Monoblock steel sleeper and procedure for its production

Abstract

The invention relates to a one-piece steel sleeper (1) comprising a steel sleeper channel body (100) made of a hollow profile (130) with end caps (160) folded at opposite ends (150) of the steel sleeper channel body (100), wherein the steel sleeper channel body (100) is filled to fill the profile, at least in sections (190) provided for rail attachment, by means of at least one shaped element (400).A preferred method for manufacturing a one-piece steel sleeper (1) comprises the process steps of: (a) providing or manufacturing a steel sleeper channel body (100) from a hollow profile (130) with end caps (160) bent at opposite ends (150); and (b) arranging or forming at least one shaped body (400) in at least one section (180, 190) of the steel sleeper channel body (100), and connecting it to the steel sleeper channel body (100) such that the at least one section (180, 190) of the steel sleeper channel body (100) is filled with the at least one shaped body (400) to fill the profile.

Description

[0001] The invention relates to railway sleepers, and in particular to railway sleepers manufactured on the basis of a steel trough sleeper. The invention further relates to a method for manufacturing such railway sleepers, which are intended for use both in the main track and under switches and crossings.

[0002] Railway sleepers are part of the track bed of railways, trams, and / or subways and have been used in railway construction for centuries. The track bed typically consists of ballast, railway sleepers, and rails mounted on the sleepers. Historically, wooden sleepers were used. Today, prestressed concrete sleepers are primarily used in track construction. Before the advent of such prestressed concrete sleepers, steel sleepers were also frequently used. Since the 1970s, so-called FFU (fiber-reinforced foamed urethane) sleepers have also been used. These sleepers are mainly used in the area of ​​railway bridges, switch systems, and in locations where sleepers with a low profile are required.

[0003] Steel trough sleepers, used since the 18th century, are characterized by their very long service life in the track. These railway sleepers primarily serve to bear the load from the running rails and to secure them. This load transfer occurs both vertically and laterally to the track bed. With steel trough sleepers, the transfer of the lateral load is achieved in particular by the fact that the steel trough sleepers, which are made of a hollow profile, have bent end caps that protrude significantly beyond the profile thickness. This means that the lower edges of the bent end caps extend beyond the longitudinal edges or profile edges of the hollow profile of the steel trough sleepers in the rail fastening area. When laying them in the track bed, this means that corresponding grooves or recesses must first be prepared in the ballast to accommodate the end caps.

[0004] Besides bearing the load, railway sleepers serve to fasten the rails and thus guarantee a consistent track gauge. Ideally, they should also offer the greatest possible resistance to track narrowing caused by derailments. In this respect, steel trough sleepers often perform worse than, for example, wooden railway sleepers.

[0005] Chinese patent application CN 107 313 313 A discloses a method for manufacturing a track bed in which sleepers are arranged and fastened onto polyurethane foam blocks at a production site and transported in this arrangement to a track bed. In the track bed to be constructed, the polyurethane blocks, with the attached sleeper(s), are placed and aligned, and the track bed is completed by adding ballast around the polyurethane blocks. This is intended to accelerate production and avoid the need to pour and foam the polyurethane blocks on-site at the track bed construction site.

[0006] DE 26 36 853 A1 describes a railway cross sleeper for supporting rails on a ballast, comprising at least two rail support blocks spaced at a distance corresponding to the spacing of the rails to be supported by the cross sleeper. Each rail support block has a base surface, a rail surface, and a stiffening system connecting and attaching the support blocks. The stiffening system includes a self-supporting, plate-shaped component designed for embedding in a particulate subsoil when the cross sleeper is positioned on the ballast. This plate-shaped component is longitudinally corrugated, forming several vertical waves that mechanically interact with the subsoil, and is oriented vertically when the cross sleeper is installed on the subsoil.

[0007] JP 2 954366 A shows a sleeper fitted with a rail fastening element on its upper surface near both ends in the longitudinal direction. An underside is formed at both end sections by internally poured and hardened concrete. The end sections each correspond to the rail fastening element of the sleeper body, and an intermediate section of the sleeper body, located between the two end sections, is formed into a hollow shape with an open bottom.

[0008] Other threshold types are shown in JP2007 120044 A and JP S4 984804 U.

[0009] DE 10 2019 210 289 A1 describes a ballast-plastic composite body comprising ballast stones, wherein the ballast-plastic composite body has the form of a plate, a track bed and track body comprising the ballast-plastic composite body, as well as a method for producing the ballast-plastic composite body and a method for producing a track bed.

[0010] The present invention is based on the technical problem of creating railway sleepers and a method for their manufacture, wherein the railway sleepers achieve a long service life similar to or better than steel trough sleepers, but are easier to lay and exhibit high stability and flexibility in use as well as improved behavior compared to conventional steel trough sleepers with regard to possible track narrowing in the event of derailments and load-bearing behavior, and exhibit a lower tendency to corrosion as well as better resonance behavior, in particular due to the avoidance of undesirable hollow areas.

[0011] The problem is solved according to the invention by a steel monoblock sleeper with the features of claim 1 and a method for manufacturing a steel monoblock sleeper with the features of claim 12. Advantageous embodiments are described in the dependent claims.

[0012] The invention is based on the idea of ​​creating novel sleepers based on a steel profile, preferably one that is known and proven, in which the hollow profile is filled, at least in sections, by a molded body to fill the volume. This creates a larger bearing surface in order to transfer lateral forces, which occur perpendicular to the direction of travel, to the track bed. At the same time, this increases the sleeper weight compared to the steel trough sleepers known from the prior art, which are often considered too light in expert circles compared to various types of concrete sleepers.

[0013] In a preferred embodiment, it is thus provided that a steel monoblock sleeper is created which has a steel sleeper trough body made of a hollow profile with end caps bent at opposite ends of the steel sleeper trough body, wherein the steel sleeper trough body is filled to fill the profile at least in sections which are provided for rail fastening by means of at least one shaped body formed from reacted reactive material.

