat. The thermal design of the adapter pad 200 and the rest of the truck system may be utilized to help draw this heat away from the adapter pad 200, which may have various design benefits, such as widening the range of possible elastomer material choices, extending the useful life of the elastomer material by lowering its operating temperature, and other possible benefits.

In some embodiments, the adapter pad 200 may include additional features that can improve its ability to reduce heat in the adapter pad 200. For example, in some embodiments, the first lateral flange 216 and/or the second lateral flange 218 may include a portion that extends laterally from a sidewall of the sideframe pedestal area. In use, the laterally projecting flanges will be in direct contact with the air flow generated by the moving vehicle cabin, as opposed to the central portion which is isolated by the metal roller bearing adapter and the steel sideframe axle box area. These laterally projecting flanges may provide free surface area to transfer heat from the adapter pad 200 to the atmosphere. This may help dissipate heat from the elastomer hysteresis cycle, the increase in roller bearing temperature, and any other heat in the adapter pad 200. In certain embodiments, with the first lateral flange 216 and/or the second lateral flange 218, the operating temperature of the adapter pad system 198 may be reduced. For example, under a normal lateral shear cycle, as described below, with a constant 5mph air flow over the first and second lateral flanges 216, 218, the temperature difference between the lateral flanges 216, 218 and the center of the pad may be about 15 degrees fahrenheit or in the range of about 5 degrees fahrenheit to about 25 degrees fahrenheit. The increased temperature transfer from the center of the pad to the lateral flanges may allow for further increased heat transfer to the atmosphere and thus increased durability.

In some embodiments, one or both of the outer surface 224 of the central portion 226 or the inner surface 244 of the central portion 246 may include one or more of a variety of surface features, and in some embodiments, a pattern of surface features, such that these surfaces are not smooth. For example, the upper surface may include one or more of bumps, ridges and valleys, a rough surface, a "sticky" surface, and the like. These surfaces can be formed by a variety of methods, including shot peening the surface, machining the surface, applying different substances (such as different types of rubber) to the surface, and the like. When provided, these surface features may reduce the likelihood of the adapter pad sliding laterally and/or longitudinally and/or rotating relative to the pedestal roof 152, which may improve adapter pad 200 dynamic load and strength performance, and may also reduce localized heat generated within the adapter pad 800 due to friction between the adapter pad 200 and the pedestal roof 152, which must be removed from the adapter pad 200 (as described elsewhere herein). Similarly, a thermal barrier coating (such as ceramic or porcelain) may be applied to the top plate 220 or the bottom plate 240. Optionally, a thermal shield may be used to thermally isolate heat generated by frictional sliding during high amplitudes. This may be achieved in conjunction with wear plates commonly used with steel-to-steel adapter plates. The plate may be formed such that an air gap is maintained and the contact area is at the outside edge of the adapter.

the bottom plate 240 may be formed in a similar configuration and material as the top plate 220. Similarly, the outer surface 244 of the bottom plate may include a surface treatment and coating of elastomeric material 265 as a top member.

In some embodiments, the entirety or a majority of the adapter pad 200 can include a coating of the elastomeric material 265, for example as shown in fig. 13C and 13E. In some embodiments, for example, the elastomeric material coating may contact the pedestal roof 152, the side frame 4, and the roller bearing adapter pad 199, including the pedestal crown 102 and the vertical shoulder 106. In other embodiments, for example, the portions of the adapter pad 200 that contact the pedestal roof 152, side frame 4, and roller bearing adapter pad 199 may be free of elastomeric material. As described elsewhere herein, the elastomer layer 265 may provide damping and calibrated flexibility to the pad, and provide a compressible surface to minimize wear between the adapter pad 200, pedestal roof 152, and roller bearing adapter pad 199. The elastomeric coating 265 may conform to the outer surface of the adapter pad 200 and may have a uniform thickness along the outer surface of the adapter pad 200, or in other embodiments, a uniform thickness within discrete portions of the pad, such as a uniform thickness in the central portion 210, a uniform thickness (which may or may not be the same) on one or both of the upper lateral flanges 232, 234, a uniform thickness (which may or may not be the same) on one or both of the upturned portions 228, 230, and so forth.

In some embodiments, conductive additives may be used in the elastomeric materials described herein to provide conductivity and shunt capability through the top plate 220 and the bottom plate 240. These additive particles may include materials such as nickel-plated graphite, silver-plated aluminum, or silver-plated copper. The amount of these additives may be as small as 0.5% of the total amount of elastomer in order to provide sufficient electrical conductivity. Similarly, to make an electrical connection between the truck side frame and the adapter, a flexible conductor may be molded into the elastomeric pad, connecting the upper pad plate with the bottom plate. The encapsulated conductor protects the conductor from environmental corrosion. Its flexibility allows it to bend when the elastomeric (e.g., rubber) material is strained. In some embodiments, as shown in fig. 13D-13E, the electrical connection between the side frame 4 and the adapter 199 is achieved through the use of a ground strap 266. As shown in fig. 13D-13E, the ground strap 266 may be attached to the top plate 220 and the bottom plate 240 using an aperture 267 that may be less than about 0.20 inches from the edge of the plate. The ground strap 266 passes through apertures 267 in the top plate 220 and the bottom plate 240. The edges of the plates may be crushed or deformed 268 to crimp or secure the ground strap 266. In some embodiments, ground strap 266 may be a stainless steel braid having a diameter of about 0.100 inches, but may be as small as 0.050 inches.

in some embodiments, as shown in fig. 11, the adapter pad 200 is constructed such that it is symmetrical with respect to a lateral vertical plane that cuts through the geometric center C of the adapter pad (shown in fig. 11 as passing through line B) and/or symmetrical with respect to a longitudinal vertical plane that cuts through the geometric center C of the adapter pad 200 (shown in fig. 11 as passing through line a).

In some embodiments, as best shown in fig. 11C, the outer lateral edges 281 and 282 of the lateral flanges of the top and bottom plates 220 and 240, respectively, are aligned along the same vertical plane. In these embodiments, the lateral length of the lateral flange of the bottom plate 240 is less than the lateral length of the lateral flange of the top plate 220.

In the present application, exemplary dimensions of the adapter pad 200 are described and shown, however, other dimensions for the various portions of the adapter pad may be used depending on the fixed dimensions of the side frames and bearings used with a particular railcar truck system.

In some embodiments, as shown for example in fig. 3 and 11-11C, the adapter pad 200 can further include pads or clamps on the top plate 220 and bottom plate 240 of the adapter pad that can be configured to position the adapter pad 200 relative to the side frame top plate 152 and the bearing adapter 199, and also to engage and limit the movement of the adapter pad 200 relative to the pedestal top plate 152 and the bearing adapter 199 so that the movement (i.e., shear) of the adapter pad 200 can be focused to the elastomeric member 360. Assembling the adapter pad 200 to the roller bearing adapter 199 can force the adapter pad 200 to be reasonably centered with respect to the roller bearing adapter 199 and the bearing by using the vertical shoulder 106 and including a grip. In addition, the adapter pad system 198 urges the adapter 200 and wheelset back to a centered position or a centered position where the force is near zero.

For example, the adapter pad 200 may include a first lateral adapter clamp 270 disposed between the first vertical shoulder 106 of the adapter 199 and the first upturned region 248 of the floor 240; and a second lateral adapter grip 271 disposed between the second vertical shoulder 106 of the adapter 199 and the second upturned region 250 of the base plate 240. The lateral adapter grips 270, 271 can extend along the entire longitudinal length of the adapter pad 200 or a portion of the longitudinal length of the adapter pad 200. In other embodiments, the lateral adapter grips 270, 271 can include a plurality of lateral adapter grips that extend the entire lateral length of the adapter pad 200 or any portion thereof.

The lateral adapter pad grips 270, 271 may be integrally formed with the base plate 240, including with any elastomer coating 265 on the adapter pad 200. In other embodiments, the lateral adapter pad grips 270, 271 can be integrally formed with the adapter 199. In other embodiments, the lateral adapter pad grips 270, 271 can be attached to the adapter 199 and/or the adapter pad 200 by using an adhesive or other known methods.

The adapter pad 200 may further include: a first lateral side frame clamp 272 disposed on the outer surface 224 of the first upturned region 228 of the top plate 220; and a second lateral side frame grip 273 disposed on the outer surface 224 of the second upturned region 230 of the top plate 220. In some embodiments, the first lateral side frame clamp 272 may be disposed on the outer surface 224 of the first lateral flange 232 of the top plate 220; and a second lateral side frame grip 273 is disposed on the outer surface 224 of the second lateral flange 234 of the top plate 220. The lateral side frame grips 272, 273 can extend the entire longitudinal length of the adapter pad 200 or a portion of the longitudinal length of the adapter pad 200. In other embodiments, the lateral adapter grips 272, 273 can include a plurality of lateral adapter grips that extend the entire lateral length of the adapter pad 200 or any portion thereof.

The grips 270, 271, 272, 273 can be formed of an elastomeric material or any other suitable material and can be used in certain embodiments to properly position the adapter pad 200 relative to the side frame pedestal 152 and the adapter 199. Additionally, the first and second lateral adapter grips 270, 271 can be configured to reduce or eliminate slippage that occurs between the adapter 199 and the base plate 240 of the adapter pad 200. Similarly, the first and second lateral side frame clamps 272, 273 can be configured to reduce or eliminate slippage that occurs between the outer surface 224 of the top plate 220 and the pedestal 152. In certain embodiments, this may reduce or eliminate slippage that occurs between the mating surfaces of the adapter 199 and adapter pad 200 and between the mating surfaces of the side frame pedestal roof 199 and adapter pad 200 during system operation. Additionally, in some embodiments, the reduction in slippage between the contact surfaces may reduce the amount of heat generated by any such slippage.

As described above, the clamping features may significantly reduce relative motion between horizontal surfaces of the adapter pad system by maintaining a close-fitting contact between the vertical mating surfaces of the adapter pad assembly. The reduction in relative motion between the side frame pedestal 152 and the adapter pad 200 may improve the stiffness characteristic of the adapter pad 200. As shown in fig. 14, for example, an improvement may be observed at the end of travel where the adapter pad/pedestal interface exhibits greater resistance to longer lateral travel rather than sliding than an adapter pad system that does not include a clamp, as compared to the lateral stiffness of adapter pad systems with and without clamps. The reduction of slippage between the components may also reduce physical wear of the adapter pad system.

In some embodiments, heat may be generated by movement of the adapter pad 200 relative to the roller bearing adapter 199 and pedestal roof 152. The heat is generated by the cyclic hysteresis of the elastomeric material in shear displacement. As described above, excessive heat may negatively affect the performance of the elastomeric member 360 and reduce the durability of the adapter pad. As shown in fig. 15, comparing the adapter pad fatigue dynamics with and without the clamp, the adapter pad 200 with the clamp generates less heat than the adapter pad 200 without the clamp. In some embodiments, the adapter pad 200 will not exceed about 130 degrees fahrenheit when the adapter pad 200 is between the roller bearing adapter 199 and the pedestal roof 152 of a side frame of a traveling railcar. In some embodiments, the adapter pad system 198 can be configured to limit the temperature of the elastomer below the degradation temperature of the particular elastomer and/or adhesive material used in the pad structure, and in some embodiments, the adapter pad system can be configured to lower the melting point of the elastomer member.

As described above, and as shown primarily in fig. 16A-16B and 11B-11C, the elastomeric member 360 is disposed between the top plate 220 and the bottom plate 240. The elastomeric member 360 supports vertical loads and allows limited longitudinal, lateral, and rotational movement of the top plate 220 (which supports the side frames) relative to the bottom plate 240 (which is supported by the adapter). This allows relative movement of the side frame with respect to the adapter with low stiffness and therefore low load, as compared to sliding adapter designs. As shown in fig. 17A-17D, the movement of the top plate 220 relative to the bottom plate 240 can be measured in longitudinal displacement (fig. 17B), lateral displacement (fig. 17C), and rotational displacement (fig. 17D). The adapter pad elastomeric material 360 may be a hysteresis material and have material damping during a deflection cycle. This provides another energy absorbing feature depending on the material and damping selected. For example, a material with too much damping may cause overheating of the elastomeric member 360 and reduce its short term stiffness and long term durability. The elastomeric member 360 may be formed from any suitable elastomeric material (e.g., rubber) having suitable strength, flexibility, and stiffness characteristics. In some embodiments, the material used for the elastomeric material should have a durometer (hardness) of Shore A70 +/-10. Elastomers that may be used may include, but are not limited to: natural rubber; butyronitrile; hydrogenating the butanenitrile; butadiene; isoprene or polyurethane, and may have a durometer (hardness) of about 60-80 shore a.

Generally, the elastomeric member 360 may be attached to the top plate 220 and the bottom plate 240 by injection molding. Typically, the top plate 220 and the bottom plate 240 may be placed within a mold. In some embodiments, portions of the top plate 220 and the bottom plate 240 may be coated with an adhesive to allow the elastomeric member 360 to adhere to the plates. Further, in some embodiments, spacers may be placed in certain areas within the mold where the elastomeric material is not needed. Once set, the elastomeric material may be heated and filled into the mold, and the elastomeric material may flow throughout the mold cavity, adhering to the adhesive coated areas. The elastomer may then undergo vulcanization and/or curing.

Elastomeric member 360 may provide damping within adapter pad 200, allow for discrete changes in stiffness and/or flexibility within adapter pad 200, and allow for differences in damping, stiffness, flexibility, or other parameters within different portions of adapter pad 200 to allow for a suitable design.

