US20240167231A1

US20240167231A1 - Rail Brace Assembly

Info

Publication number: US20240167231A1
Application number: US18/510,368
Authority: US
Inventors: Steven D. Singleton; Evan G. Eaton; Donald A. Bielski; Brandon M. Airgood
Original assignee: Koppers Industries of Delaware Inc
Current assignee: Koppers Industries of Delaware Inc
Priority date: 2022-11-21
Filing date: 2023-11-15
Publication date: 2024-05-23
Also published as: MX2023013841A; CA3220113A1

Abstract

A rail brace assembly for first and second rails includes a first support having an electrically insulating material configured to be engaged with a first side of base portions of the first rail and the second rail, with the first support defining a plurality of openings, a second support having an electrically insulating material configured to be engage with a second side of the base portions of the first rail and the second rail, with the second support defining a plurality of openings, a first base member having an electrically insulating material configured to be engaged with a bottom surface of the base portions of the first rail and the second rail, and a plurality of fasteners each configured to extend through one of the plurality of openings of the first support and the second support.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Application Ser. No. 63/426,940, filed Nov. 21, 2022, and U.S. Provisional Application Ser. No. 63/441,467, filed Jan. 27, 2023, the disclosures of which are hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates to a rail brace assembly.

Description of Related Art

A rail system is generally divided into sections or blocks for detecting trains, which permit more trains to travel on one stretch of track or railroad rails. Each section is electrically isolated from all other sections so that when no train is present, a high electrical resistance can be measured over the parallel railroad rails in that section. When a train enters the section, the train short circuits adjacent railroad rails and the electrical resistance drops, thus indicating that a train is in that section.
Railroad tracks are created generally by welding railroad rails to each other or by attaching railroad rails to each other using metal bars and bolts. High-performance, non-metallic joints are typically used for electrically-isolating adjacent rail sections of a rail system in order to create an electrically-isolated section. However, the non-metallic joints are very expensive due to the special high-performance material needed to endure the high tensile and flexural forces exerted on a rail joint as the wheels of a locomotive or rail car pass over the joint. An alternative to a non-metallic joint is a steel rail joint having electrically-insulating material, such as resin and/or composite material affixed to the rail joint surface for isolating rail sections. Standard or insulated rail joints may be positioned at an unsupported or suspended portion of the track, which increases the stress and forces on the rail joint and can lead to premature failure of the rail joint.

