EP2074261B1

EP2074261B1 - Resilient rail support block assembly

Info

Publication number: EP2074261B1
Application number: EP07818712A
Authority: EP
Inventors: Gerrit Marinus Van Der Houwen; Willem Paul Schram
Original assignee: Edilon Sedra BV
Current assignee: Edilon Sedra BV
Priority date: 2006-10-03
Filing date: 2007-10-02
Publication date: 2010-12-15
Anticipated expiration: 2027-10-02
Also published as: ATE491845T1; EA014736B1; DE602007011307D1; WO2008040549A1; KR20150071032A; UA96611C2; EP1908881A1; ES1065079U; PL2074261T3; KR101670308B1; ES1065079Y; KR20090082884A; JP5220752B2; EP2074261A1; ES2357987T3; EA200970343A1; DK2074261T3; JP2010506065A; KR20160100310A

Abstract

A prefabricated resilient member for in a rail support block assembly, which assembly is adapted to be mounted embedded in or mounted on a railway substructure. The assembly comprises said resilient member (1) as well as a block having a top (10), a bottom and peripheral wall, said block being adapted for fastening one or more rails on the top of said block. The prefabricated resilient member is adapted to be fixed to said block so as to extend under said bottom of the block as well as around at least a lower region of the peripheral wall of the block. The prefabricated resilient member (1) has an outer tray (2) and inner tray (3) arranged within said outer tray, and said prefabricated resilient member comprises a resilient intermediate structure (5) being arranged between said outer and inner trays.