As shown in fig. 11A, the elastomeric member 360 includes: a center portion 362 disposed within the center portion 210 of the adapter pad 200, and first and second outer elastomeric members 364, 366 disposed within the respective first and second lateral flanges 216, 218. The outer elastomeric members 364, 366 increase the shear area and volume of the elastomeric layer 360 by extending the elastomeric material outside the standard adapter clearance envelope area using the lateral flanges 216, 218. This provides a larger area for the elastomeric member 360 and may increase the stiffness of the adapter pad 200.

As best shown in fig. 16A, the central elastomeric portion 362 may be generally square in top view, and in some embodiments, may have one or more rounded corners 363, as shown in fig. 16A. The rounded corners of the entire elastomeric member 360 may reduce or eliminate stress concentrations as compared to an elastomeric member 360 having square corners. As discussed above, the thickness of the elastomeric member 362 may have a uniform thickness throughout the central portion 210.

the central elastomeric portion 362 may be disposed primarily in the central portion 210, but may also be disposed in the first and second upturned regions 212, 214 (as shown in fig. 16B) and in the lateral flanges 216, 218 in some embodiments. As shown in fig. 16B, the central elastomeric member 362 may have a lateral length of about 6.7 inches, or a lateral length in the range of about 6.5 inches to about 10 inches. In some embodiments, and as shown in fig. 16B, an elastomer 360 may be located in the upturned regions 212, 214 and disposed between the top plate 220 and the bottom plate 240. In some embodiments, if the elastomer 360 is disposed between the plates in the upturned region, the elastomer may compress or shear under side loads. Such compression of the elastomer in the upturned regions 212, 214 (consistent with shearing of the elastomer in the other regions) may allow the adapter pad to achieve high stiffness which may enhance performance.

As best shown in fig. 16A, the outer elastomeric portions 364, 366 in one or both of the first and second lateral flanges 216, 218 form outer edges 374, 376, respectively, from a top view. The outer edges 374, 376 may be disposed between the top plate 220 and the bottom plate 240 such that a portion of one or both of the top plate 220 or the bottom plate 240 extends radially outward beyond at least a portion of the outer edges 374, 376 of the elastomeric portions.

In some embodiments, the outer edges 374, 376 may be outer longitudinal edges (374a, 376a) (i.e., may extend generally longitudinally when the adapter pad 200 is installed within a truck system), and may include curved portions that are differently shaped and misaligned with the outer longitudinal edges of the top plate 220 and/or the bottom plate 240. The term "outboard longitudinal edge" when used is intended to define an outer edge portion extending between the opposing lateral edges 280, 282 (i.e., two edges extending laterally between the first and second lateral flanges 216, 218 and through the central portion 210) and may be curved as discussed herein, wherein each curved portion includes at least one vector component toward the lateral direction (i.e., perpendicular to the direction of motion of the truck receiving the adapter pad 200).

For example, at least a portion 374R, 376R of the outer edge 374, 376 may be formed to have a continuous radius (R) relative to a geometric center of the adapter pad (as labeled "C" on fig. 16A). In some embodiments, each outer edge 374, 376 may include two discontinuous curved edges 374R, 376R having a constant radius with a central portion between the two that may be straight or in a different curve than the constant radius portion. In other embodiments, the constant radius portion may be continuous and extend proximally toward two opposing side edges 380, 382 on the respective lateral flange, such as extending over the entirety of the respective lateral flange, or extending between the opposing side edges but matching a portion 374z, 376z extending from the respective upturned portion 212, 214 to the edge 374, 376 having the radius geometry.

In some embodiments, the side edges 380, 382 and the lateral longitudinal edges 374a, 376a, as well as any other edges of the elastomeric portion 360, may include an inwardly concave profile 381, as best depicted in fig. 11A-11C. In some embodiments, the inwardly recessed profile 381 may be the same profile around the entire perimeter of the elastomeric member 360, while in other embodiments, the inwardly recessed profile 381 may form a different profile depending on the expected compression experienced by the corresponding portion of the elastomeric member 360.

As can be appreciated, and as discussed elsewhere herein, the elastomeric member 360 compresses and deforms under load, and the elastomeric material presses radially outward near the outer edge. The inwardly recessed profile 381 minimizes or eliminates deformation in the elastomeric member 360 beyond the nominal outer edge of the member 360, which may, in some embodiments, extend the fatigue life of the adapter pad 200.

The inwardly recessed profile 381 may include a first portion 383 extending generally downwardly from the lower surface of the top plate 220, a second portion 385 extending generally upwardly from the upper surface of the bottom plate 240, and a transition portion 384 therebetween. In some embodiments, one or both of the first and second portions 383, 385 can be planar (along a straight portion of the elastomeric portion) or linear (along a curved portion of the elastomeric portion) (generally a linear portion) that extend at angles α and β from respective surfaces of the top and bottom plates 220, 240.

In some embodiments, the first and second portions 383, 385 may extend at the same relative angle, while in other embodiments, the first and second portions 383, 385 may extend at different relative angles. In some embodiments, the angle may be about 30 degrees, such as one angle in a range between about 15 degrees and about 45 degrees, including all angles in this range, relative to the adjacent surface of the top plate 220 or the bottom plate 240. As shown in fig. 11B, central elastomeric portion 362 may likewise include a similar inwardly recessed profile 381 that extends around the outer edge of the central portion.

As best shown in fig. 11A, 11C, and 16B, one or both of the upturned portions 212, 214 may include a hollow portion 372 within the cavity formed between the top plate 220 and the bottom plate 240, the hollow portion being a void having substantially no elastomeric material therein, and a discontinuity may be formed in the respective elastomeric member within the first upturned portion 212 and/or the second upturned portion 214. The hollow portion 372 may provide complete separation between the elastomeric member 360 disposed within the central portion 210 and the elastomeric members disposed in the lateral flanges 216, 218. In certain embodiments, the void may comprise a very small thickness layer of elastomeric material contacting each of the top plate 220 and bottom plate 240 through the transition portion, which may depend on possible limitations of tooling used in the molding process, but this thin layer (when present) does not materially contribute to the performance of the adapter pad 200. Additionally, in some embodiments, the hollow portion 372 may comprise a small portion of elastomeric material extending between the top plate 220 and the bottom plate 240, but otherwise it is substantially hollow. In some embodiments, the width of the hollow portion 372 may be about 0.25 inches or in the range of about 0.1 inches to about 0.5 inches, or at least as wide as the maximum lateral and rotational movement on the adapter pad 200. In some embodiments, the hollow portion 372 is configured to provide lateral clearance between the top plate 220 and the bottom plate 240 extending through the respective transition portions 212, 214 such that the respective inner surfaces of the top plate 220 and the bottom plate 240 within the transition portions do not contact each other during lateral or rotational relative movement between the top plate 220 and the bottom plate 240 and/or during lateral and/or rotational displacement through the adapter pad 200 disposed on the railcar truck during railcar operation.

The hollow portion 372 may act to limit bending stresses in the top plate 220 and the bottom plate 240. The hollow portion 372 may be about 0.25 inches. Over a range of motion of about 0.25 inches, the upturned regions of the top plate 220 and the bottom plate 240 may engage and prevent further relative motion. This may place an upper limit on elastomer strain and metal stress in the lateral direction.

As detailed below, the elastomeric member 360, and in particular the outer elastomeric members 364, 366, may be configured in the following manner: such that the rotational shear stress achieved by the elastomer through displacements up to 41 milliradians is no greater than its lateral and longitudinal shear stresses achieved through lateral displacements up to 0.23 inches and longitudinal displacements up to 0.14 inches. For example, the outer elastomeric members 364, 366 may be configured such that any point on the curved portions 374R, 376R has a rotational shear displacement that is less than or equal to a lateral or longitudinal shear displacement. Also, because shear strain is proportional to shear displacement, all points along the bends 374R, 376R may experience the same strain.

The elastomeric member 360 may be measured in a cross-section through the vicinity of the center of the elastomeric material 360 that is centered between the inner surfaces of the top plate 220 and the bottom plate 240. In embodiments where there are multiple elastomeric members, each member may be measured separately, and each member may be added to determine a measurement for the entire elastomeric member 360. In some embodiments, the total shear width or length in the lateral direction of the elastomeric member 360 may be about 9.6 inches or in the range of about 6 inches to about 14 inches. Similarly, the total cut length or length in the longitudinal direction of elastomeric member 360 may be about 6.9 inches or in the range of about 6 inches to about 10 inches. The composite shear perimeter or all portions of the elastomeric member may have a perimeter of about 51.70 inches or in the range of about 35 inches to about 75 inches. In some embodiments, the total surface area on the shear plane of the elastomeric member 360 may be about 55.5 square inches or in the range of about 50 square inches to about 70 square inches. The total surface area of the elastomeric member 360 outside of the central portion may be about 15.5 square inches or in the range of about 5 square inches to about 30 square inches, or greater than 5 square inches. Accordingly, the surface area of the elastomeric member in the lateral flanges 216, 218 may be about 7.75 square inches or in the range of about 2.5 square inches to about 15 square inches or greater than 2.5 square inches, respectively.

As described in detail below, the elastomeric layers 364, 366 outside the central region 210 can contribute to the overall stiffness of the adapter pad 200. For example, in some embodiments, the elastomeric member 360 outside of the central region 210 may account for about 15% or in the range of about 5% to about 30% of the total lateral and longitudinal stiffness of the adapter pad, and 33% or in the range of about 15% to about 60% of the rotational stiffness of the adapter pad 200.

As previously discussed, the elastomeric member 360 of the adapter pad 200 provides shear resistance when loaded in the lateral, longitudinal, and rotational directions under a vertical load. This shear resistance is caused by the relative movement between the top plate 220 and the bottom plate 240 caused by the interaction of the elastomeric member 360. Simple shear strain (Simple shear strain) is defined as d/t, where d is the displacement of the elastomeric member and t is the thickness of the elastomeric member. In some embodiments, the shear strain may reach values above 100% at maximum displacement. For example, in some embodiments, the lateral strain is up to 110% or 120% or 130%. In some embodiments, the shear strain does not exceed 105%, 110%, 115%, or 120%, or 130% at maximum displacement.

To reduce stress in the elastomeric member 360 at maximum shear displacement, it may be advantageous to provide normal stress or compression to the elastomeric member 360 during shear loading. In some embodiments, the vertical load of the adapter pad is transferred to the center region 210 through the pedestal roof 152 of the side frame. Additionally, although the top and bottom plates 220, 240 may contact the vertical shoulders of the adapter, in some embodiments, the top and bottom plates 220, 240 are flexible and vertical loads on the central region 210 are not equally transferred to the lateral flanges 216, 218 and may result in uneven vertical load distribution on the elastomeric member 360. This may result in less compression of elastomeric member 360 outside of the area under pedestal roof 152. Various methods of increasing the normal stress or compression on elastomeric members 360 other than pedestal roof 152 (e.g., in lateral flanges 216, 218) may be used.

In embodiments, elastomeric member 360 outside the region of pedestal roof 152 may be compressed beyond 0.020 inches or greater than 7% of the static thickness of elastomeric member 360. In certain embodiments, precompression of this magnitude can improve the fatigue life of the elastomeric member 360. Additionally, in the embodiments discussed herein, the adapter pad lateral flanges 216, 218 may each share about 10% to 30% of the vertical force when the vertical force is applied to the central portion 210 of the adapter pad 200. Also, in the embodiments discussed herein, the interaction of the vertical load at the vertical shoulder 106 may provide a vertical force of greater than 3000 pounds to pre-compress the elastomeric member.

In some embodiments, as shown primarily in fig. 18, compression of elastomeric member 360 in areas other than pedestal roof 152 (in outer elastomeric members 364, 366) may be achieved by providing elastomeric member 360 with a non-uniform thickness along the length of elastomeric member 360. For example, in some embodiments, first outer portion 364 and/or second outer portion 366 can form a thickness X, while central portion 362 can form a different or lesser thickness Y. The geometry of the top and bottom plates 220, 240 (such as the curvature of the upturned portions 212, 214) may be formed to accommodate the thickness difference between X, Y, allowing the elastomeric portions in the central and outer portions to contact the inner surfaces of the top and bottom plates 220, 240 as intended. In certain embodiments, the difference in thickness of the elastomeric members forming first and/or second outer portions 364, 366 and central portion 362 may assist in reducing the simple shear strain of the outer layer based on in-plane forces (in-plane forces) applied to the adapter pad in the longitudinal, lateral, and rotational directions.

In some embodiments, as shown in fig. 18, one or both of the lateral flanges 216, 218 may be formed such that the elastomeric layers 364, 366 therein comprise a thickness X of about 0.25 inches, such as in the range of 0.15 inches to 0.30 inches, including all thicknesses within that range. In this embodiment, the thickness y of the elastomer layer 360 of the central portion 362 may be about 0.20 inches, for example, in the range of 0.15 inches to 0.25 inches, including all thicknesses within this range. The thickness of the elastomeric layer as described herein refers to the static thickness of the elastomeric layer or the thickness of the elastomeric layer in the absence of an external load on the elastomeric layer. One or both of the lateral flange portions 364, 366 and the central portion 362 may have different thicknesses with the upper portion being thicker than the central portion, which may achieve the desired effect of substantially increasing the load or compression of one or both of the lateral flange portions 364, 366, as the material properties of the elastomeric layer additionally increase its strength and durability based on the expected loads during orbital operation.