[0014] A corresponding preferred method for manufacturing a steel monoblock sleeper comprises the process steps (a) providing or manufacturing a steel sleeper trough body from a hollow profile with bent end 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, such that the at least one section of the steel sleeper trough body is filled by the at least one shaped body to fill the profile.

[0015] Because the steel sleeper trough body is completely filled with the molded body, at least in sections, unintended voids during installation, which occur in prior art steel trough sleepers that are not properly bedded with ballast, are avoided. This also significantly improves the resonance behavior compared to conventional steel trough sleepers.

[0016] A shaped body is a body with a defined external form. Here, the external form is adapted to a section of a hollow profile of a steel sleeper trough body and can completely fill this section.

[0017] According to the invention, a further process step is provided: filling reactive material into a hollow profile mold, the hollow shape of which corresponds at least to a section of the hollow profile of the steel sleeper trough body, and reacting the reactive material to form the at least one molded body filling the hollow profile mold.

[0018] Preferably, an intumescent plastic is chosen as the reactive material. Polyurethanes are particularly suitable for this purpose, as they exhibit high strength and rapid reaction kinetics and are recyclable, as described, for example, in application DE 10 2021 211 499, which was not yet published at the time of this application. This makes it possible to produce the molded parts quickly. The manufactured molded parts can be processed and / or finished within a timeframe that meets the requirements. Polyurethanes also offer high resistance to environmental influences. They provide sufficiently high stability and durability. However, they also exhibit a certain degree of elasticity, so that when laid in a gravel bed, edges and points of the gravel stones can engage with the lower surface, thus particularly affecting shear forces, i.e.,Forces acting perpendicular to the mounted rails can be efficiently transferred from the steel monoblock sleeper to the ballast bed. Furthermore, polyurethanes are suitable because they bond with a wide variety of materials, coating or encasing them and forming a strong, adhesive bond.

[0019] To influence the strength and mass of the molded parts, the invention states that at least one of the molded parts is manufactured as a solid foam composite, preferably as a crushed stone foam composite. The crushed stone preferably has a grain size between 31 mm and 62 mm, such as is common for track ballast. Track ballast is particularly preferred. However, other embodiments can also use other loose solids in the form of plastic parts, plastic rods, or other materials, as well as other grain sizes.

[0020] The method according to the invention thus provides that, before or simultaneously with the filling of the reactive material into the hollow profile mold, the hollow profile mold is additionally filled with loose solids, and the loose solids are preferably compacted by vibration. Compaction can also be achieved and / or supported alternatively or additionally by evacuating the hollow profile mold. The filling and reaction of the reactive material is preferably carried out such that the reactive material encloses the loose solids and forms the molded body as a composite body, the outer contour of which is adapted to at least a section of the contour of the hollow profile mold. A molded body produced in this way exhibits high strength and is able to transfer and dissipate high loads in both the vertical and horizontal planes from the rails attached to it to the track bed.

[0021] The reactive material is preferably injected via nozzles located above the preferably compacted, loose solids-based filler material. Alternatively, the nozzles can be inserted into the preferably compacted, loose solids-based filler material and withdrawn after injection of the reactive material. This allows the reactive material to be applied inside the hollow profile and ensures a uniform distribution. However, other methods of applying the reactive material during injection are also possible.

[0022] For example, reactive material can be poured or sprayed into the hollow profile mold, or applied using a rake. Immersion of the hollow profile mold in reactive material is also possible.

[0023] It has been shown that by selecting a precise injection time and weight, as well as a specific composition or ratio of the material's components (e.g., polyol, catalyst, and isocyanate), molded parts can be reproduced consistently. Therefore, a casting time and the weight of the shot / injection must be predetermined and set. The reactive material can be selected and / or adjusted, especially if it consists of two components, so that the reaction begins only after a time delay following injection. For example, a liquid mixture can be applied from above into or onto the filler material, initially distributing itself within the filler material—i.e., in the spaces between the loose solids—primarily due to its flow properties and gravity, and / or wetting these spaces, before completing the reaction.Foam up and preferably completely fill the spaces between the loose solids / cavities of the filling material.

[0024] The amount of reactive material used is adjusted to the volume of the solids filled into the hollow profile mold such that, during the reaction of the reactive material, the entire volume of the hollow profile mold, at least in the section where the at least one molded body is formed, is preferably completely filled by the solids and the reacted reactive material, i.e., the foam. Thus, preferably no or only small gas inclusions remain in the molded body, such that, for example, a previously loose solid in the form of a stone cannot twist out of its compacted position.

[0025] To minimize or prevent changes to the existing solid density prior to the reaction of the reactive material, and / or to avoid or minimize the formation of gas inclusions and cavities in the resulting molded body, the open side of the hollow profile mold is sealed with a load-bearing cover during the reaction process. Forces in the range of 5,000 N / m², which can be achieved, for example, by applying a weight of approximately 500 kg / m², are generally sufficient.

[0026] This preferably also prevents the reactive material from escaping the hollow profile mold. This also enables efficient use of the material. For this purpose, the cover has, for example, a silicone coating on one side facing the hollow profile mold, which prevents a force-fit or material-bonded connection from forming between the cover and the reactive material. Other non-stick coatings and release systems can also be used.

[0027] To influence, for example, the sound transmission properties and / or mechanical vibration properties of the monoblock threshold, the mass of the reactive material can be altered by adding admixtures and fillers, and the density can also be varied. With polyurethane foams, different properties can be achieved depending on the choice and proportion of isocyanate and polyol. To increase the mass of the foam formed by the reactive material, for example, fillers and additives can be added, such as barium sulfate or calcium carbonate, each in powder form.

[0028] To influence the acoustic and / or vibration properties, the loose solid material can also be varied and selected accordingly. Besides track ballast, other materials such as tapping slag or similar can be used, provided they exhibit sufficient stability against compressive loads. This can improve the CO₂ balance of the manufactured sleepers, as a waste product of steel production is utilized.