SUMMARY OF THE INVENTION

In one aspect or embodiment, a rail brace assembly for first and second rails each having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, includes a first support having an electrically insulating material configured to be engaged with a first side of the base portions of the first rail and the second rail, with the first support defining a plurality of openings, a second support having an electrically insulating material configured to be engaged with a second side of the base portions of the first rail and the second rail, with the second support defining a plurality of openings, a first base member having an electrically insulating material configured to be engaged with a bottom surface of the base portions of the first rail and the second rail, and a plurality of fasteners each configured to extend through one of the plurality of openings of the first support and the second support.
The rail brace assembly may further include a second base member configured to abut the first base member and extend between the first support and the second support. The second base member may be a metal plate.
The first support and the second support may each be a rail joint bar. The first support and the second support may each be a polyurethane encapsulated rail joint bar. The plurality of fasteners may each be a bolt and a nut.
The rail base assembly may further include a first washer plate configured to be engaged with the first support and a second washer plate configured to be engaged with the second support, where the first and second supports and the first and second washer plates are configured to be positioned between the nut and a head of the bolt. The first base member may include a body defining a plurality of openings configured to be aligned with the plurality of openings of the first and second supports.
In a further aspect or embodiment, a rail joint assembly includes a first rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, a second rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, a first rail joint bar attached to a first side of the first and second rails, a second rail joint bar attached to a second side of the first and second rails, and a rail brace assembly. The rail brace assembly includes a first support having an electrically insulating material engaged with a first side of the base portions of the first rail and the second rail, with the first support defining a plurality of openings, a second support having an electrically insulating material engaged with a second side of the base portions of the first rail and the second rail, with the second support defining a plurality of openings, a first base member having an electrically insulating material engaged with a bottom surface of the base portions of the first rail and the second rail, and a plurality of fasteners each extending through one of the plurality of openings of the first support and the second support.
In a further aspect or embodiment, a rail brace assembly for first and second rails each having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, includes a base plate defining a plurality of openings, a plurality of clips, with each of the plurality of clips having an electrically-insulating material configured to engage the base portion of the first rail or second rail, and with each of the plurality of clips defining an opening configured to be aligned with one of the plurality of openings of the base plate, and a plurality of fasteners configured to extend through respective openings of the plurality of clips and the plurality of openings of the base to secure the clips and the base plate to the first and second rails.
The base plate may be metal. The rail brace assembly may further include a plurality of washer plates configured to be positioned on a top surface of each of the plurality of clips, where the plurality of fasteners each include a bolt with a head and a nut. Each of the plurality of washer plates, each of the plurality of clips, and the base plate are positioned between the head of the bolt and the nut when the rail brace assembly is attached to the first and second rails. The rail brace assembly may further include an insulator plate configured to be positioned between the base portions of the first and second rails and the base plate.
In a further aspect or embodiment, a rail joint assembly includes a first rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, a second rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, a first rail joint bar attached to a first side of the first and second rails, a second rail joint bar attached to a second side of the first and second rails, and a rail brace assembly. The rail brace assembly includes a base plate positioned below the base portions of the first and second rails, with the base plate defining a first opening and a second opening, a first clip having an electrically-insulating material engaged with the base portion of the first rail or second rail at the first side of the first and second rails, with the first clip defining an opening, a second clip having an electrically-insulating material engaged with the base portion of the first rail or second rail at the second side of the first and second rails, with the second clip defining an opening, a first fastener extending through the opening of the first clip and the first opening of the base plate to secure the first clip and the base plate to the first and second rail, and a second fastener extending through the opening of the second clip and the second opening of the base plate to secure the second clip and the base plate to the first and second rails.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a rail brace assembly according to one aspect or embodiment of the present application;

FIG. 2 is a side view of a rail brace assembly according to a further aspect or embodiment of the present application;

FIG. 3 is a side view of a rail brace assembly according to a further aspect or embodiment of the present application;

FIG. 4 is a partial cross-sectional view of a rail brace assembly according to one aspect or embodiment of the present application;

FIG. 5 is a partial cross-sectional view of a rail brace assembly according to one aspect or embodiment of the present application;

FIG. 6 is a perspective view of a rail brace assembly according to a further aspect or embodiment of the present application;

FIG. 7 is an exploded perspective view of the rail brace assembly of FIG. 6 ;

FIG. 8 is a front view of the rail brace assembly of FIG. 6 ;

FIG. 9 is a side view of the rail brace assembly of FIG. 6 ;

FIG. 10 is a partial cross-sectional view of the rail brace assembly of FIG. 6 ; and

FIG. 11 is a partial cross-sectional view of the rail brace assembly of FIG. 6 , showing the rail brace assembly with a different rail profile.

