EP4245917A1 - Traverse monobloc en acier et son procédé de fabrication - Google Patents

Traverse monobloc en acier et son procédé de fabrication Download PDF

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Publication number
EP4245917A1
EP4245917A1 EP22161890.3A EP22161890A EP4245917A1 EP 4245917 A1 EP4245917 A1 EP 4245917A1 EP 22161890 A EP22161890 A EP 22161890A EP 4245917 A1 EP4245917 A1 EP 4245917A1
Authority
EP
European Patent Office
Prior art keywords
sleeper
steel
hollow profile
trough body
trough
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22161890.3A
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German (de)
English (en)
Inventor
Jürgen Frenzel
Jörg Frenzel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BAUPOLY AG
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to EP22161890.3A priority Critical patent/EP4245917A1/fr
Priority to PCT/EP2023/056474 priority patent/WO2023174932A1/fr
Publication of EP4245917A1 publication Critical patent/EP4245917A1/fr
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B3/00—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails
    • E01B3/16—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from steel
    • E01B3/26—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from steel combined with inserts of wood artificial stone or other material

Definitions

  • the invention relates to railway sleepers and in particular to railway sleepers produced on the basis of a steel trough sleeper.
  • the invention further relates to a method for producing railway sleepers that are intended for use both in the main track and under switches and crossings.
  • railway sleepers are part of the track of railways, trams and/or subways and have been used in railway construction for centuries.
  • the track body usually consists of ballast, railway sleepers and rails that are mounted on the sleepers.
  • Steel trough sleepers which have been used since the 18th century, are characterized by their very long stays in the track.
  • the railway sleepers are primarily used to absorb loads from rails and to fasten them. This involves load transfer both in the vertical direction and in the transverse direction to the track.
  • the transverse load is particularly achieved by ensuring that the steel trough sleepers, which are made from a hollow profile, have bent head caps that protrude significantly beyond the profile thickness. This means that the lower edges of the bent head caps protrude beyond the longitudinal edges or profile edges of the hollow profile of the steel trough sleepers in the fastening area of the rails. When laying in the track bed, this means that there must first be appropriate grooves or recesses in the ballast to accommodate the head caps during laying.
  • the railway sleepers are used to fasten the rails and thereby guarantee a track width. It is also desirable to have the greatest possible resistance to track narrowing caused by derailments. In this point Steel trough sleepers often perform worse than, for example, railway sleepers made of wood.
  • a method for producing a track bed in which sleepers are arranged and fastened in a production site on blocks which are foamed from polyurethane and are transported in this arrangement to a track bed.
  • the polyurethane blocks with the railway sleeper or sleepers attached to them are placed and aligned and the track bed is completed by adding ballast around the polyurethane blocks. This is intended to speed up production and prevent the polyurethane blocks from being poured and foamed at the location where the track bed is formed.
  • the DE 10 2019 210 289 A1 describes a ballast-plastic composite body, comprising ballast stones, the ballast-plastic composite body having the shape of a plate, a track bed and track body, having the ballast-plastic composite body, and a method for producing the ballast-plastic composite body and method to create a track bed.
  • the present invention is based on the technical task of creating railway sleepers and a method for their production, whereby the railway sleepers achieve a long service life similar to or better than steel trough sleepers, but are easier to lay and have a high level of stability and flexibility in use as well as improved behavior in the Compared to conventional steel trough sleepers with regard to possible track narrowing in the event of derailments and load transfer behavior and have a lower tendency to corrosion and show better resonance behavior, in particular due to the avoidance of undesirable hollow layers.
  • the invention is based on the idea of creating novel sleepers based on a, preferably known and tested, steel profile, in which the hollow profile is filled at least in sections by a shaped body to fill the volume. This creates a larger contact surface in order to be able to transfer transverse forces that occur transversely to a rail direction to a track bed. Increased at the same time This means that the weight of the sleeper differs from that of the steel trough sleepers known from the prior art, which are often viewed by experts as being too light compared to various types of concrete sleepers.
  • a steel monoblock sleeper which has a steel sleeper trough body made of a hollow profile with head caps bent over at opposite ends of the steel sleeper trough body, the steel sleeper trough body at least in sections that are intended for rail fastening by means of at least one made of fully reacted reactive Material formed molded body is filled to fill the profile.
  • a corresponding preferred method for producing a steel monoblock sleeper comprises the method steps (a) providing or producing a steel sleeper trough body from a hollow profile with bent head caps at opposite ends; (b) arranging or forming at least one shaped body in at least one section of the steel sleeper trough body and connecting it to the steel sleeper trough body, so that the at least one section of the steel sleeper trough body is filled in a profile-filling manner by the at least one shaped body.
  • the steel sleeper trough body is at least partially filled with the shaped body, unintentional cavities during laying, which occur in the prior art with steel trough sleepers that are not correctly lined with gravel, are avoided. This significantly improves the resonance behavior compared to the known steel trough sleepers.
  • a shaped body is a body with a defined external shape.
  • the outer shape here is adapted to a section of a hollow profile of a steel sleeper trough body and can fill this section to fill the volume.
  • Preferred embodiments provide as a further process step: Filling reactive material into a hollow profile shape, the hollow shape of which corresponds to at least a section of the hollow profile of the steel sleeper trough body, and reacting the reactive material to form the at least one shaped body that fills the hollow profile shape.
  • An intumescent plastic is preferably chosen as the reactive material.