[0029] The formwork of a non-load-bearing alternative is manufactured using a pure concrete infill. The concrete formwork is connected by fasteners, e.g., made of iron, which are spot-welded to the steel sleeper trough body, and thus held in place within the trough formed by the hollow profile. Prestressing in the concrete is not necessary. Damping materials can be embedded in the concrete while wet or subsequently bonded to the underside, creating a soft layer facing the ballast structure of the tamped track. This layer increases lateral displacement resistance and reduces vibrations and noise emissions.

[0030] A major advantage of the manufactured steel monoblock sleepers compared to known steel trough sleepers is that the end edges can be designed variably, since the lateral displacement resistance is primarily defined by the shape of the sleeper body. In a preferred embodiment, the bent end caps are designed to be flush with the longitudinal or profile edges of the hollow profile, or at least not to project beyond them on one side of the hollow profile. The end caps of the steel sleepers forming the hollow profile can therefore be bent or cut to length only so that the bent end caps are flush with the longitudinal or profile edges of the hollow profile. The 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 end caps. The end caps do not project beyond the profile edges.This eliminates the complex installation work required with traditional steel trough sleepers, which necessitates inserting the protruding end caps into the ballast. With the newly developed steel monoblock sleepers, where the end caps of the steel sleeper trough body do not extend beyond the longitudinal edges of the hollow profile from which they are formed, the shear forces are thus transferred across the entire surface of the at least one molded section that at least partially fills the steel sleeper trough body. The shear force transfer is therefore more evenly distributed and prevents stresses in the ballast bed.

[0031] Additionally, at least one angle profile, oriented transversely to a longitudinal direction of the hollow profile of the steel trough body, can be welded or already welded to an underside of the steel sleeper trough body. This means that the profile orientations of the hollow profile and the at least one angle profile are transverse to each other, preferably perpendicular to each other. At the same time, preferably one leg of the at least one angle profile is 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 the first leg and projects downwards. This allows for improved transfer of shear forces into a ballast bed into which the other leg of the at least one angle profile projects. The underside of the steel sleeper trough body is the side opposite the side intended for rail fastening.

[0032] Preferably, at least one angle iron projects laterally in the profile extension direction on one or, preferably, both sides of the steel sleeper trough body. This increases the horizontal stability of the steel monoblock sleeper.

[0033] Preferably, at least one angle iron spans the trough of the steel trough body filled with the molded part and is attached to both profile edges with one leg of the angle iron. This creates a particularly stable fastening.

[0034] Preferably, the at least one angle iron comprises two angle irons that are spaced apart and attached to the underside of the steel trough body. The spacing preferably corresponds approximately to the track gauge for which the steel monoblock sleepers are designed. They are thus preferably attached opposite the rail fastening devices.

[0035] By aligning the angle profile with a rail axis, the installation of the steel monoblock sleeper during track assembly is greatly simplified, and safe passage under train load. Unwanted deflection of the sleeper is effectively prevented.

[0036] Some designs may also have more than two angle irons.

[0037] The at least one angle profile can have openings or through-holes at opposite ends. These can be used, provided the angle profile is of a suitable length adapted to the spacing of the steel monoblock sleepers, to connect steel monoblock sleepers intended for adjacent installation or already installed adjacent to each other, using connecting plates. This creates a hinged frame.

[0038] In some embodiments, ribbed plates are welded onto the steel monoblock sleeper, designed to guide and secure the rails. Rail fastening devices can be attached directly to these welded-on ribbed plates. A ribbed plate comprises two attached strips between which the band-shaped foot of a laid rail is positioned transversely, providing a positive fit. Fasteners connect the rail to the steel monoblock sleeper via the ribbed plate to form a track frame. This track frame is designed to be rotationally and shear-resistant, preventing the rail from shifting longitudinally, tipping over, or twisting.

[0039] Other embodiments additionally or alternatively provide that the monoblock sleepers are manufactured with dowels or dowel recesses. Advantageously, the dowels are inserted and fixed at appropriate locations in the hollow profile mold before the forming of the body. This fixing can be achieved, for example, by means of mandrels or projections extending into the hollow profile mold, which may optionally protrude into the hollow profile mold through openings opposite the open side. To fix the dowels, they can also be screwed to the hollow profile mold through such openings during the manufacturing of the body. Alternatively or additionally, a dowel receptacle block, also called a dowel block for short, can be inserted into the hollow profile mold at the appropriate locations before the reactive material and any additional loose solids are added.Here too, fixing by means of fasteners projecting into the hollow shape of the hollow profile is advantageous.

[0040] A dowel mounting block preferably has one or more dowel recesses, which are slightly larger in diameter than the dowel to be fitted later.

[0041] The hollow profile mold used for manufacturing the molded body can be a separate mold from the steel sleeper trough body. Alternatively, and preferably, the at least one molded body is manufactured directly in the hollow mold formed by the trough of the steel sleeper trough body. To fix dowels or dowel receptacle blocks during the manufacturing of the at least one molded body, slot-like or round openings are preferably provided in the steel sleeper trough body at corresponding positions where dowels or screws for track fastening devices are to be inserted later. Fixing elements in the form of protruding pins and / or screws for sleeper screw dowels, inserts, and the like are then formed through these openings during the manufacturing of the molded body. Such inserted elements are referred to as functional elements.

[0042] The rail fastening to the steel monoblock sleeper can be designed as a fully insulated construction. It is advantageous to use a modification of the S15 rail fastening system known from the prior art for Y-shaped steel sleepers. For this purpose, openings are incorporated into the upper side of the steel trough body. The upper side of the steel trough body, and also the upper side of the steel monoblock sleeper, is considered to be the side intended for rail fastening. The lower side of the steel trough body is correspondingly the opposite open side into which the shaped element is or will be inserted.

[0043] For example, four openings, preferably circular, are made in the top of the steel trough body. Additionally, four transverse rails are welded to the top to guide the rails.