Description

The present invention relates to the field of supporting rails of a railway track, such as for trains, underground, trams, etc.
In the field of railway track technology systems have been developed to reduce hinder, in particular noise and vibration.
In a known arrangement a rail of a railway track is supported on rail support blocks arranged at intervals under the rail. These blocks are embedded in a concrete slab. The slab is commonly poured around the blocks, but it is also known to place the blocks in corresponding cavities in a slab. To reduce noise and vibrations resulting from rail vehicles passing over the railway a resilient member is present between each block and the slab.
In a known system developed by the present applicant a resilient rail support block assembly is manufactured, which is ready to be mounted to the rail to be supported. The assembly includes a concrete block adapted for fastening the rail on the top of the block. This assembly further includes a concrete tray extending below and spaced from the bottom of the block as well as around and spaced from the lower region of the peripheral wall of the block. A resilient material, such as sold under the trade name Corkelast, has been poured during manufacture of the assembly between the concrete tray and the block. Upon polymerisation (while maintaining its resilient property) the resilient material adheres to the concrete block and concrete tray and thus bonds said tray to the block. When installing a rail, the known rail support block assemblies are positioned at intervals along the rails and fastened thereto. Thereafter a slab of concrete is poured, so that the concrete trays are embedded in and become integral with the slab. This method is known in the art as the "fix and forget method".
For the installation of a lengthy stretch of railway a very large number of such railway support block assemblies is required. Due to their weight it is preferred to organize the manufacture of the assemblies at a factory for concrete building products located relative close to the railway installation site. In practice this approach is faced with difficulties in the manufacturing of the railway support block assemblies. In particular it has been found difficult to establish a reliable quality of the assemblies, especially with regard to the adherence of the components in the known assembly. In detail it has been found difficult to control the adherence between the concrete block, the concrete tray and the pourable resilient material as quite extensive pre-treatment steps, e.g. of the concrete surfaces are required.
This adherence is considered important by the applicant as during its service life the resilient material of the assembly is subjected to cyclic compression and relaxation. Should the adherence deteriorate or fail completely the block is as it were "released" from slab. This considered undesirable, as the rail itself is then no longer connected to the slab in a satisfactory manner. In addition water/fuel or other liquids will be able to enter between the components that are no longer (sufficiently) bonded and a "pump action" will result upon each passage of a rail vehicle. This causes noise and vibration disturbance, and also leads to wear and damage which then has to be resolved with maintenance activities.
EP 919 666 discloses a system according to the preamble of claim 1, wherein a rail support block is placed in a prefabricated tray, e.g. of plastic or concrete. The tray is adapted to be embedded in the concrete slab. Within the tray elastic elements are arranged, in particular between the tray and the bottom of the block and between each side face of the tray and the opposed face of the block. The fixation of the tray with its elastic elements to the block is based on the clamping forces created by a precompression of the elastic elements by the block as it is placed in the tray.
In this system known from EP 919 666 it is envisaged that the block can be removed from a tray embedded in the slab in order to replace the block, e.g. when damaged. Such removal can be simply done by lifting the block out of the tray. In order to avoid the entry of water or the like between the tray and the block a number of alternative solutions are proposed, including pouring a silicone filling material into the spaces between the block and the tray with its associated resilient elements that support the block.
The present invention aims to propose one or more measures that allow to obtain an improved resilient railway support block assembly and/or improved manufacturing method therefor.
The present invention further aims to provide a manufacturing method that can be economically performed with a high quality of the manufactured assemblies.
The present invention provides a prefabricated resilient member for in a resilient rail support block assembly, which assembly is adapted to be mounted embedded in or mounted on a railway substructure and which assembly comprises said resilient member as well as a block having a top, a bottom and peripheral wall, said block being adapted for fastening one or more rails on the top of said block, the prefabricated resilient member being adapted to be fixed to said block so as to extend under said bottom of the block as well as around at least a lower region of the peripheral wall of the block.
According to the invention the prefabricated resilient member comprises an outer tray and inner tray arranged within said outer tray, and said prefabricated resilient member further comprises a resilient intermediate structure being arranged between said outer and inner trays.
The present invention further more relates to a method for manufacturing a rail support block assembly, wherein the inventive resilient member is prefabricated, the block is manufactured, and then the block is fixed in the inner tray of the resilient member.
In a preferred practical embodiment of said manufacturing method the resilient member is manufactured at a first site, preferably at a company specialized in the resilient intermediate structure for railway applications, and the block is manufactured at a second, remote site, preferably at a company specialized in manufacture of concrete building products. Then the block is placed in the inner tray of the resilient member, preferably at the second site, and the block is adhered to the inner tray. The completed railway support block assembly is then transported to the railway installation site.
Preferably the block is fixed to the inner tray by application of an adhesive, e.g. pouring an adhesive or mortar, such as e.g. a suitable epoxy, between the block and the inner tray.
An advantage provided by the resilient member according to the invention is that the manufacturing of said member can take place by specialized company in a controlled environment. In this manner perfect quality of the resilient member can be ensured. The process step of creating the adhesion between the inner tray and the block is found to be less complicated and sensitive than the adhesion discussed above between the pourable resilient material and the concrete components as discussed with reference to applicants prior art assembly. Therefore said adhesion can take place at the location of the production of the concrete block or even at another location (e.g. at the railway installation site).
The invention will be discussed in more detail below referring to the drawings. In the drawings:

Fig. 1 shows an example of railway support block and an exemplary prefabricated resilient member according to the invention,
Fig. 2 shows an assembly according to the invention composed of the block and resilient member of figure 1, said resilient member being fixed to the block,
Fig.3 shows a rail provided with the assembly of figure 2 prior to embedding in a concrete slab, and
Fig. 4 shows the rail of figure 3 with the assembly embedded in the concrete slab,
Fig. 5 shows a rail system with a sleeper supported by a prefabricated resilient member according to the invention,
Fig. 6 shows a rail system with a railway switch sleeper supported by a prefabricated resilient member according to the invention
Fig. 7 shows a rail system with a sleeper supported at its ends by prefabricated resilient members according to the invention,
Fig. 8 shows an example of an inner tray for a prefabricated resilient member according to the invention,
Fig. 9 shows an example of an outer tray to be used in combination with the inner tray of figure 8.