DESCRIPTION OF THE INVENTION

For purposes of the description hereinafter, the words “upward” and “downward”, and spatial terms, if used, shall relate to the described embodiments as oriented in the drawing figures. However, it is to be understood that many alternative variations and embodiments may be assumed except where expressly specified to the contrary. It is also to be understood that the specific devices and embodiments illustrated in the accompanying drawings and described herein are simply exemplary embodiments of the invention.
Referring to FIGS. 1-5 , a rail brace assembly 10 according to aspects or embodiments of the present application are shown. The rail brace assembly 10 is configured to reinforce or further support a rail joint positioned at an unsupported or suspended portion of the track. The rail brace assembly 10 is configured to support the rail joint to prevent excess force on the rail joint and to maintain alignment in the case of a mechanical rail joint failure.
Referring again to FIGS. 1-5 , in one aspect or embodiment, a rail joint assembly 12 includes a first rail 14 having a head portion 22, a web portion 24 extending from the head portion 22, and a base portion 26 extending from the web portion 24, a second rail 16 having a head portion 22, a web portion 24 extending from the head portion 22, and a base portion 26 extending from the web portion 24, with a longitudinal axis of the first rail 14 aligned with a longitudinal axis of the second rail 16, a first rail joint bar 18 attached to a first side of the first and second rails 14, 16, a second rail joint bar 20 attached to a second side of the first and second rails 14, 16, and the rail brace assembly 10.
The rail brace assembly 10 includes a base plate 50 positioned below the base portions 26 of the first and second rails 14, 16, with the base plate 50 defining a first opening and a second opening, a first clip 52 having an electrically-insulating material engaged with the base portion 26 of the first rail 14 or second rail 16 at the first side of the first and second rails 14, 16, with the first clip 52 defining an opening, a second clip 54 having an electrically-insulating material engaged with the base portion 26 of the first rail 14 or second rail 16 at the second side of the first and second rails 14, 16, with the second clip 54 defining an opening, a first fastener 56 extending through the opening of the first clip 52 and the first opening of the base plate 50 to secure the first clip 52 and the base plate 50 to the first and second rails 14, 16, and a second fastener 58 extending through the opening of the second clip 54 and the second opening of the base plate 50 to secure the second clip 54 and the base plate 50 to the first and second rails 14, 16. The clips 52, 54 may be formed entirely from an electrically-insulating material, such as fiberglass. In some aspects or embodiments, the clips 52, 54 are formed from a metal core encapsulated by the electrically-insulating material, such as plastic or an elastomeric material. The base plate 50 may be formed from steel and the rail brace assembly 10 may include an insulating plate 60, such as a fiberglass plate, positioned between the base portions 26 of the rails 14, 16 and the base plate 50.
Referring to FIG. 1 , in one aspect or embodiment, the first clip 52 and the first fastener 56 includes a plurality of clips and fasteners, and the second clip 54 and the second fastener 58 includes a plurality of clips and fasteners.
Referring to FIG. 2 , in one aspect or embodiment, the first and second clips 52, 54 may each extend the length of an unsupported portion of the first and second rails 14, 16. The first and second clips 52, 54 each have a length close to the length of the base plate, such as 90-100% of the length of the base plate. In some aspects or embodiments, the base plate 50 is 12-15 inches long and may be 14 inches long.
Referring to FIG. 3 , in one aspect or embodiment, the base plate 50 and the first and second clips 52, 54 do not extend the full or close to the full unsupported length of the rail joint 12. The base plate 50 may be 5-8 inches and the first and second clips 52, 54 may be 4-7 inches. In one aspect or embodiment, the base plate 50 is 6.75 inches and the first and second clips 52, 54 are 5.75 inches.
The rail brace assembly 10 may be utilized in connection with various rail profiles, with the rail brace assembly 10 configured to provide clearance with various types of existing rail joints. The rail brace assembly 10 may be utilized in connection with an existing bonded 136 RE type joint with a lug and toe (FIG. 4 ) or an existing bonded 115 RE type joint that is toeless (FIG. 5 ).
Referring again to FIGS. 1-5 , in some aspects or embodiments, a first washer plate 62 is positioned on a top surface of the first clip 52 and a second washer plate 64 is positioned on a top surface of the second clip 54, with the first and second fasteners 56, 58 each including a bolt with a head and a nut. The first washer plate 62, the first clip 52, and the base plate 50 is positioned between the head of the bolt and the nut of the first fastener 56, and the second washer plate 64, the second clip 54, and the base plate 50 are positioned between the head of the bolt and the nut of the second fastener 58. The first and second washer plates 62, 64 may be formed from steel.