  • Polyurethanes are preferably suitable for this because, on the one hand, they have high strength and fast reaction kinetics and are recyclable, such as those in the application that had not yet been disclosed at the time of this application DE 10 2021 211 499 is to describe. This makes it possible to produce the shaped bodies in a short time. The shaped bodies produced can be processed and/or completed within a period of time that meets the requirements. Polyurethanes also offer high durability against environmental influences. They offer a sufficiently high level of stability and longevity.
  • ballast stones also offer a certain degree of elasticity, so that when laying in a ballast bed, edges and tips of ballast stones can engage in the lower surface and, in particular, transverse forces, i.e. forces that act transversely to the mounted rails, can be transferred well from the steel monoblock sleeper to the ballast bed can be.
  • Polyurethanes are also suitable because they combine with a wide variety of materials and coat or enclose them and form a strong, adhesive connection.
  • the at least one molding is preferably produced as a solid foam composite, preferably as a scree foam composite.
  • a grain size between 31 mm and 62 mm, as is common for track ballast, is preferably used as rubble.
  • the scree is particularly preferred as track ballast.
  • other embodiments can also use other loose solids in the form of plastic parts, plastic rods or other materials, but also other grain sizes.
  • a further development of the method therefore preferably provides that before filling or at the same time as the reactive material is filled into the hollow profile mold, the hollow profile mold is additionally filled with loose solids and the loose solids are preferably compacted by shaking. Compaction can also alternatively or additionally be effected and/or supported by evacuating the hollow profile shape.
  • the filling and reaction of the reactive material is preferably carried out in such a way that the reactive material encloses the loose solids and forms the shaped body as a composite body, the outer contour of which is adapted to at least a section of the contour of the hollow profile shape.
  • a molded body produced in this way has a high Strength and is able to transfer and transfer high loads in both vertical and horizontal planes from the rails attached to it to the track bed.
  • the reactive material is preferably filled in via injection nozzles which are located above the preferably compacted filling material consisting of loose solids.
  • the injection nozzles can be inserted into the preferably compacted, loose solid filler material and withdrawn after the reactive material has been injected. This allows the reactive material to be applied inside the hollow profile shape and a uniform distribution of the reactive material to be achieved.
  • other forms of application of the reactive material during filling are also possible.
  • reactive material can be poured or sprayed into the hollow profile shape or applied by means of a rake. It is also possible to dip the hollow profile shape into reactive material.
  • a casting time and a weight of the shot/entry must be predetermined and set.
  • the reactive material can be selected and/or adjusted, particularly if it is composed of two components, so that the reaction only begins with a time delay after introduction.
  • a liquid mixture can be applied from above into the filling material or onto the filling material, initially spreading in the filling material, i.e. in the spaces between the dissolved solids and/or wetting them, essentially due to its flow behavior and gravity, and only then fully reacting, i.e. foam and preferably completely fill the spaces between the loose solids/cavities of the filling material.
  • the amount of reactive material filled is selected in accordance with the volume of the solid bodies filled into the hollow profile mold so that when the reactive material reacts completely, the entire volume of the hollow profile mold is preferably completely filled by the hollow profile mold, at least in the section in which the at least one molded body is formed Solid body and the fully reacted reactive material, ie the foam, is filled.
  • the fully reacted reactive material ie the foam
  • no or only small gas inclusions remain in the molded body in such a way that, for example, a previously loose solid in the form of a stone cannot twist out of its compacted position.
  • the open side becomes the open side while the reactive material is fully reacted the hollow profile shape is closed with a force-loaded cover.
  • Forces in the range of 5,000 N/m 2 which can be achieved, for example, by supporting a weight of approximately 500 kg/m 2 , are generally sufficient.
  • the cover has, for example, a silicone coating on one side facing the hollow shape of the hollow profile shape, which prevents a force-fitting or cohesive connection from being formed between the cover and the reactive material.
  • Other non-stick coatings and release systems can also be used.
  • a mass of the reactive material can be changed by admixtures and fillers and the density can also be varied.
  • polyurethane foams different properties can be achieved depending on the choice and proportion of isocyanate and polyol.
  • fillers and additives can be added to it, for example barium sulfate or calcium carbonate, each in powder form.
  • the loose solid material can also be varied and selected accordingly.
  • other materials such as tapping slag or similar can also be used, as long as they have sufficient stability against pressure loads. This can reduce the CO 2 balance of the products manufactured be improved because an otherwise resulting waste product from steel production is used.
  • the shaped body can also be produced using pure concrete filling.
  • the molded body made of concrete is connected by connecting elements, for example made of iron, which are spot-welded to the steel sleeper trough body, for example, and is thus held in the trough formed by the hollow profile. Prestressing in the concrete is not necessary. Damping materials can be inserted into the concrete on the underside when wet or subsequently glued on, so that a soft layer is created that is directed towards the ballast grain structure of the packed track, which increases the transverse displacement resistance and reduces vibrations and sound emissions.
  • a major advantage of the manufactured steel monoblock sleepers compared to known steel trough sleepers is that the head edges can be designed variably, since the transverse displacement resistance is primarily defined by the shaped body.
  • the bent head caps end with longitudinal edges or profile edges of the hollow profile or at least do not protrude beyond them on one trough side of the hollow profile.
  • the end caps of the steel sleepers of the hollow profile to be formed can therefore be bent or cut to length at most so that the bent head caps end with longitudinal edges or profile edges of the hollow profile.
  • a height or thickness of the steel monoblock sleeper and the steel sleeper trough body is thus determined by the height or thickness of the hollow profile and not by the head caps. The head caps do not protrude beyond the profile edges.
  • At least one angle profile oriented transversely to a longitudinal direction of the hollow profile of the steel trough body can be welded or welded to an underside of the steel sleeper trough body.
  • the Profile extension directions of the hollow profile and the at least one angle profile are oriented transversely to one another, preferably perpendicular to one another.