In some embodiments, as shown in fig. 18, the adapter pad 200 may be formed by injection molding without bonding the top plate 220 (as shown in fig. 18) or, alternatively, the bottom plate 240 to the elastomeric member 360. After vulcanization of the elastomeric member 360, the top plate 220 (as shown in fig. 18) or, optionally, the bottom plate 240, may be attached or bonded to the elastomeric member. Because the outer elastomeric members 364, 366 have a greater thickness than the central elastomeric member 362, the lateral flanges 216, 218 must be compressed to attach or bond the top plate 220 (as shown in fig. 24) or, alternatively, the bottom plate 240 to the elastomeric member. In some embodiments, the central elastomeric member 362 interacts with the compressive load to maintain the wing in a state of compressive strain.

In some embodiments, as shown in fig. 19-23, compression of elastomeric member 360 in regions outside of pedestal roof 152 may be accomplished by forming elastomeric member 360 with a gap in central portion 362. In some embodiments, for example, central portion 362 includes one or in other embodiments a plurality of elongated gaps 868 that partially or completely divide central portion 362 into a plurality of portions 862a, 862b, 862c, 862d, 862e, as shown in fig. 19. One or more (hereinafter "plurality" for convenience, but also including a single gap) gaps 868 collectively form a plurality of discontinuities within central portion 362. When adapter pad 200 is fitted between the side frame and bearing adapter 199, the central portion 210 of adapter pad 200 can carry significant compressive forces that are sensed by the relatively compressible elastomeric portion 360 (when compared to top plate 220 and bottom plate 240) such that the elastomeric portion 360 is prone to lateral and longitudinal deformation and expansion (based on the material being compressed vertically). The presence of the plurality of gaps 868 may provide dedicated space for lateral expansion (in embodiments where the plurality of gaps 868 each extend longitudinally). Likewise, in embodiments where multiple gaps also extend laterally or instead extend laterally, the presence of multiple gaps 868 provides dedicated space for longitudinal expansion.

as best shown in fig. 19, in some embodiments, a plurality of gaps 868 extend longitudinally between the opposite side edges 880, 882, respectively, of the elastomer portion 860 and parallel to one another. In some embodiments, the plurality of gaps 868 each communicate through the first and second longitudinal edges 880, 882 when the adapter pad 800 is in an unloaded configuration. In the loaded condition, all or a portion of the plurality of gaps 868 are deformable (as discussed above) such that only a portion of the respective gaps 868 communicate by way of the respective longitudinal edges 880, 882, or in some embodiments, substantially the entire gaps 868 may close and closely intersect the longitudinal edges 880, 882 such that no visible openings in the gaps 868 are perceptible (visible from the respective edges 880, 882 in the unloaded configuration).

In some embodiments, as shown in fig. 19 and 22, each of the plurality of gaps 868 may be formed to have a uniform cross-section along its length, and all of the plurality of gaps 868 (in an unloaded state) may be formed to have the same cross-section, or each of the plurality of gaps 868 may be defined to have a constant cross-section along its length.

Fig. 20A-20C illustrate various types of cross-sections of the plurality of gaps 868. In general, it is contemplated that the plurality of gaps 868 can include one or more curved or flat sides, and each of the plurality of gaps 868 can include a combination of curved and flat features. For example, a plurality of gaps 868a having a circular cross-section or including curved sides. In some embodiments, the opposing sides (extending between the top plate 220 and the bottom plate 240) may have the same size and geometry, while as shown in fig. 20A, one side may have a different shape or size than its opposing side (see 866' and 868 "in fig. 20A).

Fig. 20B shows an alternative shape gap 868c that is generally oval. Fig. 20C shows an alternative shape of gap 868d shaped as a truncated diamond with two opposing flat sides (where the truncated portion contacts the baseplate 240). Fig. 21A-21C provide schematic illustrations of different possible shapes of the plurality of gaps 868 under an applied load (F) to the adapter pad 200.

In some embodiments, and as shown in fig. 22, the plurality of gaps 868e extend only a partial longitudinal distance through the elastomeric member 860, and as shown, not to the longitudinal edges 880, 882, while other arrangements are contemplated (such as extending to one of the two longitudinal edges 880, 882, or the end being closer to one of the two longitudinal edges 880, 882). In this embodiment, the gap 868d may be sized and shaped based on the various sizes and shapes contemplated above.

In other embodiments shown in fig. 23, the plurality of gaps 868f can extend a thickness that is less than a total distance between the top plate 220 and the bottom plate 240, wherein a portion of the elastomeric member is disposed perpendicular with respect to one or more of the plurality of gaps 868f and contacts one or both of the top plate 220 and the bottom plate 240. As shown in fig. 23, gap 868f contacts the lower surface of top plate 220, but not bottom plate 240.

As best shown in fig. 23, the inner surface of the top plate 220 or the bottom plate 240 may include recessed portions 825a provided along portions of the top plate 220 or the bottom plate 240 in communication with the plurality of gaps 868. A recessed portion 825a may be provided to index a mold of elastomeric portion, such as a core or other type of molding apparatus known in the art, to form a gap 868 relative to the top plate 220 or the bottom plate 240. The recessed portion 825a may additionally provide space for the elastomeric member 860 to expand/deform under load, thereby minimizing the size of the gap 868, while still providing the benefits of expansion/deformation as desired.

Additionally, there are other ways in which the compression of the elastomeric member 360 in the lateral flanges 216, 218 may be increased. For example, as shown in fig. 24, in some embodiments, the lateral flanges 216, 218 may be compressed together after the elastomeric members 364, 366 are inserted between the top plate 220 and the bottom plate 240. Compressing top plate 220 and bottom plate 240 together may cause plastic deformation of the steel. Plastic deformation of top plate 220 and bottom plate 240 may create normal stresses in outer elastomer layers 364, 366 and may increase compression. Compression of the top plate 220 and the bottom plate 240 may be accomplished using a die or other suitable apparatus. As used herein, the term insert may encompass a variety of processes, including the use of an injection molding process or a casting process, as well as other known techniques for inserting an elastomer.

In further embodiments, compression may be created in the lateral flanges 216, 218, for example, by manufacturing the lateral flanges 216, 218 of the top and bottom plates 220, 240 to be angled toward one another and then molding the flanges to a generally parallel position. For example, the top plate 220 can be manufactured such that the lateral flanges 232, 234 are angled outwardly and downwardly, and the lateral flanges 252, 254 of the bottom plate 240 are angled outwardly and upwardly prior to assembly of the adapter pad 200. Thus, when initially manufactured, the lateral flanges of the top and bottom plates are not parallel, but are angled towards each other. The plates 220, 240 are then assembled with the elastomeric portion 360 and the lateral flanges 232, 234, 252, 254 are forced to resiliently flex into generally parallel alignment with one another. In some embodiments, this step may be accomplished using an injection molding machine, wherein the elastic member 360 is injected into a mold. Once the adapter pad is cured, there may be elastic strain in the laterally protruding flanges that applies a normal load to the outer elastomer layers 364, 366, which may thereby create a compressive strain.

In further embodiments, as shown in fig. 25 and 26, the compression of the elastomeric member 360 in the lateral flanges 216, 218 may be increased by using compression shims within or below the laterally projecting flanges 216, 218. A compression spacer may be used herein such that when a vertical force is applied to the central portion 210 of the adapter pad 200, the reaction of the vertical load at the vertical shoulder 106 provides a vertical force of greater than 3000 pounds, such that the adapter pad lateral flanges 216, 218 each share about 10% to 30% of the vertical force. In some embodiments, the compression shims may force more of the vertical load of the car to be distributed from the central elastomeric layer 360 to the outer elastomeric layers 364, 366. As shown in fig. 25, a first adapter compression spacer 290 may be disposed between the upper surface of the vertical shoulder of the roller bearing adapter 199 and the outer surface 244 of the first lateral flange 216 of the bottom plate 240. Similarly, although not shown in the figures, a second adapter compression spacer 290 may be similarly positioned relative to the second lateral flange 218 (not shown). Adapter compression spacer 290 may be about 0.05 inches thick or in the range of about 0.06 inches to about 0.18 inches. The compression gasket as discussed herein may have any number of different shapes and configurations in order to provide the necessary load for compressing the outer elastomer. For example, the compression pad may be rectangular, square, trapezoidal, tapered, may have a hollow cross-section, and may be a plurality of compression pads. Additionally, the compression pads as discussed herein may be integrally formed with the adapter pad during the molding process, may be integrally formed with the roller bearing adapter, or may be added to the roller bearing adapter system after the molding process.

as shown, for example, in fig. 25A-25I, the compression pads as discussed herein may have a variety of different shapes and configurations. As shown in fig. 25A, the compression spacer 290 may be generally rectangular and may have a width equal to or less than the width of the outer surface 244 of the lateral flanges 252, 254 of the bottom plate 240. Similarly, the length of the compression spacer 290 as shown in FIG. 25A may be less than or equal to the length of the outer surface 244 of the lateral flanges 252, 254 of the bottom plate 240. The compression pad 290 may have a constant or variable thickness. As shown in fig. 25B, 25C, and 25D, the compression pad 290 may have a curved, trapezoidal, or triangular cross-sectional shape. Additionally, as shown in fig. 25E and 25D, the compression pad 290 may have a raised central portion 295, which may be generally curved as shown in fig. 25E or may be generally triangular as shown in fig. 25F or may be any other suitable shape. As shown in fig. 25G, the compression gasket 290 may include a hollow portion 296. Additionally, as shown in fig. 25H and 25I, the compression pad 290 may include a plurality of compression pads.

As shown in fig. 26, the adapter pad 200 may also include a compression gasket between the elastomeric member 360 and the top plate 220 or the bottom plate 240. As shown in fig. 26, the adapter pad 200 can include a first upper adapter pad compression gasket 291 disposed between the first lateral flange 216 and the top plate 220 and the first outer elastomeric member 364. Similarly, although not shown in the figures, a second upper adapter pad compression pad 291 may be disposed on the second lateral flange 218 between the top plate 220 and the second outer elastomeric member 366. Additionally, although not shown in the figures, similar first and second lower adapter pad compression spacers may be disposed between the first and second lateral flanges 216 and 218 and between the elastomeric member 360 and the bottom plate 240. The upper and lower adapter pad compression pads 291 may be about 0.05 inches thick or in the range of about 0.06 inches to about 0.18 inches.

To apply the upper or lower adapter pad compression gasket 291, as shown in fig. 26, the adapter pad 200 may be injection molded without applying adhesive to the top plate 220 or the bottom plate 240 at the laterally projecting flanges 216, 218. This may prevent the outer elastomer layers 364, 366 from adhering to the top plate 220 or the bottom plate 240. After vulcanization, an upper or lower adapter pad compression gasket 291 may be inserted between the outer elastomers 364, 366 and the top plate 220 or bottom plate 240. As discussed above, this may compress the elastomeric members 360 located at the laterally projecting flanges 216, 218, thereby increasing the normal stress.

As discussed above, it has been determined through testing that the performance of the adapter pad system 198 is a function of the stiffness of the adapter pad 200. More specifically, in certain embodiments, it has been determined that adapter pad performance, including design life, can be improved by increasing the stiffness (measured in force (pounds)/deflection (inches)) of the adapter pad system 198.

The physical measurement of pad stiffness may be determined as follows: cycling the adapter pad 200 in three main directions, namely lateral, longitudinal and rotational; while bearing a constant vertical load of typically 35,000 pounds on the pad. The force displacing the pad corresponding to the distance the pad is displaced is recorded throughout the measurement test. The data from the test can then be collected and plotted on a force-displacement graph, an example of which is shown in fig. 27. The stiffness, damping and hysteresis for each direction of motion can then be determined using the following methods: the stiffness of the pad 200 may be determined by determining the upper and lower bounds of the linear portion of the capture force-displacement curve, then calculating the slope of the best fit line between the upper and lower bounds (for the upper and lower portions of the curve). The stiffness is then determined by averaging the upper and lower slopes. As discussed above, longitudinal stiffness is measured in the rail or course direction, lateral stiffness is measured perpendicular to the course direction, and lateral roll stiffness is measured in resistance to rotation of the adapter about a vertical axis at the longitudinal and lateral centerlines (labeled "C" on fig. 16A) of the pedestal opening. Hysteresis is determined by measuring the upper and lower y-axis intercepts, and subtracting the lower y-axis intercept from the upper y-axis intercept, an example of which is shown in fig. 27. Damping was determined by measuring the area in the force-displacement loop as shown in fig. 27. The amount of pad damping in a given displacement range is proportional to the area contained within the loop at the desired frequency.

Embodiments disclosed herein have target damping values of 0.10 to 0.30tan δ and rubber/elastomeric material hardness target values of 60A to 80A. Tan δ is a measure of the damping of a material under cyclic loading, defined as the ratio of out-of-phase (90 degrees on sinusoidal loading) to in-phase (0 degrees). Typical values for elastomers may be 0.04 to 0.35.

The area of the hysteresis loop per cycle is a more direct measure of the energy absorption of the adapter pad. For the embodiments described herein, δ ε may be calculated by π 3GTan²Hysteresis energy absorption was estimated where G is a shear modulus of about 360psi, Tan δ is about 0.3 and strain ∈ 1 during about 100% of the swing. At 4Hz, the energy absorption was about 4,070 inch-pounds/second. A reasonable range may be +/-25%.