[0044] Precisely fitting sleeper screw anchors, made of plastic, are pressed into these openings, which are preferably circular. Preferably, two of these sleeper screw anchors are connected to each other to form a sleeper screw anchor pair. The spacing between any two of the four openings is adapted to a "dowel spacing" of the sleeper screw anchor pair, so that one sleeper screw anchor pair fills two of the openings when pressed in.

[0045] Other embodiments may provide for openings to be designed as slots (e.g., 48 x 62 mm). A sleeper screw anchor with lateral fastening projections is then inserted into each slot. Each fastening projection has a notch into which, when the sleeper screw anchor is rotated 90° around its longitudinal axis, the top surface of the hollow profile of the steel sleeper trough body penetrates and is clamped. This secures the sleeper screw anchors with fastening projections to the steel sleeper trough body, preferably before the molded body is formed.

[0046] The openings can be formed by drilling, punching, or laser cutting or drilling and / or high-pressure water cutting or drilling.

[0047] Suitable plastic for threshold dowels is known from the prior art.

[0048] The insertion of the sleeper screw anchors or sleeper screw anchor pairs preferably takes place before the forming of the molded body, at least if the molded body is formed within the hollow profile of the steel trough itself. The sleeper screw anchors are preferably completely enclosed by the at least one molded body.

[0049] However, some embodiments may provide that the sleeper screw anchors are prefabricated so that their length is adapted to the depth of the trough of the steel sleeper trough body. They are preferably dimensioned so 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 anchors themselves have a through-hole that terminates in one outer surface, specifically 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 allows any water penetrating the sleeper screw anchor(s) to drain downwards. The sleeper screw anchors or sleeper screw anchor bodies of a sleeper screw anchor pair may also be designed with a through-hole.

[0050] Embedding the sleeper screw anchors in the molded body also offers the advantage that a damaged sleeper screw anchor can be drilled out and easily replaced with a new one during a repair.

[0051] Another embodiment provides that one or more sheathing tubes are permanently attached to the hollow profile of the steel sleeper trough body at those points, preferably by welding or bonding / gluing, where sleeper screw anchors are to be arranged. The sheathing tube consists of a material, preferably steel, that allows a sleeper screw anchor to be permanently received under dynamic load and provides it with pull-out resistance. The cross-sectional shape of the enclosed area of ​​the sheathing tube(s) can be suitably selected, and in the case of multiple sheathing tubes, different shapes may be chosen. This cross-sectional shape can be, for example, circular, oval, polygonal, e.g., rectangular, in particular square, triangular, hexagonal, etc., but can also have any other shape, e.g., circular with one or more indentations and / or protrusions.The one or more steel sheathing tubes are preferably arranged concentrically with openings in the upper surface of the steel sleeper trough body, which are provided for receiving the sleeper screws. Preferably, the openings are designed and dimensioned such that they also accommodate the upper end of a sleeper screw anchor. The sleeper screw (not shown) is thus isolated from the steel sleeper trough body by the sleeper screw anchor when screwed in.

[0052] Preferred embodiments include those in which the steel casing 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 anchor. This prevents the sleeper screw anchor from being pulled out, as its inner diameter is adapted to that of the steel casing, at least in the section that is received within it.

[0053] Preferably, a steel sheathing tube edge facing away from the top of the steel sleeper trough body is flush with the side edges of the hollow profile of the steel sleeper trough body or at least does not project beyond them.

[0054] The molded body(s) enclose the steel casing tube(s). These are welded or bonded to the steel sleeper trough body before the molded body(s) are formed or inserted, for example, using a two-component adhesive. If the molded body(s) are formed in a hollow profile separate from the steel sleeper trough body, this profile has one or more corresponding inserts that correspond to the steel casing tube(s) welded into the steel sleeper trough body.

[0055] Additional fastening devices for the rails can then be pre-assembled using the sleeper screw dowels or sleeper screw dowel pairs before transport to an installation site.

[0056] It is not always desirable for the at least one shaped element to completely fill the trough of a steel sleeper trough body. Therefore, in some embodiments, dividing profiles are welded into the trough, i.e., the hollow form of the steel sleeper trough body, dividing it into different sections. Such dividing profiles are also called partition profiles. For example, a shaped element can be formed and created between a head cap and such a welded-in partition profile, beneath each of the two end sections of the steel monoblock sleeper, serving as fastening sections. Alternatively, appropriately shaped elements, referred to as partitions, can be inserted into these sections and connected to the steel sleeper trough body. This leaves a cavity in a central section of the trough body.This offers the advantage of reducing the need to ride over the sleepers. Furthermore, the cavity can be used to accommodate and pre-install signaling or measuring equipment before the steel monoblock sleeper is laid. This also saves on filler material and weight.

[0057] Alternatively or additionally to the separating profiles, an insert block can also be used as a separating element to create the sections for forming the at least one molded body within the trough of the steel sleeper trough body. Such an insert or separating element can, for example, be a plastic body made of polyurethane or another plastic. This insert or separating element can also have a recess in its center, preferably facing the open side of the hollow form of the steel sleeper trough body. This recess can also be used to prevent the sleepers from riding up against each other and / or to accommodate other components such as signal and measurement technology. This also offers a way to save on filler material and weight. In some embodiments, the insert block or separating element can be integrated into the molded body.Multiple insert blocks can be used, but not in sections intended for track assembly. The separating element can also be attached, for example glued, to the steel sleeper trough body before filling the section(s) it delineates and forms.

[0058] In particular, if separating profiles are used in the trough of the steel sleeper trough body, a lockable inspection opening can be provided in the steel sleeper trough body to allow access from above to the cavity created between the separating profiles when installed.

[0059] To connect the molded part to the steel sleeper trough body, adhesives are preferably used. In some embodiments, the reactive material itself can act as an adhesive and directly bond the molded part, formed in the trough of the steel sleeper trough body, to the steel sleeper trough body during manufacturing. In other embodiments, regardless of whether the molded part is formed in a separate hollow profile mold or the steel sleeper trough body itself served as the hollow profile mold for manufacturing the molded part, it can be bonded to the steel sleeper trough body in a separate step.