  • one leg of the at least one angle profile is preferably oriented parallel to the edges of the hollow profile of the steel trough body.
  • the other leg of the angle profile is preferably oriented perpendicular to one leg and projects downwards. This makes it possible to achieve an improved ability to carry transverse forces into a ballast bed into which the other leg of the at least one angle profile protrudes.
  • the bottom of the steel sleeper trough body is the side opposite the side intended for fastening rails.
  • the at least one angle iron also projects laterally in the direction of profile extension on one or preferably both sides of the steel sleeper trough body. This increases the horizontal stability of the steel monoblock sleeper.
  • the at least one angle iron thus spans the trough of the steel trough body filled with the shaped body and is fastened to the two profile edges with one leg of the at least one angle iron. This creates a particularly stable attachment.
  • the at least one angle iron comprises two angle irons which are attached at a distance from one another to the underside of the steel trough body.
  • the spacing preferably corresponds approximately to a track width for which the steel monoblock sleepers are designed. They are therefore preferably attached opposite the fastening devices for rails.
  • Some embodiments may also include more than two angle irons.
  • the at least one angle profile can have openings or through holes at opposite ends. This can be done with a suitable length of at least one Angle profile, which is adapted to a laying distance of the steel monoblock sleepers, can be used to connect steel monoblock sleepers intended for adjacent laying or laid adjacent to one another by means of connecting plates. This allows an articulated frame to be created.
  • ribbed plates are welded onto the steel monoblock sleeper and are intended to guide and fasten the rails.
  • Rail fastening devices can be attached directly to these welded ribbed plates.
  • a ribbed plate comprises two attached strips, between which the band-shaped foot of a placed rail is positioned transversely to it in a form-fitting manner.
  • Fasteners connect the rail via the ribbed plate to the steel monoblock sleeper to form a track frame.
  • This track frame is designed to be resistant to twisting and pushing through, so that the rail cannot move in the longitudinal direction, tip over or twist.
  • the monoblock sleepers are manufactured with dowels or dowel recesses.
  • the dowels are inserted and fixed at appropriate locations in the hollow profile mold before the shaped body is formed. This fixing can take place, for example, via thorns or projections projecting into the hollow profile shape, which optionally protrude into the hollow shape of the hollow profile shape through openings that are opposite the open side.
  • a dowel receiving block also called a shortened dowel block, can be inserted into the hollow profile shape at the appropriate points before the reactive material and any additional loose solids are filled in.
  • fixation by means of fasteners protruding into the hollow shape of the hollow profile shape is advantageous.
  • a dowel receiving block preferably has one or more dowel recesses which are slightly larger in diameter than the dowel to be fitted later.
  • the hollow profile shape used for the production of the shaped body can be a shape designed separately from the steel sleeper trough body.
  • the at least one shaped body is placed directly in the hollow mold, which passes through the trough the steel sleeper trough body is formed.
  • slot-like or round openings are preferably made in the steel sleeper trough body at corresponding positions at which dowels or screw connections of track fastening devices are to be made later. These are then used to form fixing means in the form of projecting thorns and/or screw connections for sleeper screw dowels, inserts and the like during the production of the molded body.
  • Such inlaid items are called functional elements.
  • the rail fastening to the steel monoblock sleeper can be designed as a fully insulated construction. It is advisable to use a modification compared to the rail fastening of type S15 known from the prior art for Y-steel sleepers. For this purpose, openings are made in the top of the steel trough body.
  • the side that is intended for fastening rails is considered the top of the steel trough body and also the top of the steel monoblock sleeper.
  • An underside of the steel trough body is correspondingly the opposite open side into which the shaped body is or will be inserted.
  • four, preferably circular, openings are made in the top of the steel trough body.
  • four crossbars are welded onto the top to guide the rails.
  • Precise sleeper screw dowels made of plastic are pressed into these openings, preferably circular ones.
  • two of these sleeper screw dowels are connected to each other to form a pair of sleeper screw dowels.
  • the distances between two of the four openings are adapted to a "dowel distance" of the pair of sleeper screw dowels, so that a pair of sleeper screw dowels fills two of the openings when pressed in.
  • Openings can be designed as slots (e.g. 48x62 mm).
  • a sleeper screw dowel with side fastening projections is then inserted into each slot.
  • the fastening projections each have a notch into which when rotated through 90° around the longitudinal axis of the sleeper screw dowel the top of the hollow profile of the steel sleeper trough body penetrates and is clamped.
  • these sleeper screw dowels which are provided with fastening projections, are attached to the steel sleeper trough body, preferably before the shaped body is formed.
  • the openings can be drilled, punched or formed using laser cutting or drilling and/or high-pressure water cutting or drilling.
  • the sleeper screw dowels or pairs of sleeper screw dowels are preferably pressed in before the shaped body is formed, at least if it is formed in the hollow profile of the steel trough body itself.
  • the sleeper screw dowels are preferably completely enclosed by the at least one shaped body.
  • the sleeper screw dowels are prefabricated such that their length is adapted to a depth of the trough of the steel sleeper trough body. They are preferably dimensioned such that, when pressed into the openings, they are essentially flush with a plane defined by the profile edges of the hollow profile.
  • the sleeper screw dowels themselves have a through hole, which then ends in one outer surface, more precisely in the outer surface facing the underside of the steel monoblock sleeper or in the outer surface forming the underside of the steel monoblock sleeper, of the formed body. This means that any water that gets into the sleeper screw anchor(s) can drain downwards.
  • the sleeper screw dowels or sleeper screw dowel bodies of a pair of sleeper screw dowels can also be designed with a through opening.