As discussed herein, certain embodiments include elastomeric member 360 (portions 364 and 366) under shear outside of the area under pedestal roof 152. In such embodiments, there may be more elastomeric material available for use in shear than in a typical adapter pad. This may allow the adapter pad 200 to achieve increased stiffness without reducing shear thickness or increasing elastomer stiffness. Reducing the shear thickness and/or increasing the elastomer stiffness can increase the strain and shorten the useful life of the pad. Thus, the adapter pad 200 may increase the stiffness of the adapter pad system 198, which may improve overall railcar performance while extending the useful life of the adapter pad 200. The outer elastomer layers 364, 366 may increase the rotational stiffness of the adapter plate 200 by providing additional elastomer at a distance further away from the axis of rotation. In some embodiments, for example, the outer elastomeric layers 364, 366 may account for about 15%, or about 10% to about 20%, or greater than 10% of the total lateral and longitudinal stiffness of the adapter pad 200, and may account for about 33%, or about 25% to about 40%, or greater than 25% of the rotational stiffness of the adapter pad 200.

Embodiments disclosed herein may have high lateral and longitudinal stiffness without having a high force to displacement hysteresis ratio. Hysteresis is proportional to the energy dissipated through the displacement cycle and can be lost in the form of heat or noise. In general, the higher the hysteresis, the greater the temperature rise in the adapter pad 200, and the lower the fatigue life. Embodiments disclosed herein achieve high stiffness of the adapter pad while improving fatigue life by minimizing hysteresis and allowing the pad to shift to the maximum magnitude set by the ARR: 41 mrad in the direction of rotation, 0.23 inches laterally and 0.14 inches longitudinally.

Embodiments disclosed herein may require an increased amount of force to displace the top plate 220 at a higher magnitude relative to the bottom plate 240. The thickness, length, and amount of elastomeric material located in the hollow portion 372 can be adjusted to change the slope and shape of the force-displacement graph. In some embodiments, the elastomeric material of the pad located adjacent to the upturned adapter wing may have different stiffness characteristics than the characteristics of the elastomeric material located in the central region of the adapter pad.

Exemplary measurements and test results of the embodiments disclosed herein using the test methods described above are shown in table 2 below. It should be understood that these embodiments are examples, and that other structural embodiments with other test results may exist.

TABLE 2

Other embodiments of adapter pad 400 are shown in fig. 28-43. The embodiment of the adapter pad 400 illustrated in fig. 28-43 is similar in many respects to the previously described adapter pad embodiments. As described above, the adapter pad 400 is configured to be disposed between the roller bearing adapter 199 (shown in fig. 36A-36E) and the side frame pedestal roof 152 of the side frame 4 and can engage the roller bearing adapter 199 and the side frame pedestal roof 152 of the side frame 4. As shown in fig. 28-43, the adapter pad 400 generally includes: an upper element or plate 420 having an inner surface 422 and an outer surface 424, a lower element or bottom plate 440 having an inner surface 442 and an outer surface 444, and an elastomeric member 560 disposed along a portion of the adapter pad 400 between the inner surface 422 of the top plate 420 and the inner surface 442 of the bottom plate 440. Adapter pad 400 includes a central portion 410 disposed below the lower surface of pedestal roof 152, and plates 420, 440 have corresponding central portions 426, 446, respectively. The adapter pad 400 also includes first and second upturned regions 412, 414 and first and second lateral flanges 416, 418. The top plate 420 has: corresponding first 428 and second 430 upturned regions projecting upwardly from opposite edges of the central portion 426 of the top plate 420, a first lateral flange 432 projecting outwardly from the first upturned region, and a second lateral flange 434 projecting outwardly from the second upturned region 430. Similarly, the bottom plate 440 has: a first upturned region 448 and a second upturned region 450 projecting upwardly from opposite edges of the central portion 446 of the bottom panel 440, a first lateral flange 452 projecting outwardly from the first upturned region, and a second lateral flange 454 projecting outwardly from the second upturned region 450. When the truck system is assembled, the lateral flanges 416, 418 are disposed laterally outboard of the pedestal roof 152 and the center section 410 is disposed below the pedestal roof 152. The first and second upturned regions 412, 414 are disposed between the central portion 410 and the respective first and second lateral flanges 416, 418 and provide a transition therebetween.

As described above, for other embodiments, the central portion 410 may be comprised primarily of three portions, including the central portion 426 of the top plate, the central portion 446 of the bottom plate, and the elastomeric member 560 disposed therebetween. As discussed above, the adapter pad 400 is disposed between the side frame pedestal roof 152, which generally has a substantially flat horizontal engagement surface, and the roller bearing adapter 199, which generally has a curved or crowned roof. As shown in fig. 30, central portion 446 of bottom plate 440 may have a curved lower surface such that the outer surface generally conforms to the curved or crowned shape of adapter 199. More specifically, in some embodiments, the edges 461, 462 of the central portion 446 toward the central portion 446 have a thickness that is greater than the thickness of the center of the central portion 446. As described above, the center of the central portion 246 can be about 0.15 inches or about 0.06 inches to about 0.35 inches thick, and the edges 461, 462 can be about 0.26 inches or about 0.15 inches to 0.5 inches thick.

In some embodiments, as shown in fig. 30, the central portion 426 of the top plate 420 may include a substantially horizontal and parallel outer surface 424 and inner surface 422. The central portion 426 of the top plate 420 may have a thickness of about 0.25 inches or about 0.15 inches to about 0.5 inches. In such a system, the thickness of the elastomeric portion 560 is substantially similar throughout the central portion 410, and in some embodiments, such a thickness improves performance characteristics.

With further reference to fig. 31, the first upturned portion 428 and the second upturned portion 430 of the top plate 420 may include outer planar portions 428a, 430a (only the first upturned region is shown in fig. 31) and inner planar portions 428d, 430 d. In some embodiments, the planar portions 428a, 430a and 428d, 430d may extend at an angle Δ relative to a plane P extending along the outer surface 424 of the central portion 426. In some embodiments, the delta angle may be an obtuse angle, and in some embodiments, the angle may be about 95 degrees to about 115 degrees, e.g., 105 degrees or any other angle within this range. In some embodiments, as described in more detail below, where the first upturned region 412 and/or the second upturned region 414 comprise a clamp member, the plane may surround one or both sides of the clamp member, or may be optionally arranged with respect to the clamp member. The first upturned region 428 and the second upturned region 430 of the top plate 420 may also include lower curved portions 428b, 430b and 428e, 430e that transition between the central portion 426 and the planar portions 428a, 430a and 428d, 430 d. Similarly, the first and second upturned portions 428, 430 of the top plate 420 may also include upper curved portions 428c, 430c and 428f, 430f that transition between the lateral flanges 432, 434 and the planar portions 428a, 430a and 428d, 430 d. The upper and lower curved portions 428b, 430b, 428e, 430e, 428c, 430c, 428f, and 430f may be formed to have a constant curvature and/or a variable curvature. The bottom plate 440 may include similar planar portions and upper and lower curved regions. In some embodiments, the upturned regions 412, 414 may not include a planar portion and may be formed to have a constant curvature and/or a variable curvature.

With further reference to fig. 30 and 31, the first and second lateral flanges 416, 418 may extend laterally outboard of the side frame 4 and be disposed in a plane at a different vertical height than the central portion 410 or above the central portion 410 that is disposed below the pedestal roof 152 and in contact with the pedestal roof 152. Accordingly, the first and second lateral flanges 416, 418 are disposed in a vertically elevated position relative to the central portion 410. The laterally projecting flanges 416, 418 may provide a larger area for the elastomer 560, and as described above, the laterally projecting flanges 416, 418 may increase the stiffness of the adapter pad 400. In some embodiments, the outer surfaces 444 of the first and second lateral flanges 452, 454 of the bottom plate 440 may be located about 0.92 inches above the outer surface 444 of the lowest edge of the bottom plate 440 or about 0.25 inches to about 2 inches above the outer surface 444 of the lowest edge of the bottom plate 440. The first and second lateral flanges 416, 418 may include planar and horizontal outer surfaces 424, 444, which may be parallel to the outer surface 444 of the central portion 426. In some embodiments, the outer surfaces 444 of the first and second lateral flanges 452, 454 of the bottom plate 440 can be located on the vertical shoulders 106 of the roller bearing adapter 199. In other embodiments, the outer surfaces 444 of the first and second lateral flanges 452, 454 of the bottom plate 440 are not in contact with the vertical shoulder 106. In other embodiments, the outer surfaces 444 of the first and second lateral flanges 452, 454 of the bottom plate 440 may be in indirect contact with the vertical shoulder 106 through another feature, such as a compression spacer 290. As discussed above, in some embodiments, about 2500 pounds of force, or about 5% to 30% of the vertical force from pedestal roof 152, may be distributed to each of adapter pad lateral flanges 416, 418 when a vertical force is applied to the central portion 410 of the adapter pad.

While at least the embodiment of the adapter pad 400 shown in fig. 28-43 includes upturned portions 412, 414 and lateral flanges 416, 418, these need not be included in all embodiments. In some embodiments, the central portion 410 may not be used with the lateral flanges 416, 418 and/or with the upturned portions 412, 414, although such a design may affect performance. In one embodiment, the lateral flanges 416, 418 may extend from the central portion without an upturned portion and without degrading performance characteristics. Similarly, in some embodiments, the lateral flanges may extend outside of the central portion but in the same plane as the central portion. In other embodiments, the adapter pad 400 may include an upturned portion that may be connected with a lateral flange.

As shown, for example, in fig. 29, which shows top plate 420 and bottom plate 440 in phantom, top plate 420 and bottom plate 440 may include lateral edges 480a, 480b, 482a, and 482 b. The top plate 420 and the bottom plate 440 may also include longitudinal edges 484a, 484b, 486a, and 486 b. The edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b may be straight or may include curved or angled portions as viewed from the side or front or back. As shown, for example, primarily in the side views of fig. 30-33 (including fig. 31A, 31B, 33A, and 33B), the edges 480a, 480B, 482a, 482B, 484a, 484B, 486a, and 486B of the top plate 420 and the bottom plate 440, respectively, may include a shape in which the edges curve inward (fig. 31, 31A, 33, and 33A) or are angled (fig. 33A and 33B) from the outer surfaces 424, 444 of the plates 420, 440, respectively, toward the inner surfaces 422, 442. Further, as shown primarily in fig. 31A, 31B, 33A, and 33B, one or more of the edges 480a, 480B, 482a, 482B, 484a, 484B, 486a, and 486B may include a substantially vertical portion. The substantially vertical portion shown may be adjacent the outer surface 424, 444 with the trailing edge 480a, 480B, 482a, 482B, 484a, 484B then curving inwardly (fig. 31, 31A, 33, and 33A) or angling inwardly (fig. 33A and 33B) from the outer surface 424, 444 of the plate 420, 440 toward the inner surface 422, 442. In other embodiments, the vertical portion need not be vertical, for example, it may be at a different angle and/or a different degree of curvature than the remainder of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486 b. One or more portions of the perimeter of the top plate 420 and the bottom plate 440, including the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b, may include a continuous radius. In some embodiments, the continuous radius may be about a 0.25 inch radius or greater than half the thickness of the plate. Further, one or more portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of the top plate 420 and the bottom plate 440 may include a spline curvature profile (spline curvature profile) around the perimeter that includes one or more variable radii and/or flat portions. The radius portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of the top plate 420 and the bottom plate 440 may extend at a tangential angle θ relative to the inner surfaces 422, 442 of the top plate 420 and the bottom plate 440. In some embodiments, the angle θ may be an angle of about 25 degrees or an angle in the range of about 10 degrees to about 40 degrees. In some embodiments, the spline curvature profile may be tangent at 0.38 inches from the outermost portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of the top plate 420 and the bottom plate 440 or about 0.12 inches to 0.6 inches from the outermost portions of these edges. In some embodiments, the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b may extend from the outer surfaces 424, 444 of the top and bottom plates 420, 440 at an angle that is substantially perpendicular to the outer surfaces 424, 444 and extend from the inner surfaces 422, 442 at an angle that is substantially tangential to the inner surfaces 442, 444 of the top and bottom plates 420, 440. Further, in these embodiments, portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b may not be perpendicular or tangential to the inner surfaces 422, 442 or the outer surfaces 442, 444. For example, as shown in fig. 33, edge 482a may not extend perpendicular to outer surface 444 at all locations around the perimeter of top plate 420 and bottom plate 440.

In other embodiments, and as discussed above, the perimeters of the top plate 420 and the bottom plate 440 may be configured such that the outer surfaces 424, 444 extend further out relative to the substantially flat portions of the inner surfaces 422, 442 at the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486 b. For example, in some embodiments, an inverted groove edge or angled edge may be used around the perimeter of the plate.

In some embodiments, as best shown in fig. 30-33, the lateral and/or longitudinal edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of the lateral flanges of the top plate 420 and the bottom plate 440, respectively, are aligned along the same vertical plane. In these embodiments, the lateral length of the lateral flange of the bottom plate 440 is less than the lateral length of the lateral flange of the top plate 420.

In some embodiments, the outer edges 484a, 484B, 486a, 486B can include one or more curved portions when viewed from above and as shown in fig. 29B. For example, at least a portion 484R, 486R of the outer edge 484a, 484b, 486a, 486b may be formed as a continuous radius (R) relative to the geometric center of the adapter pad. In some embodiments, each outer edge 484a, 484b, 486a, 486b may include two discontinuous curved edges 484R, 486R having a constant radius, and the central portion therebetween, other than the constant radius portion, may be straight or of different curvature. In other embodiments, the constant radius portion may be continuous and extend from adjacent lateral edges to opposing lateral edges 480a, 480b, 482a, 482 b.