[0060] For the application of the adhesive, methods such as dipping, spraying, pouring into a trough or similar are possible.

[0061] Adhesives used include phenolic resins (PF plastics, especially PF resins) or urea-based resins (UF resin), as well as isocyanates, epoxides, urethanes, and polyureas.

[0062] To ensure good adhesion of the molded body and / or a coating and / or an adhesive to the steel sleeper trough body, a surface treatment may be provided, which may include, for example, sandblasting and, if necessary, additional cleaning and degreasing.

[0063] Because the steel sleeper trough body is filled by the at least one molded element on the trough side, no condensate forms in the area of ​​the molded element when the trough is installed. This condensate originates from moisture rising from the ballast bed. However, if areas are separated by partition profiles, voids remain in the trough of the steel sleeper trough body. In this embodiment, as well as in other embodiments, the steel sleeper trough body can be partially or completely coated to improve corrosion resistance. Coating / treating the trough side of the steel sleeper trough body is particularly preferred.

[0064] Polyurethanes are again the preferred coatings, offering a short reaction time, high strength, and optimal sealing. They do not tend to become brittle and are temperature-resistant across a wide range, for example, from -50°C to 120°C. Furthermore, they exhibit acid resistance and resistance to a variety of other chemicals. In addition, there is no leaching or release of environmentally hazardous substances. Polyurea coatings are also UV-resistant and sound-absorbing. If required, they can also be made fire-resistant by using flame-retardant additives.

[0065] In particular, on the side facing away from the trough, the coating of the steel sleeper trough body can be designed so that lettering or markings are visible due to added dyes. In this case, the coating can be printed to, for example, apply escape route markings or similar information directly to the monoblock sleepers during manufacturing. Furthermore, the coating is preferably slip-resistant.The coating can also be used to embed a foil made of metal or a metal alloy, in particular an aluminum foil or an aluminum alloy, a so-called neutrino or ntrino foil as described in WO 2016 / 142056 A1, in order to generate energy on-site and use it, at least for signaling or measuring equipment embedded in the sleeper, possibly in the cavities themselves, or—in case of surplus—to feed it into the track network. This coating can also be used to embed metamaterials, thereby achieving further frequency reductions of the natural vibrations and reducing structure-borne and / or airborne sound propagation. Metamaterials are artificially produced materials that exhibit properties not found in naturally occurring substances and materials.Three-dimensional phononic crystals with a very large bandgap can be used to reduce sound propagation, as described, for example, by 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). This coating can also consist of two-dimensional polymer layers to achieve maximum protection of the underlying films. A two-dimensional polymer layer is characterized by the fact that the polymer bonds are formed either entirely or at least predominantly in a two-dimensional plane.

[0066] Fully coated steel sleeper trough bodies are particularly suitable for installation locations with high humidity, such as those found in tunnels. A suitable coating material is, for example, the polyurea system Polyresyst® < S6020-90W, which is distributed by Huntsman (available at https: / / www.huntsman.com / contact / polyurethanes / customer-service). This system consists of a resin mixture made from amines and isocyanates as a hardener. The fully cured material preferably exhibits a hardness of 45 Shore D according to DIN 53505, a tensile modulus of 24.2 MPa according to DIN 53504, an elongation of 390% according to DIN 53504, and a tensile strength of 73.9 N / mm according to DIN 53505. The DIN standards refer to the version valid or current at the time of application.

[0067] The molded body can be manufactured by leaving the hollow profile open at the top, allowing the reactive material and, if applicable, loose solids or inserted dowels, dowel blocks, or separating elements to be inserted through the open side of the mold. Alternatively, the hollow profile, for example, the steel sleeper trough body, can be pressed into a layer of loose solids, effectively filling the trough, i.e., the hollow profile, from below. In this case as well, the reactive plastic material can be injected through nozzles, and the reaction of the reactive material can preferably be carried out by applying a load to the hollow profile from above.

[0068] The introduction and reaction of the reactive material preferably takes place in such a way that the reaction occurs from the hollow profile forming the trough towards the "open" side, which is usually closed off with the cover.

[0069] In any case, the shaped body is preferably formed such that the at least one shaped body arranged in the hollow profile of the steel trough body has a side surface that is flush with the longitudinal edges of the steel sleeper trough body. This ensures that a constant overall height is maintained for the steel monoblock sleepers and that installation on any type of subsoil and different track bed constructions is possible.

[0070] Furthermore, it is possible to introduce measuring or signaling elements into the hollow profile shape before the reactive material reacts, in order to enclose them in the formed body.

[0071] The invention is explained in more detail below with reference to a drawing. The drawing shows: Fig. 1 a schematic top view of a steel monoblock sleeper; Fig. 2 a cross-sectional view of a steel monoblock sleeper; Fig. 3 a side / partial longitudinal section of a steel sleeper trough body; Fig. 4 a longitudinal cross-section through one embodiment of a steel monoblock sleeper; Fig. 5 a longitudinal cross-section through another embodiment of a steel monoblock sleeper; Fig. 6 a partial view of a cross-section of a steel monoblock sleeper with a schematically represented rail; Figs. 7a-7j schematic views to illustrate the manufacture of a steel monoblock sleeper; Figs. 8a-8j schematic representations to illustrate another embodiment for the manufacture of steel monoblock sleepers; Fig. 9 a schematic top view of a steel monoblock sleeper with laterally projecting angle profiles; Fig. 10 a schematic side view of a steel monoblock sleeper with laterally projecting angle profiles; Fig.Fig. 11 a schematic cross-sectional view of a steel monoblock sleeper with laterally projecting angle profiles; Fig. 12 a schematic side view of several interconnected steel monoblock sleepers with laterally projecting angle profiles; Fig. 13 a schematic partial cross-section of a steel monoblock sleeper with a sleeper screw dowel with fastening projections; Fig. 14 a schematic drawing of a section of a steel monoblock sleeper with a sleeper screw dowel pair; Fig. 15 a partial sectional side view of the steel monoblock sleeper according to . Fig 14 Fig. 16 is a schematic enlarged sectional view of part of a pressed-in sleeper screw dowel body of a sleeper screw dowel pair; Fig. 17 is a schematic partial cross-sectional view of a sleeper screw dowel body of a sleeper screw dowel pair at the level of a notch for receiving the top of a steel sleeper trough body; Fig. 18 is a schematic partial sectional view of a top of a steel trough body to which a steel sleeve with a sleeper screw dowel received therein is welded; and Fig. 19 is another schematic partial sectional view of a top of a steel trough body to which a steel sleeve with a sleeper screw dowel received therein, secured against being pulled out, is welded.