In figure 1 an example of a prefabricated resilient member 1 is shown, which is specially adapted for integration thereof in a rail support block assembly.
In the embodiment shown here the prefabricated resilient member 1 has an outer tray 2 and an inner tray 3 arranged within said outer tray 2.
The trays 2, 3 here generally have a bottom, here a rectangular bottom, and a raised peripheral wall and are open from above.
The skilled person will appreciate that other general shapes of the trays are possible, for instance depending on the shape of the block, such as an oval outer contour, a trapezium shaped outer contour, a hexagonal block, etc.
The inner tray 3 has dimensions here so that it can be held spaced from the outer tray 2 in all directions. In practical terms said distance between the main faces of the inner and outer trays 2,3 generally is preferably at least 5 millimetres and preferably at most 20, more preferably at most 15 millimetres.
A resilient intermediate structure 5 is arranged between said outer and inner trays 2, 3. Said structure 5 here also interconnects said trays 2, 3 so as to form a unitary assembly with said trays, preferably as said structure 5 is bonded to the faces of each of the trays 2, 3.
Here, in a preferred embodiment, the resilient structure 5 has been obtained by arranged the trays 2, 3 spaced from each other and then pouring (or similar) a suitable elastomeric material between the outer and the inner tray 2, 3. As the material has been poured (or similar) between the trays 2, 3 the material bonds to essentially the entirety of the main faces of the inner and outer trays 2, 3, preferably so that no interface exists which would allow for the ingress of water or the like.
The resilient intermediate structure 5 thus both serves to interconnect the trays 2, 3 so as to form a unitary prefabricated resilient member 1 and also to provide a sound and/or vibration attenuating support of the block 10 when the assembly is embedded in a slab or mounted on another substructure.
The outer and inner trays 2, 3 are spaced from one another so as to have no points of contact and the intermediate resilient layer 5 allows for elastic motion of the inner tray (which will receive the block) in all directions.
Here, as is preferred, the inner and outer trays 2, 3 are more rigid than the resilient intermediate structure 5.
In practice the trays 2, 3 can be from materials as plastic, (fibre) reinforced plastic, composite plastic material, metal, or even wood. Plastic material is preferred and the trays 2, 3 can e.g. be injection moulded or, as is preferred, formed from plastic sheet material. The plastic material could e.g. be a polyurethane polymer or an ABS polymer.
The elastomeric material of structure 5 and the trays 2, 3 are preferably designed and selected such that a strong adherence or bond is obtained between the inner faces of the trays and the elastomeric material. For instance the elastomeric material can a polyurethane elastomer, such as e.g. Corkelast made by the applicant.
In general the figure 1 shows a sandwich type prefabricated resilient member, wherein a layer of the elastomeric material 5 is sandwiched between the trays 2,3.
The resilient intermediate structure 5, here layer of elastomeric material 5, is adapted to maintain its resiliency during its service life. For instance said structure 5 (and the resilient assembly in which it is integrated) should be able to serve in railways lines as specified in UIC code 700, "Classification of lines and resulting load limits for wagons", a relevant code of the International Union of Railways.
The inner faces of the trays 2,3 are preferably made with an adhesion enhancing surface, e.g. rough as in the drawings, and/or provided with adhesion enhancing formations, such as ribs, lugs, etc.
The inner faces of the trays 2,3 can be subjected to an adhesion enhancing pre-treatment, e.g. a mechanical treatment or a chemical treatment.
The trays 2,3 can be made from the same or from different materials. E.g. the inner tray could be made from plastic and the outer tray of metal. A metallic outer tray would result in a high resistance against damage and/or penetration of the outer tray possibly affecting the functioning of the resilient material. A metallic outer tray, e.g. of steel, could also be chosen as it could allow for mounting or integrating the tray into a steel structure, e.g. on a steel plate or on a steel member of a railway bridge or the like. The steel outer tray could be provided e.g. with a flange which can be fastened to said further steel structure.
Also the wall thickness of the trays 2,3 could be the same or differ e.g. depending on the selected material and/or application
The trays 2,3 or one of them could be made from an electrical insulation material. The intermediate resilient structure 5 also could have electrically insulating properties.
It can also be envisage that one or more preformed elastic elements, e.g. an elastic mat or plate (e.g. of a suitable foam), are placed between the trays 2,3 and possibly adhered to both trays using a suitable adhesive.