In some embodiments, any point on the lateral edge of the roller bearing adapter can have a linear displacement of less than or equal to 0.234 when the top plate is rotated up to 41 milliradians from a central position relative to the bottom plate. Further, in some embodiments, any point on the lateral edge has a linear displacement less than or equal to the maximum longitudinal displacement and the maximum lateral displacement when the top plate is rotated relative to the bottom plate from the central position up to 41 milliradians. As discussed above, for other embodiments, the top plate 420 and the bottom plate 440 may be made of one or more different types of alloys having suitable strength and other performance characteristics. For example, the top plate 420 and the bottom plate 440 may be made of ASTM A36 steel plate or steel having a strength equal to or higher than that specified in ASTM A-572. In some embodiments, the entire top plate 420 and/or bottom plate 440 is formed from a single unitary element (cast, machined, pressed, rolled, stamped, rolled, forged, or other suitable metal forming operation). In some embodiments, the plates 420, 440 may be made of a material having a constant thickness throughout. In other embodiments, the plates 420, 440 have a variable thickness. For example, as shown in fig. 30 and described above, the bottom plate 440 may be thinner toward the center of the central portion 446. Further, for example, in some embodiments, the lateral edges 432, 434, 452, 454 can have a thickness that is greater than or less than the thickness of the central portions 426, 446.

As discussed above, for other embodiments, and as shown primarily in fig. 30-33, the elastomeric member 50 is disposed between the top plate 420 and the bottom plate 440. As will be discussed in greater detail below, the elastomeric member 560 may extend outboard of the top plate 420 and the bottom plate 440 and may extend beyond the lateral and longitudinal edges of the plates. For example, the elastomeric member may extend laterally and/or longitudinally at least 0.05 inches, or about 0.01 inches to 0.25 inches, beyond the respective lateral and longitudinal edges of the plate. The elastomeric member 560 supports vertical loads and allows limited longitudinal, lateral, and rotational movement of the top plate 420 (which supports the side frame) relative to the bottom plate 440 (which is supported by the adapter). This allows relative movement of the sideframe with respect to the adapter with low stiffness and, therefore, produces low loads compared to sliding adapter designs. As discussed above, the movement of the top plate 420 relative to the bottom plate 440 can be measured in terms of longitudinal displacement (fig. 17B), lateral displacement (fig. 17C), and rotational displacement (fig. 17D). The adapter pad elastomeric material 560 may be the materials discussed above.

Typically, the elastomeric member 560 may be attached to the top plate 420 and the bottom plate 440 by injection molding. Typically, the top plate 420 and the bottom plate 440 may be placed in a mold. In some embodiments, a portion of the top plate 420 and the bottom plate 440 may be coated with an adhesive to bond the elastomeric member 560 to the plates. Furthermore, in some embodiments, some areas of the mold where elastomeric material is not needed may be provided with spacers. Once set, the elastomeric material may be heated and filled into the mold, and the elastomeric material may flow throughout the mold cavity, adhering to the adhesive coated areas. In some embodiments, the top plate 420 and/or the bottom plate 440 may include one or more holes to allow the elastomeric material to pass through each plate during the molding process. The elastomeric material may then be vulcanized and/or cured.

As described above, elastomeric member 560 may provide damping within adapter pad 400, allow for discontinuous changes in stiffness and/or flexibility within adapter pad 400, and allow for differences in damping, stiffness, flexibility, or other parameters of different portions of adapter pad 400, resulting in a suitable design.

as shown in fig. 30, the elastomeric member 560 may include a central portion 562 disposed within the central portion 410 of the adapter pad 400 and first and second outer elastomeric members 564, 566 disposed within the first and second lateral flanges 416, 418, respectively. The outer elastomeric members 564, 566 increase the shear area and volume of the elastomeric layer 560 by extending the elastomeric material beyond the standard adapter clearance envelope area using the lateral flanges 416, 418. This provides a larger area for the elastomeric member 560 and may increase the stiffness of the adapter pad 400.

The central elastomeric portion 562 may be generally square, and in some embodiments, may have one or more rounded corners. The rounded corners of the elastomeric member 560 may reduce or eliminate stress concentrations as compared to elastomeric members 560 having square corners. As discussed above, the elastomeric member 562 may have a uniform thickness throughout the central portion 410.

The central elastomeric portion 562 may be disposed primarily in the central portion 410, but may also be disposed in the first and second upturned regions 412, 414 (as shown in fig. 30 and 31) and in the lateral flanges 416, 418 in some embodiments. The central elastomeric member 562 may have similar dimensions as the central elastomeric member described above. In some embodiments, and as shown in fig. 30 and 31, an elastomer 560 may be disposed between the top plate 420 and the bottom plate 440 at the upturned regions 412, 414. In some embodiments, if the resilient body 560 is disposed between the plates of the upturned region, the resilient body may compress or shear under side loads. Such compression of the elastomer at the upturned regions 412, 414 (consistent with shearing of the elastomer in the other regions) may allow the adapter pad to achieve high stiffness that may enhance performance.

As best shown in fig. 29B, at least a portion of the outer elastomeric portions 564, 566 located within one or both of the first and second lateral flanges 416, 418, respectively, form outer longitudinal edges 574, 576 from a top view. The outer longitudinal edges 574, 576 of the elastomeric section may extend outwardly beyond the top plate 420 and the bottom plate 440. The distance that the outer edges 574, 576 of the elastomeric portions extend beyond the edges of the top plate 420 and the bottom plate 440 may be substantially similar or may vary with the length of the edges. The elastomeric portion may also form lateral edges 578, 580. The outer lateral edges 578, 580 of the elastomeric portions may extend outward beyond the top plate 420 and the bottom plate 440. The distance that the outer edges 578, 580 of the elastomeric portions extend beyond the edges of the top plate 420 and the bottom plate 440 may be substantially similar or may vary with the length of the edges. One or more of the edges 574, 576, 578, 580 may be substantially straight in a vertical direction, as shown, for example, in fig. 28.

as described above for other embodiments, the outer surfaces of plates 420, 440 may receive a coating of elastomeric material 565, which may be the material that contacts pedestal roof 152. The elastomeric coating 565 may be formed as a flat outer surface that follows the geometric profile of the steel portion of the top plate 420 and may have a uniform thickness along the entire top plate 420, or in other embodiments, within different portions of the pad, e.g., a uniform thickness within the central portion 410, a uniform thickness (which may not be the same or may be the same) on one or both of the upper lateral flanges 432, 434, a uniform thickness (which may not be the same or may be the same) on one or both of the upturned portions 428, 430, etc.

In some embodiments, the adapter pad 400 may include, in whole or in large part, a coating 565 of elastomeric material, which may be integrally formed with the elastomeric member 560. For example, in some embodiments, a majority of adapter pad 400 may include a coating 565 of elastomeric material, except for those portions of adapter pad 400 that contact the pedestal roof 152 and the top surface of adapter 199 (e.g., the outer surfaces of top plate 420 and bottom plate 440). In some embodiments, for example, the coating of elastomeric material 565 may contact the pedestal roof 152, the side frame 4, and the roller bearing adapter pad 199, including the pedestal crown surface 102 and the vertical shoulder 106. In other embodiments, for example, the portions of the adapter pad 400 that contact the pedestal roof 152, side frame 4, and roller bearing adapter pad 199 may be free of elastomeric material. As discussed elsewhere herein, the elastomer layer 565 may provide damping and calibrated flexibility to the pad, as well as a compressible surface, thereby minimizing wear between the adapter pad 400, pedestal roof 152, and roller bearing adapter 199. The elastomeric coating 565 may have a uniform thickness along the outer surface of the adapter pad 400 and along the outer surface of the adapter pad 400, or in other embodiments, in different portions of the pad, for example, in the central portion 410, in one or both of the upper lateral flanges 432, 434 (which may be the same or different), in one or both of the upturned portions 428, 430 (which may be the same or different), and so forth.

As best shown in fig. 28-30, and as described above, one or both of the upturned portions 412, 414 may include a hollow portion 572 located within a cavity formed between the top plate 420 and the bottom plate 440 that is substantially void free of elastomeric material and may form an interruption in the elastomeric member 560 in the first upturned portion 412 and/or the second upturned portion 414. The hollow portion 572 may provide a complete separation between the elastomeric member 560 disposed within the central portion 410 and the elastomeric members disposed within the lateral flanges 416, 418. In some embodiments, the void may comprise a very small thickness layer of elastomeric material that contacts each of the top plate 420 and the bottom plate 440 through the transition portion, which may depend on possible functional limitations of the tools used in the molding process, but this thin layer (when present) may not materially contribute to the performance of the adapter pad 400. Further, in some embodiments, the hollow portion 572 can include a small portion of elastomeric material extending between the top plate 420 and the bottom plate 440, but in other cases the hollow portion is substantially hollow. In some embodiments, the width of the hollow portion may be about 0.25 inches or about 0.1 inches to about 0.5 inches, or at least as wide as the maximum lateral and rotational movement on the adapter pad 200. In some embodiments, the hollow portion 572 is configured to provide lateral clearance between the top plate 420 and the bottom plate 440 extending through the respective transition portions 412, 414 such that the respective inner surfaces of the top plate 420 and the bottom plate 440 in the transition portions do not contact each other during lateral or rotational relative movement therebetween and/or do not contact each other during lateral and/or rotational displacement of the railcar by the adapter pad 400 disposed on the railcar truck during operation thereof.

As described above, the hollow part 572 may function to limit bending stress of the top plate 420 and the bottom plate 440. The hollow 572 may be approximately 0.25 inches. Over a range of motion of about 0.25 inches, the upturned regions of the top plate 420 and the bottom plate 440 may engage and prevent further relative motion. This can create an upper limit for elastomer strain and metal stress in the lateral direction.

As described above, during use, heat may be generated in adapter pad 400 by friction and sliding of pad 400 relative to side frame pedestal roof 152 and/or relative to bearing adapter 199, and/or by hysteresis damping of elastomeric member 560 of adapter pad 200. These heat sources may cause the adapter pad to increase in temperature, which may result in reduced durability and stiffness. As described above, in some embodiments, adapter pad 400 may include features that may improve the ability to reduce heat in adapter pad 200.

Further, as described above, one or both of the outer surfaces 424 of the central portion 426 or the inner surface 444 of the central portion 446 may include one or more of a variety of different surface features, and, in some embodiments, one or both of the outer surfaces 424 of the central portion 426 or the inner surface 444 of the central portion 446 may include a pattern of surface features that makes these surfaces non-smooth.

As described above, in some embodiments, electrical conductivity may be provided between the top plate 420 and the bottom plate 440. As shown in fig. 28, the ground strap 266 may be connected to holes in the sides of the top plate 420 and the bottom plate 440. The ground strap 266 may pass through holes in the top plate 220 and the bottom plate 240. The top plate 420 and bottom plate 440 may be recessed or deformed at point 267 to crimp or secure the ground strap 266 in the top plate 420 and bottom plate 440. In some embodiments, the ground strap 266 may be a stainless steel braided wire having a diameter of about 0.100 inches, but may be as small as 0.050 inches in diameter.

as described above, the adapter pad 400 may include pads or grips on the top plate 420 and bottom plate 440 of the adapter pad that may be configured to position the adapter pad 200 relative to the side frame pedestal top plate 152 and bearing adapter 199 and also engage and limit movement of the adapter pad 400 relative to the pedestal top plate 152 and bearing adapter 199, which may focus the motion (i.e., shear) of the adapter pad 200 to the elastomeric member 360. As described above, assembly of the adapter pad 400 to the roller bearing adapter 199 can force the adapter pad 400 to be reasonably centered in the roller bearing adapter 199 and bearing by using the vertical shoulder 106 and including the grips. Further, the adapter pad system 198 facilitates centering the adapter 200 and wheel set back to a centered or near zero force.

as described above, the adapter pad 400 may include a first lateral adapter grip 270 and a second lateral adapter grip 271. The lateral adapter pad grips 270, 271 may be integrally formed with the base plate 440, including integrally formed with the elastomeric member 560 and/or any elastomeric coating 565 on the adapter pad 400. As described above, the adapter pad 400 may also include a first lateral side frame grip 272 and a second lateral side frame grip 273. The lateral side frame grips 272, 273 can be integrally formed with the base plate, including with the elastomeric member 560 and/or the elastomeric coating 565 on the adapter pad 400.

As described above, the elastomeric member 560, and in particular the outer elastomeric members 564, 566, may be configured as follows: the rotational shear stress of the elastomer through displacements up to 41 milliradians is no higher than the lateral and longitudinal shear stresses of the elastomer through lateral displacements up to 0.23 inches and longitudinal displacements up to 0.14 inches.

For other embodiments, the elastomeric member 560 may be measured as described above. As shown in fig. 28-33, the overall shear width or length in the lateral direction of the elastomeric member 560 may be about 10 inches or in the range of about 6 inches to about 14 inches. Similarly, the total cut length or length in the longitudinal direction of the elastomeric member 560 may be about 6.9 inches or in the range of about 6 inches to about 10 inches. The composite shear perimeter or the perimeter of all portions of the elastomeric member may be about 51.70 inches or in the range of about 35 inches to about 75 inches. The total surface area in the shear plane of the elastomeric member 560 may be about 55.5 square inches or in the range of about 50 square inches to about 70 square inches. The total surface area of the elastomeric member 560 outside of the central portion may be about 15.5 square inches or in the range of about 5 square inches to about 30 square inches, or greater than 5 square inches. Accordingly, the surface area of the elastomeric member in the lateral flanges 416, 418 may be about 7.75 square inches or in the range of about 2.5 square inches to about 15 square inches or greater than 2.5 square inches, respectively.