  • Embedding the sleeper screw dowels in the molded body also offers the advantage that a damaged sleeper screw dowel can be drilled out during repairs and easily replaced with a new one.
  • a further embodiment provides that one or more cladding tubes are permanently installed in the hollow profile of the steel sleeper trough body be attached, preferably by welding or gluing/gluing, to which sleeper screw dowels are to be arranged.
  • the cladding tube is made of a material, preferably steel, which offers the possibility of permanently holding a sleeper screw anchor under dynamic load application and giving it support against pull-out.
  • a cross-sectional shape of the enclosed area of the cladding tube or cladding tubes can be selected appropriately, or different if there are several cladding tubes.
  • This cross-sectional shape can be, for example, circular, oval, polygonal, for example rectangular, in particular square, triangular, hexagonal, etc., but can also have any other shape, for example circular with one or more notches and/or protuberances.
  • the one or more steel cladding tubes are preferably designed concentrically with openings in the top of the steel sleeper trough body, which are provided for receiving the sleeper screws.
  • the openings are designed and dimensioned so that they also accommodate an upper end of a sleeper screw dowel.
  • the sleeper screw (not shown) is thus isolated from the steel sleeper trough body in the screwed-in state via the sleeper screw dowel.
  • Embodiments are preferred in which the steel cladding tube has a larger inner diameter than the opening in the top of the steel sleeper trough body for receiving the sleeper screw and/or sleeper screw dowel. This can prevent the sleeper screw dowel being pulled out, which is adapted to an inner diameter of the steel cladding tube at least in the section that is accommodated in the steel cladding tube.
  • a steel cladding tube edge facing away from the top of the steel sleeper trough body terminates with the side edges of the hollow profile of the steel sleeper trough body or at least does not protrude beyond them.
  • the shaped body or bodies enclose the steel cladding tube or tubes. These are welded or glued to the steel sleeper trough body before forming or inserting the mold body or bodies, for example using a 2-component adhesive. If the shaped body or bodies are formed in a hollow profile shape that is separate from the steel sleeper trough body, this has one or more corresponding inserts that correspond to the steel cladding tube or tubes that are welded into the steel sleeper trough body.
  • dividing profiles are welded into the trough, i.e. the hollow shape of the steel sleeper trough body, which divide the hollow shape of the steel sleeper trough body into different sections.
  • Such dividing profiles are also called separating profiles.
  • a shaped body can be formed and produced under the two end sections of the steel monoblock sleeper, which serve as fastening sections.
  • appropriately designed shaped bodies which are referred to as separating bodies, can be inserted into these sections and connected to the steel sleeper trough body.
  • a cavity remains in a central section of the trough body. This offers an advantage in that riding of the sleepers can be reduced.
  • the cavity can be used to accommodate signaling or measurement equipment and to pre-assemble them before the steel monoblock sleeper is laid. This is also a way to save filling material and weight.
  • an insert block can also be used as a separating body in order to produce the sections for forming the at least one shaped body in the trough of the steel sleeper trough body.
  • Such an insert body or separating body can be, for example, a plastic body made, for example, from polyurethane or another plastic.
  • Such an insert block or separating body can also have a recess in its middle, preferably towards the open side of the hollow shape of the steel sleeper trough body. This can also be used to avoid riding the sleepers and/or to accommodate other components such as signaling and measurement technology. This is also a way to save filling material and weight.
  • the insert block or separating body can be integrated into the molded body.
  • Several insert blocks can also be used, but not in sections intended for one Track assembly is provided.
  • the separating body can also be fastened, for example glued, into the steel sleeper trough body before the section or sections delimited and formed with it are filled.
  • a closable inspection opening can be made in the steel sleeper trough body in order to enable access from above to the cavity created between the separating profiles in the installed state.
  • adhesives are preferably used.
  • the reactive material itself can act as an adhesive and directly bond the shaped body formed in the trough of the steel sleeper trough body to the steel sleeper trough body during production.
  • this can be glued to the steel sleeper trough body in a separate step.
  • Dipping methods, spraying methods, pouring into the trough or similar methods can be used to apply the adhesive.
  • Phenoplasts PF plastics, especially PF resins
  • UF resin urea-based resins
  • isocyanates as well as epoxy or urethanes and polyurea are used as adhesives.
  • a surface treatment can be provided, which can include, for example, sandblasting and, if necessary, additional cleaning and degreasing.
  • the steel sleeper trough body is filled by the at least one shaped body on the trough side, there is no accumulation of condensate in the trough in the installed state in the area of the at least one shaped body, which comes from the Gravel bed created by rising moisture instead.
  • a partial or complete coating of the steel sleeper trough body can be carried out to improve the corrosion resistance.
  • the trough side of the steel sleeper trough body is particularly preferably coated/treated.
  • Polyurethanes are again preferably suitable as coatings, as they have a short reaction time, high strength and optimal sealing. These do not tend to become brittle and are temperature-resistant in wide temperature ranges, for example -50° C to 120° C. They also have acid resistance and resistance to a number of other chemicals. In addition, there is no leaching or leakage of environmentally hazardous substances. Polyurea coatings are also UV-resistant and have a sound-absorbing effect. If necessary, they can also be made fire-resistant using flame-retardant additives.
  • a coating of the steel sleeper trough body can also be carried out in such a way that labels or markings due to added dyes are also visible.
  • the coating can be printed in order, for example, to apply escape route markings or the like to the monoblock sleepers during production.
  • the coating is preferably non-slip.