Referring to FIGS. 6-11 , a rail brace assembly 100 according to a further aspect or embodiment is shown in use with the first and second rails 14, 16. In a similar manner as the rail brace assembly 10 discussed above, the rail brace assembly 100 is configured to reinforce or further support a rail joint positioned at an unsupported or suspended portion of the track to prevent excess force on the rail joint and to maintain alignment in the case of a mechanical rail joint failure.
The rail brace assembly 100 includes a first support 102 having an electrically insulating material configured to be engaged with a first side of the base portions 26 of the first rail 14 and the second rail 16, and a second support 104 having an electrically insulating material configured to be engaged with a second side of the base portions 26 of the first rail 14 and the second rail 16. The first support 102 and the second support 104 each define a plurality of openings 106, 108. The rail brace assembly 100 also includes a first base member 110 having an electrically insulating material configured to be engaged with a bottom surface of the base portions 26 of the first rail 14 and the second rail 16 and a plurality of fasteners 112 each configured to extend through one of the plurality of openings 106, 108 of the first support 102 and the second support 104.
In some aspects or embodiments, the rail brace assembly 100 includes a second base member configured to abut the first base member 110 and extend between the first support 102 and the second support 104. The second base member 114 is a metal plate, although other suitable materials and configurations may be utilized.
In some aspects or embodiments, the first support 102 and the second support 104 are each a rail joint bar. The first and second supports 102, 104 may be polyurethane encapsulated rail joint bars having a metal core fully encapsulated with polyurethane. In other aspects or embodiments, the first and second supports 102, 104 may be fiberglass rail joint bars. A head portion 116 of the first and second supports 102, 104 is configured to engage the base portion of the rails 14, 18 and a toc portion 118 of the first and second supports 102, 104 is configured to engage the second base member 114. A recessed area 120 is defined between the head portion 116 and the toc portion 118 of the first and second supports 102, 104, with the recessed area 120 receiving a portion of the first and second rails 14, 18 and the second base member 114.
In some aspect or embodiments, the first base member 110 includes a body 122 defining a plurality of openings 124 configured to be aligned with the plurality of openings 106, 108 of the first and second supports 102, 104. The first base member 110 may be a fiberglass block, although other suitable materials and configurations may be utilized.
Referring again to FIGS. 6-11 , the rail brace assembly 100 is utilized to reinforce an unsupported rail joint, with the first support 102 engaged with the first side of the base portions 26 of the first rail 14 and the second rail 16 and the second support engaged with the second side of the base portions 26 of the first rail 14 and the second rail 16. The first base member 110 is engaged with the bottom surface of the base portions 26 of the first rail 14 and the second rail 16. The first base member 110 extends between the first support 102 and the second support 104. The plurality of fasteners 112 each extend through one of the plurality of openings 106, 108 of the first support 102 and the second support 104. The second base member 114 abuts the first base member 110 and extends between the first support 102 and the second support 104. The second base member 114 is configured to provide additional support to the first base member 110 and stiffen the rail brace assembly 100 while the first base member 110 maintains electrical isolation between first rail 14 and the second rail 16, which is necessary for signaling purposes. The plurality of fasteners 112 are each a bolt 126 and a nut 128, although other suitable fasteners may be utilized. Although four fasteners 112 are shown, two or more fasteners 112 may be utilized. A length of the first and second supports 102, 104 is sufficient to overlap and support the first and second rails 14, 16.
In some aspects or embodiments, the rail brace assembly 100 further includes a first washer plate 130 engaged with the first support 102 and a second washer plate 132 engaged with the second support 104, with the first and second supports 102, 104 and the first and second washer plates 130, 132 positioned between the nut 128 and a head of the bolt 126. An additional washer 134 may be positioned between the nut 128 and the first washer plate 130.
As shown in FIGS. 10 and 11 , the rail brace assembly 100 may be utilized in connection with various rail profiles, with the position of the first and second supports 102, 104 configured to provide clearance with various types of existing rail joints. The rail brace assembly 100 may be utilized in connection with an existing bonded 136 RE type joint with a lug and tow (FIG. 10 ) or an existing bonded 115 RE type joint that is toeless (FIG. 11 ).
Accordingly, the rail brace assemblies 10, 100 are configured to be installed on an existing rail joint to further support the rail joint without necessitating the removal of the existing rail joint. In other words, the rail brace assemblies 10, 100 do not require the removal of the existing bolts or rail joint bars, which advantageously allows a more cost effective reinforcement.
Further, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.