As described above, to reduce the stress in the elastomeric member 560 at maximum shear displacement conditions, it may be beneficial to provide normal stress or compression to the elastomeric member 560 during shear loading.

For example, as discussed above, the elastomeric member 560 outside of the pedestal roof 152 area may be compressed by greater than 0.020 inches, or greater than 7% of the static thickness of the elastomeric member 560. In some embodiments, this magnitude of precompression results in improved fatigue life of the elastomeric member 560. Further, in the embodiments discussed herein, when a vertical force is applied to the central portion 410 of the adapter pad 400, approximately 10% to 30% of the vertical force may be distributed to each of the adapter pad lateral flanges 416, 418. Also, in the embodiments discussed herein, the reaction of the vertical load at the vertical shoulder 106 may provide a vertical force of greater than 3000 pounds to pre-compress the elastomeric member.

Further, as described above, compression of the elastomeric member 560 in the outboard region of the axial top plate 152 (in the outer elastomeric members 464, 466) may be achieved by having an elastomeric member 560 with a non-uniform thickness along its length. For example, the first and/or second outer portions 564, 566 can be formed to have a thickness X, while the central portion 462 can be formed to have a different or lesser thickness Y. The geometry of the top plate 420 and bottom plate 440 (e.g., via bending of the upturned portions 412, 414) may be shaped to accommodate the difference in thickness between X and Y, thereby allowing the elastomeric portions of the central and outer portions to contact the inner surfaces of the top plate 420 and bottom plate 440 as desired. In some embodiments, the difference in thickness of the elastomeric members forming the first and/or second outer portions 464, 466 and the central portion 462 may help reduce the single shear strain of the outer layer based on in-plane forces applied to the adapter pad in the longitudinal, lateral, and rotational directions.

Further, as discussed above, one or both of the lateral flanges 416, 418 may be shaped such that the elastomeric layers 564, 566 therein include a thickness X of about 0.25 inches (e.g., in the range of 0.15 inches to 0.30 inches, including all thicknesses within that range). In this embodiment, the thickness Y of the elastomeric layer 560 of the central portion 562 may be about 0.20 inches, for example, in the range of 0.15 inches to 0.25 inches, including all thicknesses within this range. The thickness of the elastomeric layer as discussed herein refers to the static thickness of the elastomeric layer or the thickness of the elastomeric layer in the absence of an external load on the elastomeric layer. One or both of the lateral flange portions 564, 566 and the central portion 562 may have different thicknesses, with the upper portion being thicker than the central portion, to achieve the desired effect, and in general, the load or compression of one or both of the lateral flange portions 564, 566 may be increased, as the material properties of the elastomeric layer may additionally increase its strength and durability based on the loads expected during railcar operation.

Further, as discussed above, and as shown in fig. 30 and 31, compression of the elastomeric members 560 in the lateral flanges 416, 418 may be increased by using compression shims 290 within or below the lateral flanges 416, 418. Compression shims may be used herein to cause the reaction of the vertical load on vertical shoulder 106 to provide a vertical force of greater than 3000 pounds when a vertical force is applied to central portion 410 of adapter pad 400, thereby distributing approximately 10% to 30% of the vertical force to each adapter pad lateral flange 416, 418. In some embodiments, the compression spacers may force more of the vertical load of the vehicle to be distributed from the central elastomeric layer 560 to the outer elastomeric layers 564, 566. As shown in fig. 30 and 31, a first adapter compression spacer 290 may be disposed between the upper surface of the vertical shoulder of the roller bearing adapter 199 and the outer surface 244 of the first lateral flange 416 of the bottom plate 440. A second adapter compression spacer 290 may be similarly disposed relative to the second lateral flange 418. The adapter compression spacer 290 may have a thickness of about 0.05 inches or in the range of about 0.03 inches to about 0.18 inches. The compression pads discussed herein may have any number of different shapes and configurations to provide the necessary load to compress the outer elastomer. For example, the compression pad may be rectangular, square, trapezoidal, tapered, may have a hollow cross-section, and may be a plurality of compression pads. Further, the compression shims discussed herein may be molded as one piece with the adapter pad during the molding process, may be molded as one piece with the roller bearing adapter, or may be added to the roller bearing adapter system after molding.

As discussed above, testing determined that the performance of the adapter pad system 198 is a function of the stiffness of the adapter pad 400. More specifically, in some embodiments, it has been determined that adapter pad performance, including design life, can be improved by increasing the stiffness (measured in force (pounds)/deflection (inches)) of the adapter pad system 198. The physical measure of pad stiffness may be determined as discussed above.

Exemplary measurements and test results for the embodiments disclosed herein using the test methods described above are listed in table 3 below. It should be understood that these embodiments are exemplary and that other structural embodiments with other test results may exist.

TABLE 3

As discussed above, the elastomeric layers 564, 566 outside the central region 210 may contribute to the overall stiffness of the adapter pad 200. For example, in some embodiments, the elastomeric member 560 outside of the central region 210 may comprise about 15% or in the range of about 5% to about 30% of the adapter pad's total lateral and longitudinal stiffness, or 33% or in the range of about 15% to about 60% of the adapter pad's 200 rotational stiffness.

As described above, the elastomeric member 560 (which may include the elastomeric coating 565) of the adapter pad 400 provides shear resistance during loading under vertical loads in the lateral, longitudinal, and rotational directions. The shear resistance is created by the relative movement between the top plate 420 and the bottom plate 440 that interact through the elastomeric member 560. Simple shear strain or strain is defined as d/t, where d is the displacement of the elastomeric member and t is the thickness of the elastomeric member. Fig. 34a and 34b show a simulation of 0.234 inches of lateral displacement of the top plate 420 relative to the bottom plate 440. As shown in fig. 34a and 34b, the strain in the lateral flanges 416, 418 is lower than the strain in the central portion 410. In some embodiments, this may increase the life of the adapter pad. Further, as shown in fig. 34a and 34b, the highest strain value occurs inside the outer edge of the elastomer portion. Similarly, fig. 35a and 35b show a simulation of a longitudinal displacement of 0.234 inches of the top plate 420 relative to the bottom plate 440. As shown in fig. 35a and 35b, the strain in the lateral flanges 416, 418 is lower than the strain in the central portion 410. In some embodiments, this may improve the life of the adapter pad. Further, as shown in fig. 35a and 35b, the highest strain value occurs inside the outer edge of the elastic body portion.

further, in some embodiments, the shear strain of adapter pad 400 does not exceed 100% under maximum displacement conditions. For example, the lateral strain may be about 74% or less than 80%, or less than 90% for a lateral displacement of 0.234 inches. For a lateral displacement of 0.234 inches, this may be about 45% less strain than existing adapter pad systems. Further, for example, for a longitudinal displacement of 0.139 inches, the longitudinal strain may be about 72%, or less than 80%, or less than 90%. This may be about 30% less strain than existing adapter pad systems for a longitudinal displacement of 0.139 inches.

Exemplary dimensions of the adapter pad 400 are shown and described herein, however, other dimensions may be used for various portions of the adapter pad, depending on the fixed dimensions of the side frames and bearings used for a particular railcar truck system.

Examples

In one embodiment, an adapter pad system configured to be disposed between a wheelset roller bearing and a sideframe pedestal roof of a railway car truck is disclosed herein. The adapter pad system can include a roller bearing adapter having first and second vertical shoulders that project upwardly from a top surface of the adapter. The adapter pad system may also include an adapter pad configured to interact with the roller bearing adapter, having: a top plate having inner and outer surfaces, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, and a second lateral flange projecting outwardly from the second upturned region; a bottom panel having an inner surface and an outer surface, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, and a second lateral flange projecting outwardly from the second upturned region. The first and second laterally projecting flanges of the top and bottom plates of the adapter pad system may be disposed above the vertical shoulders of the roller bearing adapter.

the roller bearing adapter of the adapter pad system may be cast or forged. An adapter pad is engageable with the side frame and with the roller bearing adapter. The top plate of the adapter pad is engageable with the side frame such that movement between the top plate and the side frame is limited. The bottom plate of the adapter pad can engage the roller bearing adapter such that movement between the bottom plate and the roller bearing adapter is limited. The roller bearing adapter can include a longitudinal stop configured to limit longitudinal movement of the bottom plate relative to the roller bearing adapter. The vertical shoulder may be configured to limit lateral movement of the bottom plate relative to the roller bearing adapter. The roller bearing adapter top surface may include a crowned surface. The longitudinal stop and the vertical shoulder may be configured to limit rotational movement of the base plate relative to the roller bearing adapter. The roller bearing adapter can be symmetrical about a lateral centerline. The roller bearing adapter may be symmetrical with respect to the longitudinal centerline. The top plate of the roller bearing adapter may be continuous. The bottom plate of the roller bearing adapter may be continuous.

The adapter pad system may include an elastomeric member disposed between the inner surfaces of the top and bottom plates. The elastomeric member disposed between the top plate and the bottom plate may be a plurality of elastomeric members. The plurality of elastomeric members may include: a first outer elastomeric member disposed between the first lateral flanges of the top and bottom plates, a second outer elastomeric member disposed between the second lateral flanges of the top and bottom plates, and a central elastomeric member disposed between the central portions of the top and bottom plates. The first hollow portion may be disposed between the central elastomeric member and the first outer elastomeric member and the second hollow portion may be disposed between the central elastomeric member and the second outer elastomeric member. The width of the first and second hollow portions may be about 0.25 inches. The first and second hollow portions may be configured to limit bending stresses in the top and bottom plates. The outer elastomeric member may be in a compressed state. The thickness of the outer elastomeric member may be compressed from a static state by at least 0.020 inches. The thickness of the outer elastomeric member may be compressed from a static state by at least 7%. The first outer elastomeric member, the second outer elastomeric member, and the neutral elastomeric member may each be substantially planar and may each be substantially horizontal when the adapter pad is disposed under a side frame pedestal roof of a railway car truck. The elastomeric material may be positioned perpendicular to the direction of lateral displacement to increase the compressive stiffness. The elastomeric material may be positioned perpendicular to the direction of longitudinal displacement to increase the compressive stiffness. The elastomeric material may be positioned perpendicular to the direction of rotational displacement to increase the compressive stiffness. The elastomeric material may be positioned perpendicular to the direction of vertical displacement to increase the compressive stiffness.

The first outer elastomeric member may have a surface area at a cross-section through the first outer elastomeric member centrally located between the inner surfaces of the top and bottom plates of greater than 2.5 square inches. The surface area of the second outer elastomeric member at a cross-section formed through the second outer elastomeric member in a plane centered between the inner surfaces of the top and bottom plates may be greater than 2.5 square inches. The first and second outer elastomeric members may have a combined surface area at a cross-section formed through the first and second outer elastomeric members in a plane centered between the inner surfaces of the top and bottom plates of greater than 5 square inches. The combined surface area of the first and second outer elastomeric members at a cross-section formed through a plane centered between the inner surfaces of the top and bottom plates through the first and second outer elastomeric members may be at least 10% of the surface area of the central elastomeric member at a cross-section through the center of the central elastomeric member centered between the inner surfaces of the top and bottom plates.

The central elastomeric member may define a plurality of voids that form a plurality of discontinuities in the elastomeric member disposed between the central portion of the top plate and the central portion of the bottom plate. The plurality of voids have a thickness less than a total distance between the top and bottom plates, wherein a portion of the elastomeric member may be disposed perpendicularly with respect to one or more of the plurality of voids and contact one or both of the top and bottom plates.

The central elastomeric member may define an outer edge, wherein a portion or portions of the outer edge are curved from a top view. At least a portion of an outer edge of the central elastomeric member may define an inwardly concave profile. The first and second outer elastomeric members may define an outer edge, wherein a portion or portions of the outer edge may be curved in a top view. A portion or portions of the outer edge of the elastomeric member may include a continuous radius measured from a center point of the central portion of the top plate. Any edge of the elastomeric member may define an inwardly concave profile.

One or both of the first and second outer elastomeric members may define an outer edge, wherein one or both of the first and second lateral flanges of the top and bottom panels extend outwardly through at least a portion of the outer edge located inwardly of the respective first and second lateral flanges.

The adapter pad can include an elastomeric support disposed between the outer surfaces of the first and second lateral flanges of the base plate and the vertical shoulder of the roller bearing adapter.

At least a portion of an outer edge of the elastomeric member may define an inwardly recessed profile. The inwardly recessed profile may be defined by a first linear portion extending from the proximal end to the inner surface of the top panel and a second linear portion extending from the proximal end to the inner surface of the bottom panel. The first and second linear portions may be connected by a transition portion extending between the first and second linear portions. The first and second linear portions may extend from adjacent portions of the respective top or bottom plate at an angle of about 25 degrees to about 35 degrees to a plane through the surface of the respective top or bottom plate from which the respective linear portion extends.

The thickness of the first and second outer elastomeric members may be the same as or greater than the thickness of the central elastomeric member. The first and second outer elastomeric members may have a thickness of about 0.15 inches to about 0.30 inches. The central elastomeric member may have a thickness of about 0.15 inches to 0.25 inches. The adapter pad may have a thickness of about 0.4 inches to about 0.8 inches.