  • the coating can also be used to incorporate into the coating itself a foil made of metal or a metal alloy, in particular a foil made of aluminum or an aluminum alloy, a so-called neutrino or ntrino foil as in the WO 2016/142056 A1 describe, embed, in order to generate energy on site and to use it at least for signaling or measurement devices embedded in the sleeper, possibly in the cavities themselves, or - if there is excess - to feed it into the track network.
  • This coating can also be used to embed in these metamaterials and thus achieve further frequency reductions of the natural vibrations and reduce the propagation of structure-borne and/or airborne sound. Metamaterials are man-made materials that have properties found in naturally occurring materials and Materials do not occur.
  • three-dimensional phononic crystals with a very large band gap can be used, such as those from L. D'Alessandro et al. in the article "Modeling and experimental verification of an ultra-wide bandgap in 3D phononic crystal” in Applied Physics Letters 109, 221907 (2016 ) are described.
  • This coating can also consist of two-dimensional polymer layers in order to achieve the greatest possible protection for the films underneath.
  • a two-dimensional polymer layer is characterized by the fact that the polymer bonds are each or at least essentially only formed in a two-dimensional plane.
  • Fully coated steel sleeper trough bodies are particularly suitable for installation locations with high levels of moisture, such as those found in tunnels.
  • a suitable coating material is, for example, the polyurea system, Polyresyst ® S6020-90W, which is sold by Huntsman at the Internet address https://www.huntsman.com/contact/polyurethanes/customer-service.
  • This system consists of a resin mixture formed from amines and isocyanates as hardeners.
  • the fully reacted material preferably has a hardness of 45 Shore D according to DIN53505, a tensile modulus of 24.2 MPa according to DIN53504, an extensibility of 390% according to DIN53504 and a tensile strength of 73.9 N/mm according to DIN53505.
  • the DIN standards refer to the version valid or current at the time of registration.
  • the molded body can be produced in such a way that the hollow profile mold is open at the top and the reactive material and, if necessary, the loose solids or inserted dowels, dowel blocks or separating bodies are inserted or introduced through the open side of the hollow mold.
  • the hollow profile shape for example the steel sleeper trough body, into a layer consisting of loose solids and to fill the trough, ie the hollow profile shape, so to speak from below.
  • the reactive plastic material can be injected via nozzles and the reactive material can preferably be fully reacted while the hollow profile shape is being loaded from above.
  • the reactive material is preferably introduced and reacted in such a way that the reaction takes place from the hollow profile forming the trough to the "open" side, usually closed with the cover.
  • the shaped body is preferably formed in such a way that the at least one shaped body arranged in the hollow profile of the steel trough body has a side surface that terminates with the longitudinal edges of the steel sleeper trough body. This ensures that a constant height is maintained for the steel monoblock sleepers and that they can be laid on any surface and different track bed constructions.
  • FIG. 1 A top view of a steel monoblock sleeper 1 is shown schematically. From the top, a steel sleeper trough body 100 made from a steel profile and its top 110 can be seen. The steel sleeper trough body 100 formed from a hollow profile 130 is bent at opposite ends 150. The bent ends are referred to as head caps 160. The steel sleeper trough body 100 forms a trough that is open at the bottom, in which an in Fig. 1 Shaped body that cannot be recognized is arranged to fill the profile at least in sections and is connected to the steel sleeper trough body 100.
  • Fig. 2 is a cross section 140 along a line AA (compare Fig. 1 ) represented by the steel monoblock sleeper 1.
  • the same technical features are marked with the same reference numbers in all figures.
  • the hollow profile 130 of the steel sleeper trough body 100 can be seen as well as the profile of the shaped body 400 fitted therein, which completely fills at least the section whose cross section is shown, the hollow profile 130 of the steel sleeper trough body 100.
  • Fig. 3 is a schematic side and partial longitudinal section view of a steel sleeper trough body 100 of the steel monoblock sleeper 1 Fig. 1 shown. It can be seen that the head caps 160 of the hollow profile 130 are bent so that head cap edges 165 terminate with profile edges 170 of the hollow profile 130, from which the steel sleeper trough body 100 is formed.
  • Rib plates 250 are schematically shown welded onto the top 110 and are intended for guiding and fastening rails. In the schematic representation, no fasteners for fastening the rails are shown here.
  • the steel sleeper trough body 100 represents a hollow profile shape 1000, which is open on an underside 120.
  • the hollow profile shape 1000 is thus formed by the trough formed by the steel sleeper trough body 100.
  • Inside this trough can be divided into sections 180 by welded-in separating profiles 200, which are also referred to as ribs. To indicate that these are optional, the separation profile is 200 in Fig. 3 shown in dashed lines.
  • Another separating profile is usually welded symmetrically to a central axis 105 in the part of the steel sleeper trough body 100 that is not shown.
  • the steel sleeper trough body 100 is thus divided into two fastening sections 190, in which the fastening of a rail is provided, and a middle section 195.
  • a longitudinal cross section through an embodiment of a steel monoblock sleeper 1 is shown schematically.
  • the trough formed by the steel sleeper trough body 100 is filled over the entire length by the shaped body 400 in the illustrated embodiment, the shaped body 400 showing a depression 470 in a central section 195 on an underside 420.
  • this recess 470 on the one hand, signaling or measurement devices can be accommodated and, on the other hand, the resulting free space serves to prevent the steel monoblock sleeper 1 from riding.
  • the shaped body 400 comprises a fully reacted reactive material 700.
  • This is preferably a polyurethane.
  • the shaped body 400 is a composite body which consists of loose solids 600, particularly preferably rubble 610 and most preferably track ballast 620. This is foamed by the reactive material 700 and is particularly preferably directly connected to the steel sleeper trough body 100 in a non-positive manner.