The use of one or more preformed flexible foam element(s) between the bottoms of the trays is e.g. envisaged to obtain a softer support of the rail(s).
When using one or more preformed elastic elements between the trays, any remaining spaces between the trays 2,3 are filled with a pourable elastomeric material, as explained with regard to structure 5 in figure 1.
Figure 1 further shows an example of a railway support block 10. This block 10 here is made a pourable material which is poured in a suitable mould at a production location. Preferably the block 10 is made of concrete. It is envisaged that said concrete can be a polymer concrete. Other concrete containing embodiments of the block, e.g. including reinforcement materials, are also envisaged. The block could also be made of other materials, such as from steel, e.g. a cast block or a welded steel block.
The block 10 has a top 11, a bottom 12 and peripheral wall 13. Here the block 10 is adapted as a monobloc for supporting a single rail of a railway track, but the block could also be designed as a duo-block supporting two or even more rails (as a railway sleeper). The block 10 here has a significant height.
In order to fasten the rail to the top 11 of the block 10 one or more rail fastener members 15 are provided on the block 10. Also an elastic plate 16 is positioned here on top of the block 10, which will lie under the rail.
In figure 2 it is shown that the block 10 has been placed in the inner tray 3 of the prefabricated resilient member 1. It is shown here that the top of the block 10 is spaced vertically from the top edge of the trays 2,3.
In figure 2 it is also shown that the block 10 has been fixed in the inner tray 3 here, as is preferred, by application of a suitable adhesive 17 between the inner tray 3 and the block 10. This adhesive preferably hardens so as to be rigid in hardened condition, thereby rendering the inner tray 3 a unitary body with the block 10. Such adhesives are known I the field and are e.g. sold under the trade name DEX.
It is noted that the inner dimensions of the inner tray 3 are preferably selected so as to take account of any variations of the dimensions of the block 10 as a result of the block production method.
In figure 3 it is shown that the assembly of figure 2 is mounted on a rail 20 to be installed. In practice said rail 20 is held in its desired position by temporary supports.
In figure 4 a concrete or asphalt slab 25 has been poured below the rail 20 so as to embed the resilient member 1 in the slab 25.
To enhance the embedding of the outer tray 2 into the slab 25, the outer tray 2 can have a roughened exterior and/or anchoring formations (e.g. ribs(s), lug(s), bolts or pins, etc. protruding outwards from the tray 2).
In a practical embodiment the outer tray on the outside and/or the inner tray on the inside can be roughened by provision of a rough mineral coating, e.g. crushed pebbles, rock, gravel, etc. This crushed material can be fixed with an adhesive, e.g. epoxy, to the respective face of the tray.
It is also envisaged to have the outer tray 2 with inward sloping peripheral wall or parts thereof, so that the embedded outer tray can not be pulled upwards out of the slab.
A tray could be provided with one or more perforations.
In an embodiment not shown the assembly is not embedded but fastened onto a substructure, e.g. on a substructure plate (metal or concrete) or a beam.
In figure 5 the block is embodied as a sleeper 30 for with rail fasteners for supporting two parallel rails 31, the sleeper 30 e.g. being made of concrete or wood. The resilient member 40 according to the invention has a shape and size adapted to the sleeper 30. A system includes a concrete base 50, the assembly of resilient member 40 and sleeper 30 being fastened thereto by pouring a hardenable material 55, e.g. concrete, around the member 40 (e.g. as the base 50 includes holes for receiving the assemblies.
In figure 6 the sleeper 60 is a railway switch sleeper with four rail fastening members 6 for four rails. The member 40 is adapted to the size and shape of the sleeper 60.
In figure 7 a sleeper 30 is supported at both its ends by a resilient member 70 according to the invention. Each member 70 includes an inner and outer tray having a bottom and a peripheral wall which extends around the end of said sleeper.
Figure 8 shows outer tray 80 of a prefabricated resilient member according to the invention. This tray 80 is injection molded from suitable plastic material. The outside of the tray 80 includes anchoring members 81 which are to be embedded in the hardenable material that is to be poured around the tray 80.
Figure 9 shows inner tray 90 that is to be positioned within tray 80 with interposition of a resilient intermediate structure as disclosed herein. As can be seen the inside of the inner tray 90 is provided with anchoring members 91, 92 which enhance the anchoring to the mortar or other adhesive that connects the inner tray 90 to the block. As can be seen in this example the anchoring members are co-moulded with the tray. Also the anchoring members 91, 92in this example include wall section spaced inward from the tray and connected to said tray via ribs.