The adapter pad system may also include an elastomeric layer disposed over the outer surface of the top plate and/or may include an elastomeric layer disposed under the outer surface of the bottom plate. The elastomeric layer may cover all or a portion of the outer surface of the adapter pad. The thickness of the top and bottom plates of the adapter pad may be non-uniform. The thickness of the top and bottom plates may be uniform. The top plate may have a non-uniform thickness. The top plate may have a uniform thickness. The base plate may have a non-uniform thickness. The bottom plate may have a uniform thickness.

The adapter pad system may be configured to return to an intermediate or centered position within the side frame pedestal after the load thereon is removed.

The first and second lateral flanges of the top plate may include a planar outer surface, which may be parallel to an outer surface of the central portion of the top plate.

The respective inner surfaces of the first and second upturned regions of the first and second plates of the adapter pad may include a planar portion. The respective inner surfaces of the first and second upturned regions of the first and second plates of the adapter pad may include a curved portion. At least a portion of the first and second upturned regions of the first and second panels of the adapter pad may extend at an obtuse angle to a plane passing through an outer surface of the central portion of the top panel.

The first and second lateral flanges of the top plate of the adapter pad may include outer surfaces that are exposed when the adapter pad contacts the side frame pedestal. The first and second lateral flanges may contact air outside the enclosure of the side frame at the pedestal opening. The first and second lateral flanges may be configured to reduce heat from the adapter pad. The first and second lateral flanges may be configured to reduce heat of the adapter pad system.

The adapter pad may include a lateral length of the central portion, which may be equal to a distance between the sidewalls on the pedestal roof surface. The lateral length of the center section may be about 0.125 inches, which is greater than the length between the side walls of the side frame on the pedestal roof surface. The entire lateral length of the top plate may be at least 7.5 inches.

The adapter pad system may further comprise: a first lateral adapter clamp disposed between an inside surface of a first vertical shoulder of the roller bearing adapter and the first upturned region of the bottom plate, a second lateral adapter clamp disposed between an inside surface of a second vertical shoulder of the roller bearing adapter and the second upturned region of the bottom plate. The first and second lateral adapter clamps may be formed of an elastomeric material. The first and second lateral adapter grips can be configured to limit sliding or relative movement between the roller bearing adapter and the outer surface of the base plate of the adapter pad. The first and second lateral adapter grips can be configured to center the bottom plate of the adapter pad on the roller bearing adapter.

The adapter pad system may further comprise: a first lateral side frame clamp disposed on an outer surface of the first upturned region of the top plate, and a second lateral side frame clamp disposed on an outer surface of the second upturned region of the top plate. The first lateral side frame clamp may be disposed between an outer surface of the first lateral flange of the top plate and the side frame pedestal, and the second lateral side frame clamp may be disposed between an outer surface of the second lateral flange of the top plate and the side frame pedestal. The first and second lateral side frame grips can be formed of an elastomeric material. The first and second lateral side frame grips can be configured to limit sliding or relative movement between the outer surface of the top plate and the side frame directly above the pedestal area.

In some embodiments, the adapter pad system may be configured to limit the elastomer temperature below the degradation temperature of the particular elastomer and/or bonding material used in the pad construction. The adapter pad system may also be configured to lower the melting point of the elastomeric member.

The adapter pad system can include a first adapter compression gasket disposed between an upper surface of the first vertical shoulder of the roller bearing adapter and an outer surface of the first lateral flange of the bottom plate. The adapter pad system can further include a second adapter compression gasket disposed between an upper surface of the second vertical shoulder of the roller bearing adapter and an outer surface of the second lateral flange of the bottom plate. The first and second adapter compression spacers may have a thickness of about 0.06 inches to about 0.18 inches.

the adapter pad may include a first lower adapter pad compression gasket disposed between the elastomeric member and the first lateral flange of the bottom plate. The adapter pad may further include a second lower adapter pad compression gasket disposed between the elastomeric member and the second lateral flange of the bottom plate. The first and second lower adapter pad compression pads may be about 0.06 inches to 0.18 inches thick.

The adapter pad may include a first upper adapter pad compression gasket disposed between the first lateral flange of the top plate and the first outer elastomeric member. The adapter pad may further include a second upper adapter pad compression gasket disposed between the second lateral flange of the top plate and the second outer elastomeric member. The first and second upper adapter pad compression spacers may have a thickness of about 0.06 inches to about 0.18 inches.

The compression gasket may be configured to provide a vertical compression load of at least 3000 pounds to the outer elastomeric member when a vertical load of 35,000 pounds is applied to the central portion of the adapter pad. The compression gasket may be rectangular. The compression pad may have a rectangular cross-sectional shape, a curved cross-sectional shape, a triangular cross-sectional shape, or a trapezoidal cross-sectional shape. The compression gasket may include a raised portion. The compression gasket may include a hollow portion. The compression gasket may comprise a plurality of compression gaskets.

The lateral flange of the adapter pad may be supported vertically by the vertical shoulder of the roller bearing adapter. When a vertical force is applied to the center portion of the adapter pad, approximately 10% to 30% of the vertical force may be distributed to each adapter pad lateral flange. The action of the vertical load on the vertical shoulder may provide a vertical force of at least 3000 pounds to pre-compress the elastomeric member.

When a vertical load of 35,000 pounds is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad can provide a longitudinal stiffness of at least 45,000 pounds per inch by a longitudinal displacement of the top plate relative to the bottom plate of up to 0.139 inches from a central position. The longitudinal hysteresis of the adapter pad system may be less than about 1500 pounds.

When a vertical load of 35,000 pounds is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a lateral stiffness of at least 45,000 pounds per inch by a lateral displacement of the top plate relative to the bottom plate of up to 0.234 inches from the central position. The adapter pad system may have a lateral displacement hysteresis of less than about 6,000 pounds.

When a vertical load of 35,000 pounds is applied to the central portion of the adapter pad, the top plate, the bottom plate, and the elastomeric member of the adapter pad may provide a rotational stiffness of at least 250,000 pounds per inch per radian of rotation through rotational displacement of the top plate relative to the bottom plate up to 41 milliradians off-center. The torsional hysteresis may be less than about 16,000 pounds per inch.

The top plate, bottom plate, and elastomeric member of the adapter pad may provide a vertical stiffness of at least 5,000,000 pounds per inch with a vertical displacement of 0.05 inches. The vertical displacement may be non-linear and may be 5,000,000 to 30,000,000 pounds per inch, depending on the non-linear variations in durometer, thickness tolerance, and compressive stiffness.

The combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a lateral stiffness in the range of about 10% of the longitudinal stiffness when a vertical load is applied to the central portion of the adapter pad.

When a vertical load is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a lateral strain within the elastomeric member that is substantially similar throughout the elastomeric member.

When a vertical load is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a longitudinal strain within the elastomeric member that is substantially similar throughout the elastomeric member.

When a vertical load is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a rotational strain within the elastomeric member that is substantially similar throughout the elastomeric member.

When a vertical load is applied to the central portion of the adapter pad, the combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a rotational strain that is less than or equal to a lateral strain at any point within the elastomeric member.

The combined top plate, bottom plate, and elastomeric member of the adapter pad may provide a shear strain of no more than 120% at maximum displacement conditions.

The thickness of the central portion of the bottom plate of the adapter pad may be non-uniform. The central portion of the bottom plate has a thickness at the lateral edges that is greater than a thickness at the center of the central portion.

The elastomeric member disposed between the central portions of the top and bottom plates may be substantially uniform in thickness.

In another embodiment, a method of forming an adapter pad may comprise: providing a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly from the second upturned lateral portion; inserting an elastomeric member between the top plate and the bottom plate, wherein a first outer elastomeric member is disposed between the first lateral flanges, a second outer elastomeric member is disposed between the second lateral flanges, and a central elastomeric member is disposed between the central portions; and compressing the first lateral flange of the top plate and the first lateral flange of the bottom plate toward each other; and compressing the second lateral flange of the top plate and the second lateral flange of the bottom plate toward each other.

The compression step may deform the first and second lateral flanges after the forming operation is completed. This deformation may result in preloading of the outer elastomeric member. The compressing step may apply a compressive force of greater than 3000 pounds in the outer elastomeric member. The compressing step may compress the outer elastomeric member by at least 0.02 inches of its static thickness. The compressing step may cause the outer elastomeric member to be compressed by greater than 7% of the static thickness of the outer elastomeric member.

In another embodiment, a method of forming an adapter pad may comprise: providing a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly and downwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly and downwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly and upwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly and upwardly from the second upturned lateral portion; inserting an elastomeric member between the top plate and the bottom plate; and compressing the top and bottom plates such that lateral portions of the top and bottom plates are substantially parallel.

The compressing step may cause the outer elastomeric member to compress at least 0.02 inches of the static thickness of the outer elastomeric member. The compressing step may compress the outer elastomeric member by greater than 7% of a static thickness of the outer elastomeric member.

In another embodiment, a method of forming an adapter pad may comprise: providing a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; inserting a first outer elastomeric member between the first lateral flange of the top plate and the first lateral flange of the bottom plate; inserting a second outer elastomeric member between the second lateral flange of the top plate and the second lateral flange of the bottom plate; and inserting a central elastomeric member between the central region of the top plate and the central region of the bottom plate.

The thickness of the central elastomeric member may be less than or equal to the thickness of the first and second outer elastomeric members.

In another embodiment, a method of forming an adapter pad may include providing: a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, and a second lateral flange projecting outwardly from the second upturned lateral portion; inserting a first outer elastomeric member between the first lateral flange of the top plate and the first lateral flange of the bottom plate; inserting a second outer elastomeric member between the second lateral flange of the top plate and the second lateral flange of the bottom plate; and inserting a central elastomeric member between a central region of the top plate and a central region of the bottom plate; compressing the first and second lateral flanges of the top and bottom plates together; and bonding the top plate with the first outer elastomeric member, the second outer elastomeric member, and the central elastomeric member.

The central elastomeric member may have a thickness less than a thickness of the first and second outer elastomeric members.

The compressing step may cause the outer elastomeric member to compress at least 0.02 inches of its static thickness. The step of compressing causes the outer elastomeric member to compress by greater than 7% of its static thickness.

In another embodiment, an adapter pad system for use between a rail car side frame pedestal and a rail car wheel axle roller bearing adapter is disclosed herein. The sideframe pedestal may define: a first outer side, an opposing second outer side, and a pedestal roof located between and extending between the first outer side and the second outer side. The adapter pad system may include a bearing adapter defining a bottom surface mounted to a rail car axle roller bearing and a top surface defining opposing first and second vertical shoulders projecting upwardly from the top surface on either side of a side frame directly above a pedestal roof. The adapter pad system may include an adapter pad configured to interface with a bearing adapter, the adapter pad including: a top panel having an inner surface and an outer surface, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, and a second lateral flange projecting outwardly from the second upturned region; a floor having an inner surface and an outer surface, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, and a second lateral flange projecting outwardly from the second upturned region.

The central portions of the top and bottom plates may be disposed below a pedestal roof of a side frame pedestal, and the first and second laterally projecting flanges of the top and bottom plates may be disposed above the vertical shoulder of the roller bearing adapter and outside of the pedestal roof of the side frame pedestal and along first and second outer sides of the side frame pedestal.

In another embodiment, an adapter pad configured to be positioned between an adapter of a railcar truck and a side frame pedestal roof is disclosed herein. The adapter pad may include: a top panel having an inner surface and an outer surface, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region; a floor having an inner surface and an outer surface, a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, and a second lateral flange projecting outwardly from the second upturned region.

The outer surfaces of the first and second laterally protruding flanges of the bottom plate may be higher than the outer surface of the central portion of the top plate in the vertical direction.

In another embodiment, a method of forming an adapter pad may comprise: providing a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; inserting a first outer elastomeric member between the first lateral flange of the top plate and the first lateral flange of the bottom plate; inserting a second outer elastomeric member between the second lateral flange of the top plate and the second lateral flange of the bottom plate; inserting a central elastomeric member between a central region of the top plate and a central region of the bottom plate; vulcanizing or curing the elastomeric member; inserting a first compression gasket into the first lateral flange; and inserting a second compression gasket into the second lateral flange. In some embodiments, the compression gasket may be added after vulcanization or curing of the elastomer is complete.

In another embodiment, a method of forming an adapter pad may comprise: providing a top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; providing a bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned lateral portion, a second lateral flange projecting outwardly from the second upturned lateral portion; inserting a first outer elastomeric member between the first lateral flange of the top plate and the first lateral flange of the bottom plate; inserting a second outer elastomeric member between the second lateral flange of the top plate and the second lateral flange of the bottom plate; inserting a central elastomeric member between a central region of the top plate and a central region of the bottom plate; curing the elastomeric member; inserting a first compression gasket into the first lateral flange; a second compression gasket is inserted into the second lateral flange. The step of inserting the first and second compression pads may be performed after curing the elastomeric member.

The compressing step may compress the outer elastomeric member by at least 0.02 inches of the static thickness of the outer elastomeric member. The compressing step compresses the outer elastomeric member by more than 7% of its static thickness.