  • the molded body 400 can, as in Fig. 4 is indicated, one or more sleeper screw dowels 510 and/or a dowel block 520 may already be integrated. Sleeper screw dowels 510 are made of plastic and/or fiberglass concrete, for example.
  • a prefabricated separating body 540 is integrated into a central section, which separates the fastening sections 480 from a central section 490 and has the recess 470 of the shaped body 400 formed.
  • the molded body 400 as a whole is a composite body including the inserted or inserted components, such as the separating body 470, the sleeper screw dowel 510 or the dowel block 520.
  • the fastening sections 490 are inserted into the molded body, preferably before the reactive material has fully reacted into the hollow profile shape formed, for example, by the steel sleeper trough body, in which the shaped body 400 was formed, loose solid bodies 600 are filled, which are compacted, for example, by shaking. The spaces are then with the reactive material 700, which is foamed when it reacts, has been filled and thus surrounded by the reactive material.
  • the steel sleeper trough body 100 is thus filled from an inside by the shaped body 400.
  • separating profiles 200 are welded into the trough formed by the steel sleeper trough body 100, which separate the fastening sections 190 from the middle section 195.
  • Shaped bodies 400, 400' are formed in the fastening sections 190, which are preferably formed from rubble 610 and this foaming, fully reacted reactive material 700 in the form of, for example, polyurethane.
  • the reactive material 700 By adding barium sulfate or calcium carbonate to the reactive material 700, its mass and thereby its sound and damping properties can be influenced. Likewise, the mass of the at least one shaped body or, in which in the Fig. 5 illustrated embodiment of the two molded bodies can be influenced.
  • FIG. 6 is a schematic sectional view of a fastening section 190 of a steel monoblock sleeper 1 shown enlarged in longitudinal section.
  • rib plates 250 are welded onto the top 110 and are intended to guide a rail 2000, which is not part of the steel monoblock sleeper 1.
  • Openings 111, 112 are formed in the top 110, under which dowel openings 525 with dowels 510 of a dowel block 520 arranged therein are formed.
  • the dowel block 520 is surrounded by compacted track ballast with a grain size of 31-61 mm, ie a usual grain size for track ballast 620, which is foamed in a polyurethane foam in the compacted state.
  • the end section 180 which is a fastening section 190, is completely filled by the shaped body 400.
  • the end section is delimited on one side by the head cap 160 and on the opposite side by the separating profile 200.
  • a steel monoblock sleeper 1 is explained schematically using an example.
  • the shaped body 400 is initially formed separately from the steel sleeper trough 100 and the two are then connected to one another by gluing.
  • a hollow profile shape 1000 is shown schematically, the hollow shape of which corresponds to the hollow profile of the steel sleeper trough body 100.
  • Fixing means 1010, 1020 designed as fixing pins protrude into the hollow mold.
  • injection nozzles 1100 for the reactive material protrude into the hollow mold through closable openings 1050 of the hollow profile mold 1000.
  • a sleeper screw dowel 510 As in Fig. 7b is shown, objects inserted into the fastening means 1010, 1020, such as a sleeper screw dowel 510, a dowel block 520, and/or, in other embodiments, a separating body 540, are fastened.
  • the remaining cavity is filled with loose solids 600, preferably with rubble 610, particularly preferably with track ballast 620.
  • These solid bodies 600 are compacted, for example by shaking, which is shown schematically by double arrows to indicate a shaking device 1200.
  • Fig. 7d is shown that the open side of the hollow profile mold 1000 is closed via a cover 1300, which preferably has a non-stick layer 1320 on an underside, which is applied to an elastic layer 1310.
  • the cover 1300 is pressed against the steel profile shape so that it remains closed even when the reactive material expands.
  • the cover is pressed against the hollow profile shape using a pressing device 1370, which is shown schematically as a weight.
  • Reactive material 700 is now injected into the spaces between the compacted track ballast 620 via the injection nozzles 1100.
  • the injectors 1100 are retracted and the closures 1060 of the closable openings 1050 are closed, as shown in Fig. 7e is shown schematically.
  • the reactive material 700 reacts, it expands and forms together with the compacted loose solids 600, here the track ballast 620, and the inserted elements form the shaped body 400 as a composite body, which is in Fig. 7f is shown schematically.
  • a hollow profile 13 made of steel is bent at opposite ends 150 in order to form head caps 160 ( Fig.7g ).
  • head caps 160 Fig.7g
  • the steel sleeper trough body 100 is formed.
  • ribbed plates 250 are welded onto the steel sleeper trough body for later guiding of rails.
  • openings are punched and/or drilled into the steel sleeper trough body 100.
  • the steel sleeper trough body 100 is then coated on an inside or underside 120 in the trough and/or on an outside, ie the top 110 ( Fig. 7h ).
  • a polyurea coating 800 is preferably carried out via coating nozzles 1400.
  • the top 110 can also be printed and provided with graphic markings. In this case, a printing device 1420 is used.
  • an adhesive 850 is applied to the inside of the steel sleeper trough body and/or an outside of the shaped body 400 ( Fig. 7i ) and the shaped body 400 inserted into the trough of the steel sleeper trough body 100 and non-positively connected to it to form the steel monoblock sleeper 1.
  • the steel monoblock sleeper 1 is in Fig. 7j is shown schematically.
  • a hollow profile shape 1000 is used, which is formed separately from the steel sleeper trough body 100.
  • the at least one shaped body or optionally the several shaped bodies that fill the trough of the steel sleeper trough body 100 or sections 180 of the steel sleeper trough body 100 are manufactured in the steel sleeper trough body 100 itself.
  • Fig. 8a-8h Such an embodiment is in Fig. 8a-8h shown as an example.