Claims

The invention claimed is:

1. A rail brace assembly for first and second rails each having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, the rail brace assembly comprising:

a first support comprising an electrically insulating material configured to be engaged with a first side of the base portions of the first rail and the second rail, the first support defining a plurality of openings;

a second support comprising an electrically insulating material configured to be engage with a second side of the base portions of the first rail and the second rail, the second support defining a plurality of openings;

a first base member comprising an electrically insulating material configured to be engaged with a bottom surface of the base portions of the first rail and the second rail; and

a plurality of fasteners each configured to extend through one of the plurality of openings of the first support and the second support.

2. The rail brace assembly of claim 1, further comprising:

a second base member configured to abut the first base member and extend between the first support and the second support.

3. The rail brace assembly of claim 2, wherein the second base member is a metal plate.

4. The rail brace assembly of claim 1, wherein the first support and the second support each comprises a rail joint bar.

5. The rail brace assembly of claim 4, wherein the first support and the second support each comprise a polyurethane encapsulated rail joint bar.

6. The rail brace assembly of claim 1, wherein the plurality of fasteners each comprise a bolt and a nut.

7. The rail brace assembly of claim 6, further comprising a first washer plate configured to be engaged with the first support and a second washer plate configured to be engaged with the second support, wherein the first and second supports and the first and second washer plates are configured to be positioned between the nut and a head of the bolt.

8. The rail brace assembly of claim 1, wherein the first base member includes a body defining a plurality of openings configured to be aligned with the plurality of openings of the first and second supports.

9. A rail joint assembly comprising:

a first rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion;

a second rail having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail;

a first rail joint bar attached to a first side of the first and second rails;

a second rail joint bar attached to a second side of the first and second rails; and

a rail brace assembly comprising:

a first support comprising an electrically insulating material engaged with a first side of the base portions of the first rail and the second rail, the first support defining a plurality of openings;

a second support comprising an electrically insulating material engaged with a second side of the base portions of the first rail and the second rail, the second support defining a plurality of openings;

a first base member comprising an electrically insulating material engaged with a bottom surface of the base portions of the first rail and the second rail; and

a plurality of fasteners each extending through one of the plurality of openings of the first support and the second support.

10. The rail joint assembly of claim 9, further comprising:

a second base member abutting the first base member and extending between the first support and the second support.

11. The rail joint assembly of claim 9, wherein the first support and the second support each comprises a rail joint bar.

12. The rail joint assembly of claim 11, wherein the first support and the second support each comprise a polyurethane encapsulated rail joint bar.

13. The rail joint assembly of claim 9, wherein the plurality of fasteners each comprise a bolt and a nut.

14. The rail joint assembly of claim 9, further comprising a first washer plate engaged with the first support and a second washer plate engaged with the second support, wherein the first and second supports and the first and second washer plates are positioned between the nut and a head of the bolt.

15. The rail joint assembly of claim 9, wherein the first base member includes a body defining a plurality of openings aligned with the plurality of openings of the first and second supports.

16. A rail brace assembly for first and second rails each having a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, a longitudinal axis of the first rail aligned with a longitudinal axis of the second rail, the rail brace assembly comprising:

a base plate defining a plurality of openings;

a plurality of clips, each of the plurality of clips comprising an electrically-insulating material configured to engage the base portion of the first rail or second rail, each of the plurality of clips defining an opening configured to be aligned with one of the plurality of openings of the base plate; and

a plurality of fasteners configured to extend through respective openings of the plurality of clips and the plurality of openings of the base to secure the clips and the base plate to the first and second rails.

17. The rail brace assembly of claim 16, wherein the base plate is metal.

18. The rail brace assembly of claim 16, further comprising a plurality of washer plates configured to be positioned on a top surface of each of the plurality of clips, wherein the plurality of fasteners each comprise a bolt with a head and a nut, and wherein each of the plurality of washer plates, each of the plurality of clips, and the base plate are positioned between the head of the bolt and the nut when the rail brace assembly is attached to the first and second rails.

19. The rail brace assembly of claim 16, further comprising an insulator plate configured to be positioned between the base portions of the first and second rails and the base plate.

20. A rail joint assembly comprising:

a first rail joint bar attached to a first side of the first and second rails;

a rail brace assembly comprising:

a base plate positioned below the base portions of the first and second rails, the base plate defining a first opening and a second opening;

a first clip comprising an electrically-insulating material engaged with the base portion of the first rail or second rail at the first side of the first and second rails, the first clip defining an opening;

a second clip comprising an electrically-insulating material engaged with the base portion of the first rail or second rail at the second side of the first and second rails, the second clip defining an opening;

a first fastener extending through the opening of the first clip and the first opening of the base plate to secure the first clip and the base plate to the first and second rails; and

a second fastener extending through the opening of the second clip and the second opening of the base plate to secure the second clip and the base plate to the first and second rails.