[0072] In Fig. 1 A schematic top view of a steel monoblock sleeper 1 is shown. From the top, a steel sleeper trough body 100, made from a steel profile, and its top surface 110 are visible. The steel sleeper trough body 100, formed from a hollow profile 130, is bent over at opposite ends 150. The bent ends are referred to as end caps 160. The steel sleeper trough body 100 forms a downwardly open trough in which a Fig. 1 The non-recognizable shaped body is arranged to fill the profile at least in sections and is connected to the steel sleeper trough body 100.

[0073] In Fig. 2 is a cross-section 140 along a line AA (compare Fig. 1 ) represented by the steel monoblock sleeper 1. Identical technical features are indicated in all figures with the same reference numerals. The hollow profile 130 of the steel sleeper trough body 100 and the profile of the molded body 400 fitted therein are visible; the molded body 400 completely fills at least the section whose cross-section is shown within the hollow profile 130 of the steel sleeper trough body 100.

[0074] In Fig. 3 is a schematic side and partial longitudinal section view of a steel sleeper trough body 100 of the steel monoblock sleeper 1 according to Fig. 1 The figure shows that the end caps 160 of the hollow profile 130 are bent over so that the end cap edges 165 are flush with the profile edges 170 of the hollow profile 130, from which the steel sleeper trough body 100 is formed.

[0075] On the upper surface 110, ribbed plates 250 are shown schematically welded on, intended for guiding and fastening rails. Fastening devices for securing the rails are not shown in this schematic representation.

[0076] The steel sleeper trough body 100 represents a hollow profile shape 1000, which is open at one bottom 120. The hollow profile shape 1000 is thus formed by the trough created 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 separating profile 200 is shown in Fig. 3 Shown with dashed lines. Another separating profile is typically welded symmetrically to a central axis 105 in the uncut portion of the steel sleeper trough body 100 shown. In this embodiment, the steel sleeper trough body 100 is thus divided into two fastening sections 190, in which a rail is provided for fastening, and a central section 195.

[0077] In Fig. 4 A longitudinal cross-section through an embodiment of a steel monoblock sleeper 1 is shown schematically. In the illustrated embodiment, the trough formed by the steel sleeper trough body 100 is filled along its entire length by the shaped body 400, which has a recess 470 on its underside 420 in a central section 195. Signaling or measuring equipment can be housed in this recess 470, and the resulting clearance serves to prevent the steel monoblock sleeper 1 from riding over other road surfaces.

[0078] The molded body 400 comprises a fully reacted reactive material 700. This is preferably a polyurethane. Particularly preferably, the molded body 400 is a composite body consisting of loose solids 600, particularly preferably gravel 610 and most preferably track ballast 620. This is encased in the reactive material 700 and particularly preferably also directly and force-fittedly connected to the steel sleeper trough body 100. As described in Fig. 4 As indicated, one or more sleeper screw anchors 510 and / or an anchor block 520 may already be integrated. Sleeper screw anchors 510 are, for example, made of plastic and / or glass fiber reinforced concrete. In the illustrated embodiment, a prefabricated separating element 540 is integrated into a central section, separating the fastening sections 190 from a central section 195 and having the recess 470 of the formed body 400. The formed body 400 as a whole is a composite body including the inserted or integrated components, such as the separating element 540, the sleeper screw anchor 510, or the anchor block 520. Preferably before the reactive material reacts, loose solids 600 are filled into the fastening sections 190 of the formed body, for example, before the reactive material reacts into the hollow profile shape formed by the steel sleeper trough body in which the formed body 400 was formed. These solids are compacted, for example, by vibration.The gaps were then filled with the reactive material 700, which foamed out during the reaction process, and thus enclosed by the reactive material. The steel sleeper trough body 100 is therefore filled from the inside by the molded body 400.

[0079] In Fig. 5 Figure 1 schematically shows another longitudinal section view of a steel monoblock sleeper 1. As in all figures, technically identical features are designated with identical reference numerals. In this embodiment, separating profiles 200 are welded into the trough formed by the steel sleeper trough body 100, separating the fastening sections 190 from the central section 195. Shaped bodies 400, 400' are formed in each of the fastening sections 190, preferably made of gravel 610 and this foaming, fully reacted reactive material 700 in the form of, for example, polyurethane.

[0080] The mass of the reactive material 700, and consequently its sound and damping properties, can be influenced by adding barium sulfate or calcium carbonate. Similarly, the mass of at least one shaped body, or, in the case of the [missing information], the [missing information], can be influenced by selecting the gravel 610 or the loose solids 600, which can also consist of plastic material, recycled crushed concrete, or similar materials. Fig. 5 The illustrated embodiment of the two molded bodies is affected.