  • the steel sleeper trough body 100 is made again from a hollow profile 130 made of steel, Fig. 8a .
  • separating profiles are welded into the trough of the steel sleeper trough body.
  • openings 111, 112 are made in the steel sleeper trough body 100 ( Fig. 8b ), through which inserted sleeper screw dowels 510 or dowel blocks 520 can be fixed in the trough ( Fig.8d ).
  • the steel sleeper trough body 100 is coated on the open trough side and / or the top 110 (bottom in the figure) with a coating 800 before inserting inserts such as sleeper screw dowels 510 or a dowel block 520 etc. ( Fig. 8c ).
  • Injection nozzles 1100 for the reactive material are inserted into the hollow mold or the open trough ( Fig. 8d ).
  • the remaining cavity is then filled with rubble 610, for example track ballast 620 made of basalt, and compacted using vibration ( Fig. 8e ). In the embodiment shown, this only occurs in the fastening sections 190 in which shaped bodies are formed.
  • the trough of the steel sleeper trough body is then closed and sealed with a cover 1300, which is pressed onto the opening of the hollow profile shape 1000 formed by the steel sleeper trough body 100 using a contact pressure from a pressing device 1370.
  • the cover 1300 has closable openings 1350 through which the injection nozzles 1100 protrude.
  • the reactive material 700 is preferably selected so that, on the one hand, it foams and encloses the loose solid bodies 600, preferably selected as track ballast 620, and at the same time forms a non-positive connection with the steel sleeper trough body 100, so that the two formed bodies 400, 400 'close with the steel sleeper trough body 100 the steel monoblock sleeper 1 are connected.
  • the finished steel monoblock sleeper 1, turned into a laying orientation, is in Fig. 8h shown schematically.
  • the hollow profile shape is opened upwards.
  • the hollow trough of the steel sleeper trough body can also be pressed into a layer of loose solids, for example track ballast, and then reactive material can be injected into the interior of the trough of the steel sleeper trough body, including in the track.
  • a suitable shaped body is also formed in this way.
  • the steel sleeper trough body is subjected to force from the top during the reaction in order not to impair the compaction of the rubble inside the trough and to prevent the hollow profile shape formed by the steel sleeper trough body from lifting.
  • a schematic top view of a steel monoblock sleeper 1 with laterally projecting angle profiles 900 is shown.
  • Fig. 10 is a corresponding side view and in Fig. 11 a schematic cross-sectional view is shown.
  • Two angle profiles 900 are welded from below to the steel sleeper trough body 100, each of which protrudes laterally on both sides 105, 106 of the steel sleeper trough body 100.
  • the profile direction 905 of the angle profile 900 is oriented perpendicular to the profile direction 135 of the hollow profile 130 of the steel sleeper trough body 100.
  • One leg 910 of the angle profile 900 is oriented parallel to the profile edges 170 of the hollow profile 130 of the steel sleeper trough body 100 and rests with its top side 911 on the profile edges 170.
  • the angle profile 900 is welded to these profile edges 170.
  • the angle profiles 900 are preferably arranged opposite the fastening points for rails 2000.
  • Another leg 920 of the angle profile 900 which is preferably oriented perpendicular to the one leg 910, projects downward from the underside 120 of the steel sleeper trough body 100.
  • the angle profiles 900 improve the horizontal stability of the steel monoblock sleeper 1. Furthermore, transverse forces can be better transferred to a ballast bed into which the other legs 920 protrude when installed.
  • the angle profiles 900 can have openings 921 at one end 901 and at the other end 902 in the other leg 902 and / or in one leg 910 and by means of connecting plates 930 and connecting screws 935 can be connected to the angle profile 900 of an adjacent steel monoblock sleeper 1 to form an articulated frame.
  • Fig. 13 1 shows a schematic partial cross section of a steel monoblock sleeper 1 with a sleeper screw dowel 510, which has a round body 511 with fastening projections 512 projecting on opposite sides.
  • An extent 513 in the plane of the drawing is larger than perpendicular to it.
  • Such a sleeper screw dowel 510 is inserted into a slot-like opening 111 on the top of the steel sleeper trough body 100.
  • the extension of the slot-like opening 111 is longer perpendicular to the plane of the drawing than in the plane of the drawing.
  • the sleeper screw dowel 510 is inserted or pressed in a position rotated by 90 ° about a central axis 514 relative to the position shown and then brought into the position shown by 90 °.
  • a notch 516 formed between a clamping collar 515 and the fastening projections 512 a wall 113 of the steel sleeper trough body 100 is clamped on its top 110 and the sleeper screw dowel 510 is fastened to the steel sleeper trough body.
  • the sleeper screw dowel 510 preferably has a through hole 517. This preferably ends on the underside 420 of the shaped body 400 which surrounds the sleeper screw dowel 510 and is preferably formed around it. the sleeper screw dowel 510 is integrated into the shaped body 400. Nevertheless, water that penetrates into the sleeper screw anchor can drain down through the through hole 517.
  • Fig. 14 shows a schematic drawing of a section of a steel monoblock sleeper with a pair of sleeper screw dowels 560.
  • a pair of sleeper screw dowels 560 has two sleeper screw dowel bodies 561 which are connected to one another via a web 568 and on each of which fastening projections 562 are preferably formed.
  • the sleeper screw dowel bodies 561 each have a preferably circumferential clamping collar 565.
  • a preferably circumferential notch 566 is formed in the sleeper screw dowel body, in which the top 110 of the steel trough body 100 is formed Steel monoblock sleeper 1 is received when the sleeper screw dowel bodies 561 are pressed into preferably circular openings 111, 112 of the steel trough body 100.