Claims

A prefabricated resilient member (1) for in a rail support block assembly, which assembly is adapted to be mounted embedded in or mounted on a railway substructure (25) and which assembly comprises said resilient member (1) as well as a block (10) having a top, a bottom and peripheral wall, said block being adapted for fastening one or more rails (20) on the top of said block, the prefabricated resilient member (1) being adapted to be fixed to said block so as to extend under said bottom of the block as well as around at least a lower region of the peripheral wall of the block, said prefabricated resilient member comprising an outer tray (2) and a resilient intermediate structure,
characterized in that
said prefabricated resilient member (1) has an inner tray (3) arranged within said outer tray, and in that said resilient intermediate structure (5) is arranged between said outer and inner trays (2,3).
Resilient member according to claim 1, wherein said inner and outer trays (2,3) are more rigid than the resilient intermediate structure (5).
Resilient member according to claim 1 or 2, wherein said inner and outer tray (2,3) each have a bottom and a raised peripheral wall.
Resilient member according to one or more of the preceding claims, wherein the outer and inner tray (2,3) are spaced from one another so as to have no points of contact.
Resilient member according to one or more of the preceding claims, wherein said resilient intermediate structure (5) comprises, preferably is essentially composed of, an elastomeric material, e.g. a polyurethane elastomeric material.
Resilient member according to one or more of the preceding claims, wherein said outer tray (2) has an exterior surface, said exterior surface being provided which anchoring formations to enhance the engagement of the outer tray with a concrete slab.
Resilient member according to one or more of the preceding claims, wherein said outer and inner tray (2,3) are made of a plastic material.
Resilient member according to one or more of the preceding claims, wherein said outer and inner tray (2,3) are formed from sheet material, preferably plastic sheet material.
A resilient rail support block assembly (1,10), which assembly is adapted to be mounted embedded in or mounted on a railway substructure (25) and which assembly comprises a resilient member (1) according to one or more of the preceding claims as well as a block (10) having a top, a bottom and peripheral wall, said block being adapted for fastening one or more rails on the top of said block, the prefabricated resilient member being fixed to said block so as to extend under said bottom of the block as well as around at least a lower region of the peripheral wall of the block.
A resilient rail support block assembly (1,10) according to claim 9, wherein said prefabricated resilient member (1) is fixed to said block with an adhesive (17) or mortar.
A method for manufacturing a prefabricated resilient member according to one or more of the preceding claims, comprising the manufacture of the inner and the outer trays (2,3), and arranging said intermediate resilient structure (5) between said inner and outer trays (2,3).
A method for manufacturing a resilient rail support block assembly (1,10) according to claim 9, comprising manufacturing the resilient member (1) according to one or more of the preceding claims, manufacturing the block (10), fixing said resilient member to the block.
Method according to claim 12, wherein resilient member (1) is manufactured at a first site and the block (10) is manufactured at a second, remote site, and the resilient member (1) is transported to said second site and fixed to the block at said second site.
A railway system including one or more rails fastened to a rail support block assembly according to claims 9 or 10.