[0081] In Fig. 6 Figure 1 shows a schematic sectional view of a fastening section 190 of a steel monoblock sleeper 1, enlarged in longitudinal section. In the illustrated embodiment, ribbed plates 250 are welded to the top surface 110, which are provided for guiding a rail 2000 that is not part of the steel monoblock sleeper 1. Openings 111, 112 are formed in the top surface 110, below which dowel openings 525 with dowels 510 of a dowel block 520 are formed. The dowel block 520 is surrounded by compacted track ballast with a grain size of 31-61 mm, i.e., a typical grain size for track ballast 620, which, in its compacted state, is encased in polyurethane foam. This completely fills the end section 180, which is a fastening section 190, with the molded body 400. On one side the end section is bounded by the head cap 160 and on the opposite side by the separating profile 200.

[0082] Based on Fig. 7a-7j The production of a steel monoblock sleeper 1 is explained schematically by way of example. In the embodiment described first, the molded body 400 is initially formed separately from the steel sleeper trough 100 and both are then joined together by gluing.

[0083] In Fig. 7a A hollow profile form 1000 is shown schematically, the hollow shape of which corresponds to the hollow profile of the steel sleeper trough body 100. Fixing elements 1010, 1020, designed as fixing pins, project into the hollow form. Furthermore, injection nozzles 1100 for the reactive material project into the hollow form through closable openings 1050 of the hollow profile form 1000.

[0084] As in Fig. 7b As shown, objects inserted into the fastening means 1010, 1020, such as a threshold screw dowel 510, a dowel block 520, and / or in other embodiments a separating body 540, are fastened.

[0085] Then, as in Fig. 7c The remaining cavity is filled with loose solids 600, preferably with gravel 610, and particularly preferably with track ballast 620. These solids 600 are compacted, for example by vibration, which is schematically illustrated by double arrows to indicate a vibrating device 1200.

[0086] In Fig. 7d The figure shows that the open side of the hollow profile mold 1000 is closed by a cover 1300, which preferably has a non-stick layer 1320 on its underside, applied to an elastic layer 1310. The cover 1300 is pressed against the steel profile mold so that it remains closed even when the reactive material expands. A pressure device 1370, schematically depicted as a weight, presses the cover against the hollow profile mold. Reactive material 700 is then injected into the spaces between the compacted track ballast 620 via the injection nozzles 1100.

[0087] The injectors 1100 are retracted and the closures 1060 of the closable openings 1050 are closed, as shown in Fig. 7e This is shown schematically. During the reaction of the reactive material 700, it expands and, together with the compacted loose solids 600, here the track ballast 620, and the inserted elements, forms the shaped body 400 as a composite body, which is in Fig. 7f shown schematically.

[0088] Simultaneously or at different times, a hollow steel profile 13 is bent at opposite ends 150 to form end caps 160 ( Fig.7g This forms the steel sleeper trough body 100. Additionally, ribbed plates 250 are welded onto the steel sleeper trough body for later rail guidance. Openings may also be punched and / or drilled into the steel sleeper trough body 100.

[0089] Subsequently, the steel sleeper trough body 100 is coated on an inside or underside 120 in the trough and / or on an outside, i.e. the top 110 ( Fig. 7h In this process, a polyurea coating 800 is preferably applied via coating nozzles 1400. Alternatively and / or additionally, the top surface 110 can also be printed and provided with graphic markings. In this case, a printing device 1420 is used.

[0090] To connect the steel sleeper trough body 100 with the molded body 400, an adhesive 850 is applied to the inside of the steel sleeper trough body and / or an outside of the molded body 400 ( Fig. 7i ) and the shaped body 400 is inserted into the trough of the steel sleeper trough body 100 and positively connected to it to form the steel monoblock sleeper 1. The steel monoblock sleeper 1 is in Fig. 7j is shown schematically.

[0091] In the embodiment described above, a hollow profile form 1000 is used, which is designed separately from the steel sleeper trough body 100. In other embodiments, the at least one molded body or, if applicable, the several molded bodies that fill the trough of the steel sleeper trough body 100 or sections 180 of the steel sleeper trough body 100 are manufactured within the steel sleeper trough body 100 itself.

[0092] One such embodiment is in Fig. 8a-8h This is shown as an example. First, the steel sleeper trough body 100 is again manufactured from a hollow steel profile 130, Fig. 8a .

[0093] Additionally, separating profiles may be welded into the trough of the steel sleeper trough body. Furthermore, openings 111, 112 may be incorporated into the steel sleeper trough body 100 ( Fig. 8b ), through which sill screw dowels 510 or dowel blocks 520 inserted through can be fixed in the trough ( Fig.8d ).

[0094] If necessary, the steel sleeper trough body 100 is coated with a coating 800 on the open trough side and / or the top 110 (in the figure below) before inserting components such as sleeper screw dowels 510 or a dowel block 520 etc. Fig. 8c ).

[0095] Injection nozzles 1100 for the reactive material are inserted into the hollow mold or open trough ( Fig. 8d ). The remaining cavity is then filled with rubble 610, for example basalt track ballast 620, and compacted by vibration ( Fig. 8e ). In the illustrated embodiment, this only occurs in the fastening sections 190, in which shaped bodies are formed.

[0096] 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 1000 formed by the steel sleeper trough body 100 by a pressure exerted by a pressure device 1370. The cover 1300 has closable openings 1350 through which the injection nozzles 1100 protrude.

[0097] After reactive material 700 has been injected into the fastening sections 190 ( Fig. 8f ), the injectors 1100 are retracted by the cover 1300, which is pressed against the open side of the trough with a contact pressure, and the closable openings 1350 are closed by means of closures 1360 ( Fig. 8g The reactive material 700 is preferably selected such that it foams up and encloses the loose solid bodies 600, preferably selected as track ballast 620, and simultaneously forms a force-fit connection with the steel sleeper trough body 100, so that the two formed bodies 400, 400' are connected to the steel sleeper trough body 100 to form the steel monoblock sleeper 1. The finished steel monoblock sleeper 1, rotated into a laying orientation, is in Fig. 8h schematically represented.