  • a length 563 of the sleeper screw dowel bodies 561 is adapted to a height of the steel trough body 100 and the molded body 400, so that a through hole 567 ends around the central axis 564 of each sleeper screw dowel body 561 at the bottom 420 of the molded body 400.
  • Fig. 15 shows a partial sectional side view of the steel monoblock sleeper 1 Fig 14 .
  • Fig. 16 shows a schematic enlarged sectional view of part of a pressed-in sleeper screw dowel body of a pair of sleeper screw dowels.
  • Fig. 17 shows a schematic sectional view of a sleeper screw dowel body 561 of a sleeper screw dowel pair 560 at the level of a notch 566 for receiving the top 110 of a steel sleeper trough body 1.
  • a circumferential jagged notch edge 569 can be seen, the teeth of which act as an elastic clamping element in the radial direction when the top 110 of the steel sleeper trough body is received in the notch.
  • Fig. 18 a schematic partial sectional view of a top side of a steel sleeper trough body 100 is shown, to which a steel cladding tube 210 with a sleeper screw dowel 510 received therein is welded.
  • the steel cladding tube 210 is arranged concentrically with an opening 111 in the top 110.
  • An inner diameter 215 of the steel cladding tube 210 and an inner diameter 115 of the opening 111 for receiving the sleeper screw (not shown) are essentially identical in this embodiment.
  • the opening 111 it is also possible to design the opening 111 so that it corresponds to an outer diameter of the steel cladding tube 210.
  • the steel cladding tube 210 can be welded to the top 110 from above.
  • the screw sleeper dowel 510 has a circumferential projection 517, which protects the sleeper screw dowel 510 from being “pressed through” when the steel cladding tube 210 protrudes through the shaped body 400 or is flush with its underside 420
  • a further schematic partial sectional view of a top 110 of a steel sleeper trough body 100 is shown, to which a steel cladding tube 210 with a sleeper screw dowel 510 accommodated therein is welded, which, however, is secured against being pulled out upwards.
  • an inner diameter 115 of the opening 111 in the top 110 of the steel sleeper trough body 100 is smaller than the inner diameter 215 of the steel cladding tube 210.
  • the sleeper screw dowel 510 has a notch 516 and a clamping collar 515. The clamping collar 515 prevents, like the circumferential projection 517 in the embodiment Fig. 18 a “pushing through” of the sleeper screw dowel 510 downwards out of the steel cladding tube 210.
  • a weld seam 220 can be closed all around or in sections all around.
  • the sleeper screw dowel preferably has a through hole 567 so that liquids penetrating from above or forming inside can drain downwards.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Railway Tracks (AREA)
EP22161890.3A 2022-03-14 2022-03-14 Traverse monobloc en acier et son procédé de fabrication Pending EP4245917A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP22161890.3A EP4245917A1 (fr) 2022-03-14 2022-03-14 Traverse monobloc en acier et son procédé de fabrication
PCT/EP2023/056474 WO2023174932A1 (fr) 2022-03-14 2023-03-14 Traverse monobloc en acier et son procédé de production

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP22161890.3A EP4245917A1 (fr) 2022-03-14 2022-03-14 Traverse monobloc en acier et son procédé de fabrication

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4984804U (fr) * 1972-11-11 1974-07-23
DE2636853A1 (de) * 1975-08-18 1977-03-03 Dow Chemical Co Eisenbahnquerschwelle
JP2945366B1 (ja) * 1998-03-12 1999-09-06 光亜建設株式会社 枕 木
JP2007120044A (ja) * 2005-10-26 2007-05-17 Sekisui Chem Co Ltd まくら木
WO2016142056A1 (fr) 2015-03-06 2016-09-15 Neutrino Deutschland Gmbh Feuille en métal ou constituée d'un alliage métallique
CN107313313A (zh) 2017-05-25 2017-11-03 中国铁道科学研究院铁道建筑研究所 预制聚氨酯固化道床的排架施工方法
DE102019210289A1 (de) 2019-07-11 2021-01-14 Hyperion Verwaltung Gmbh Schotter-Kunststoff-Verbundkörper

Family Cites Families (1)

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Publication number Priority date Publication date Assignee Title
DE102021211499A1 (de) 2021-10-12 2023-04-13 Hyperion Verwaltung Gmbh Verfahren und Vorrichtung zum Recyceln von Polyurethan-Schotter-Verbünden

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4984804U (fr) * 1972-11-11 1974-07-23
DE2636853A1 (de) * 1975-08-18 1977-03-03 Dow Chemical Co Eisenbahnquerschwelle
JP2945366B1 (ja) * 1998-03-12 1999-09-06 光亜建設株式会社 枕 木
JP2007120044A (ja) * 2005-10-26 2007-05-17 Sekisui Chem Co Ltd まくら木
WO2016142056A1 (fr) 2015-03-06 2016-09-15 Neutrino Deutschland Gmbh Feuille en métal ou constituée d'un alliage métallique
CN107313313A (zh) 2017-05-25 2017-11-03 中国铁道科学研究院铁道建筑研究所 预制聚氨酯固化道床的排架施工方法
DE102019210289A1 (de) 2019-07-11 2021-01-14 Hyperion Verwaltung Gmbh Schotter-Kunststoff-Verbundkörper

Non-Patent Citations (1)

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Title
L. D'ALESSANDRO ET AL.: "Modeling and experimental verification of an ultra-wide bandgap in 3D phononic crystal", APPLIED PHYSICS LETTERS, vol. 109, 2016, pages 221907, XP012214093, DOI: 10.1063/1.4971290

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