In another embodiment, an adapter pad system for use between a rail car side frame pedestal and a rail car axle roller bearing is disclosed herein. A side frame pedestal may define a first exterior side, an opposing second exterior side, and a pedestal roof between and extending between the first exterior side and the second exterior side. The adapter pad system may include a bearing adapter defining a bottom surface and a top surface, the bottom surface being mounted to the railcar axle roller bearing. The adapter pad may be configured to interface with a bearing adapter and may further comprise: the elastomeric member includes a top plate having inner and outer surfaces, a central portion and an outer portion, a bottom plate having inner and outer surfaces, a central portion and an outer portion, and an elastomeric member disposed between the inner surfaces of the top and bottom plates and having a central portion and an outer portion.

The central portions of the top and bottom plates may be disposed below a pedestal roof of a side frame pedestal and the outer portions of the top and bottom plates may be disposed outside of the pedestal roof of the side frame pedestal.

The adapter pad system may include a continuous top plate. The adapter pad system may include a continuous backplane.

The outer portion of the elastomeric member may have a combined surface area, in a cross-section formed through the outer portion of the elastomeric member in a plane centered between the inner surfaces of the top and bottom plates, of greater than 5 square inches.

The combined surface area of the outer portions of the elastomeric member on a cross-section formed through the outer portions of the elastomeric member in a plane centered between the inner surfaces of the top and bottom plates may be at least 10% of the surface area of the central portion of the elastomeric member on a cross-section formed through the center of the central portion of the elastomeric member in a plane centered between the inner surfaces of the top and bottom plates.

The central portion of the elastomeric member may be in a different plane than the outer portions of the elastomeric member. The central portion of the elastomeric member may lie in a plane parallel to the outer portions of the elastomeric member. The outer portion may be spaced apart from the central portion in a vertical direction.

The top plate is engageable with the side frame and the bottom plate is engageable with the roller bearing adapter.

In another embodiment, an adapter pad system for use between a rail car side frame pedestal and a rail car axle roller bearing is disclosed herein. A side frame pedestal may define a first exterior side, an opposing second exterior side, and a pedestal roof between and extending between the first exterior side and the second exterior side. The adapter pad system may include a bearing adapter defining a bottom surface and a top surface, the bottom surface being mounted to a railroad wheel axle roller bearing. The adapter pad system may include an adapter pad configured to interact with a bearing adapter, the adapter pad including: the elastomeric member includes a top plate having an inner surface and an outer surface, a central portion and an outer portion, a bottom plate having an inner surface and an outer surface, a central portion and an outer portion, and an elastomeric member disposed between the inner surfaces of the top plate and the bottom plate and having a central portion and an outer portion.

The central portions of the top and bottom plates may be disposed below a pedestal roof of a side frame pedestal, and the outer portions of the top and bottom plates may be disposed outside of the pedestal roof of the side frame pedestal.

The outer portions of the top and bottom plates may be configured to receive about 10% to 30% of the vertical force applied to the central portion.

An outer portion of the adapter pad may be supported by a vertical shoulder of the bearing adapter.

In another embodiment, a roller bearing adapter configured to be disposed between a roller bearing and an adapter pad of a railcar truck is disclosed herein. The roller bearing adapter can have a bearing surface, an adapter crown surface, a longitudinal centerline, and first and second vertical shoulders projecting upwardly from a pedestal crown surface of the adapter. The thickness of the central portion of the roller bearing adapter from the bearing surface to the pedestal crown surface of the adapter, measured on the longitudinal centerline, may be less than 0.75 inches.

The thickness of the roller bearing adapter measured on the longitudinal centerline from the bearing surface to the pedestal crown surface of the adapter may be about 0.60 inches to 0.75 inches. The width of the vertical shoulder may be at least 0.5 inches.

The roller bearing adapter, at a cross-section on its longitudinal centerline, may have a cross-sectional moment of inertia about a lateral axis located approximately 5.2 inches above the central axis of the axle that is about 1.4in greater⁴Or at about 1.0in⁴To 2.0in⁴Within the range of (1). The lateral axis may be about 5.0 inches to 5.5 inches from the axle central axis. The cross-sectional moment of inertia of a cross-section on the longitudinal centerline of the roller bearing adapter about a vertical axis located at the center of the adapter may be about 86.8in⁴Or at about 50in⁴To about 100in⁴Within the range of (1).

The present invention is disclosed above and in the accompanying drawings with reference to a variety of embodiments. The disclosure herein, however, is intended to provide examples of the various features and concepts related to the invention, but not to limit the scope of the invention. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations of the present invention. It will be appreciated by persons skilled in the art that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention. For example, although the steps of a method are described in the disclosure herein in a certain order, the steps of the method need not be performed in that order unless explicitly stated otherwise.

Claims (26)

1. A roller bearing adapter pad configured for use with a three-piece truck having an AAR standard geometry and configured to engage a side frame pedestal roof, the adapter pad comprising:

A continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous top panel having first and second longitudinal edges;

A continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous bottom panel having first and second longitudinal edges;

An elastomeric member disposed between the top plate and the bottom plate;

Wherein the first lateral edge of the top panel and the second lateral edge of the top panel define an inwardly curved edge or an inwardly angled edge from the outer surface of the top panel to the inner surface of the top panel as viewed in side elevation, and wherein the first lateral edge of the bottom panel and the second lateral edge of the bottom panel define an inwardly curved edge or an inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel as viewed in side elevation;

Wherein the first longitudinal edge of the top panel and the second longitudinal edge of the top panel define an inwardly curved edge or an inwardly angled edge from the outer surface of the top panel to the inner surface of the top panel as viewed in side elevation, and wherein the first longitudinal edge of the bottom panel and the second longitudinal edge of the bottom panel define an inwardly curved edge or an inwardly angled edge from the outer surface of the bottom panel to the inner surface of the bottom panel as viewed in side elevation;

Wherein the first lateral edge of the top panel and the second lateral edge of the top panel comprise a curved portion from a top view, and wherein the first lateral edge of the bottom panel and the second lateral edge of the bottom panel comprise a curved portion from a top view;

Wherein the elastomeric member extends laterally outward beyond the first and second lateral edges of the top and bottom plates; and is

Wherein the elastomeric member extends longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

2. The roller bearing adapter pad system of claim 1, wherein the first lateral edge of the top plate and the second lateral edge of the top plate include a continuous radius measured from a vertical axis at a center point of the central portion of the top plate as viewed in top plan, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate include a continuous radius measured from a vertical axis at a center point of the central portion of the bottom plate as viewed in top plan.

3. The roller bearing adapter pad system of claim 1, wherein a portion of the elastomeric member disposed between the central portions of the top and bottom plates has a substantially uniform thickness.

4. A roller bearing adapter pad system configured for use with a three-piece truck having an AAR standard geometry, the roller bearing adapter pad system comprising:

A roller bearing adapter configured to engage a roller bearing, the roller bearing adapter comprising:

A coronal top surface;

A bottom surface configured to engage the roller bearing; and

First and second vertical shoulders projecting upwardly from opposite lateral edges of the top surface;

An adapter pad engaging the roller bearing adapter and configured to engage a side frame pedestal roof, the adapter pad comprising:

A continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous top panel having first and second longitudinal edges;

A continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous bottom panel having first and second longitudinal edges;

An elastomeric member disposed between the top plate and the bottom plate;

Wherein the first and second lateral flanges of the top plate and the bottom plate are integrally disposed on the vertical shoulder of the roller bearing adapter;

Wherein the first lateral edge of the top panel and the second lateral edge of the top panel define an edge that curves inwardly from the outer surface of the top panel toward the inner surface of the top panel or an inwardly angled edge from a side view, and wherein the first lateral edge of the bottom panel and the second lateral edge of the bottom panel define an edge that curves inwardly from the outer surface of the bottom panel toward the inner surface of the bottom panel or an inwardly angled edge from a side view.

5. The roller bearing adapter pad system of claim 4, wherein the first lateral edge of the top plate and the second lateral edge of the top plate include a curved portion from a top view, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate include a curved portion from a top view.

6. The roller bearing adapter pad system of claim 5, wherein the first lateral edge of the top plate and the second lateral edge of the top plate include a continuous radius measured from a vertical axis at a center point of the central portion of the top plate as viewed in top plan, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate include a continuous radius measured from a vertical axis at a center point of the central portion of the bottom plate as viewed in top plan.

7. The roller bearing adapter pad system of claim 4, wherein the first longitudinal edge of the top plate and the second longitudinal edge of the top plate define an edge that curves inwardly or angles inwardly from the outer surface of the top plate toward the inner surface of the top plate as viewed in side elevation, and wherein the first longitudinal edge of the bottom plate and the second longitudinal edge of the bottom plate define an edge that curves inwardly or angles inwardly from the outer surface of the bottom plate toward the inner surface of the bottom plate as viewed in side elevation.

8. The roller bearing adapter pad system of claim 4, wherein the elastomeric member extends laterally outward beyond the first and second lateral edges of the top and bottom plates.

9. The roller bearing adapter pad system of claim 4, wherein the elastomeric member extends longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

10. The roller bearing adapter pad system of claim 4, wherein a highest strain value occurs inward of an outer edge of the elastomeric member when the top plate is laterally displaced 0.234 inches relative to the bottom plate.

11. The roller bearing adapter pad system of claim 4, wherein the combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 80% when the top plate is laterally displaced 0.234 inches relative to the bottom plate.

12. The roller bearing adapter pad system of claim 4, wherein the combined top plate, bottom plate, and elastomeric member of the adapter pad provide a strain of less than 90% when the top plate is displaced 0.234 inches laterally relative to the bottom plate.

13. The roller bearing adapter pad system of claim 4, wherein a highest strain value occurs inward of an outer edge of the elastomeric member when the top plate is displaced 0.139 inches longitudinally relative to the bottom plate.

14. The roller bearing adapter pad system of claim 4, the combined top plate, bottom plate, and elastomeric member of the adapter pad providing a strain of less than 80% when the top plate is displaced 0.139 inches longitudinally relative to the bottom plate.

15. The roller bearing adapter pad system of claim 4, the combined top plate, bottom plate, and elastomeric member of the adapter pad providing a strain of less than 90% when the top plate is displaced 0.139 inches longitudinally relative to the bottom plate.

16. The roller bearing adapter pad system of claim 4, wherein the thickness of the portions of the elastomeric member between the first and second lateral flanges of the top and bottom plates is pre-compressed from a static state.

17. The roller bearing adapter pad system of claim 4, wherein the elastomeric member further comprises:

A first compression gasket disposed between the first lateral flange of the bottom plate and the first vertical shoulder of the roller bearing adapter; and

A second compression shim disposed between a second lateral flange of the bottom plate and a second vertical shoulder of the roller bearing adapter.

18. The roller bearing adapter pad system of claim 4, wherein a portion of the elastomeric member disposed between the central portions of the top and bottom plates has a substantially uniform thickness.

19. A roller bearing adapter pad configured for use with a three-piece truck having an AAR standard geometry and configured to engage a side frame pedestal roof, the adapter pad comprising:

A continuous top panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous top panel having first and second longitudinal edges;

A continuous bottom panel having a central portion, first and second upturned regions projecting upwardly from opposite edges of the central portion, a first lateral flange projecting outwardly from the first upturned region, a second lateral flange projecting outwardly from the second upturned region, the first lateral flange having a first lateral edge, the second lateral flange having a second lateral edge, the continuous bottom panel having first and second longitudinal edges;

An elastomeric member disposed between the top plate and the bottom plate;

Wherein the first lateral edge of the top plate and the second lateral edge of the top plate define an edge that curves inwardly or angles inwardly from the outer surface of the top plate toward the inner surface of the top plate as viewed in side elevation, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate define an edge that curves inwardly or angles inwardly from the outer surface of the bottom plate toward the inner surface of the bottom plate as viewed in side elevation, and

Wherein the first longitudinal edge of the top panel and the second longitudinal edge of the top panel define an edge that curves inwardly from the outer surface of the top panel toward the inner surface of the top panel or an inwardly angled edge from a side view, and wherein the first longitudinal edge of the bottom panel and the second longitudinal edge of the bottom panel define an edge that curves inwardly from the outer surface of the bottom panel toward the inner surface of the bottom panel or an inwardly angled edge from a side view.

20. The roller bearing adapter pad of claim 19, wherein the first lateral edge of the top plate and the second lateral edge of the top plate include curved portions from a top view, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate include curved portions from a top view.

21. The roller bearing adapter pad of claim 20, wherein the first lateral edge of the top plate and the second lateral edge of the top plate include a continuous radius measured from a vertical axis at a center point of the central portion of the top plate as viewed in top plan, and wherein the first lateral edge of the bottom plate and the second lateral edge of the bottom plate include a continuous radius measured from a vertical axis at a center point of the central portion of the bottom plate as viewed in top plan.

22. The roller bearing adapter pad of claim 19, wherein the elastomeric member extends laterally outward beyond the first and second lateral edges of the top and bottom plates, and wherein the elastomeric member extends longitudinally outward beyond the first and second longitudinal edges of the top and bottom plates.

23. The roller bearing adapter pad of claim 19, wherein the thickness of the portions of the elastomeric member disposed between the first and second lateral flanges of the top and bottom plates is pre-compressed from a static state.

24. The roller bearing adapter pad of claim 19, wherein the elastomeric member further comprises:

A first compression gasket disposed below the first lateral flange of the bottom plate; and

A second compression gasket disposed below the second lateral flange of the bottom plate.

25. The roller bearing adapter pad of claim 19, wherein a portion of the elastomeric member disposed between the central portions of the top and bottom plates has a substantially uniform thickness.

26. The roller bearing adapter pad of claim 19, wherein the elastomeric member has a hardness of 65-80 shore a durometer.