[0098] In the depicted variants, the hollow profile is open at the top. However, in alternative embodiments, the hollow trough of the steel sleeper trough body can also be pressed into a layer of loose solids, such as track ballast, and then reactive material can be injected into the interior of the trough, even within the track. A suitable molded body is formed in this way as well. During the reaction process, the steel sleeper trough body is subjected to a load from above to prevent the compaction of the gravel inside the trough and to prevent the hollow profile formed by the steel sleeper trough body from lifting.

[0099] In Fig. 9 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 to the bottom of the steel sleeper trough body 100, each projecting laterally on both sides 105, 106 of the steel sleeper trough body 100.

[0100] 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 upper surface 911 against 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.

[0101] Another leg 920 of the angle profile 900, which is preferably oriented perpendicular to the first leg 910, projects downwards 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, shear forces can be transferred more effectively to a ballast bed into which the other legs 920 project when installed.

[0102] As in Fig. 12 As shown, 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 the one leg 910 and can be connected to the angle profile 900 of an adjacent steel monoblock sleeper 1 by means of connecting plates 930 and connecting screws 935 to form a hinged frame.

[0103] In Fig. 13 A schematic partial cross-section of a steel monoblock sleeper 1 with a sleeper screw dowel 510 is shown, which has a round body 511 with fastening projections 512 projecting on opposite sides. An extension 513 in the plane of the drawing is larger than perpendicular to it.

[0104] A sleeper screw anchor 510 is inserted into a slot-shaped opening 111 in the upper surface of the steel sleeper trough body 100. The extension of the slot-shaped opening 111 is longer perpendicular to the plane of the drawing than in the plane of the drawing. The sleeper screw anchor 510 is inserted or pressed in a position rotated 90° about a central axis 514 relative to the position shown and then brought 90° into the position shown. A wall 113 of the steel sleeper trough body 100 is clamped in a notch 516 formed between a clamping collar 515 and the fastening projections 512 at its upper surface 110, and the sleeper screw anchor 510 is fastened to the steel sleeper trough body via this clamping.

[0105] The sleeper screw anchor 510 preferably has a through-hole 517 on its interior. This through-hole preferably terminates at the underside 420 of the molded body 400 that surrounds the sleeper screw anchor 510 and is preferably formed around it. The sleeper screw anchor 510 is integrated into the molded body 400. Nevertheless, water that penetrates the sleeper screw anchor can drain downwards through the through-hole 517.

[0106] Fig. 14 Figure 1 shows a schematic drawing of a section of a steel monoblock sleeper with a sleeper screw dowel pair 560. A sleeper screw dowel pair 560 has two sleeper screw dowel bodies 561 connected to each other via a web 568, each preferably having fastening projections 562. The sleeper screw dowel bodies 561 each have a preferably circumferential clamping collar 565. Between the clamping collar 565 and the fastening projections, a preferably circumferential notch 566 is formed in each sleeper screw dowel body. The upper surface 110 of the steel trough body 100 of a steel monoblock sleeper 1 is received in this notch when the sleeper screw dowel bodies 561 are pressed into preferably circular openings 111, 112 of the steel trough body 100.

[0107] A length 563 of the sleeper screw dowel bodies 561 is adapted to a height of the steel trough body 100 and the shaped body 400, so that a through hole 567 around the central axis 564 of each sleeper screw dowel body 561 ends at the bottom 420 of the shaped body 400.

[0108] Visible are the transverse bars 260, guide elements 270, clamping devices 280, and sleeper screws 290 for fastening a rail 2000, which are welded to the top surface 110 of the steel sleeper trough body 100. The operating state is shown on the left, and the delivery state of the fastening devices pre-assembled on the steel monoblock sleeper 1 is shown on the right.

[0109] Fig. 15 shows a partial sectional side view of the steel monoblock sleeper 1 according to Fig 14 .

[0110] Fig. 16 shows a schematic enlarged sectional view of part of a pressed-in sleeper screw dowel body of a sleeper screw dowel pair.

[0111] Fig. 17 Figure 1 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 surface 110 of a steel sleeper trough body 1. A circumferential serrated notch edge 569 can be seen, the serrations of which act as an elastic clamping element in the radial direction when the top surface 110 of the steel sleeper trough body is received in the notch.

[0112] In Fig. 18 Figure 1 shows a schematic partial sectional view of the top surface of a steel sleeper trough body 100, to which a steel sleeve 210 with a sleeper screw dowel 510 embedded within it is welded. The steel sleeve 210 is arranged concentrically with an opening 111 in the top surface 110. In this embodiment, the inner diameter 215 of the steel sleeve 210 and the inner diameter 115 of the opening 111 for receiving the sleeper screw (not shown) are essentially identical.

[0113] It is also possible to design the opening 111 such that it corresponds to an outer diameter of the steel casing tube 210. In such an embodiment, the steel casing tube 210 can be welded to the top surface 110 from above.

[0114] In the embodiment according to Fig. 18 The screw sleeper anchor 510 has a circumferential projection 517 which protects the sleeper screw anchor 510 against being "pushed through" when the steel sleeve 210 projects through the shaped body 400 or is flush with its underside 420.

[0115] In Fig. 19 Figure 1 shows another schematic partial sectional view of the top surface 110 of a steel sleeper trough body 100, to which a steel sleeve 210 with a sleeper screw anchor 510 embedded therein is welded, but secured against being pulled out upwards. In this embodiment, the inner diameter 115 of the opening 111 in the top surface 110 of the steel sleeper trough body 100 is smaller than the inner diameter 215 of the steel sleeve 210. In this embodiment, the sleeper screw anchor 510 has a notch 516 and a clamping collar 515. The clamping collar 515, like the circumferential projection 517 in the embodiment according to [reference missing], prevents [reference missing] from being pulled out upwards. Fig. 18 a "pushing through" of the threshold screw dowel 510 downwards out of the steel sheathing tube 210.

[0116] In both embodiments, a weld seam 220 can be completely closed or partially completed around the circumference.

[0117] In these embodiments, the threshold screw dowel preferably has a through hole 567, so that liquids penetrating from above or forming inside can drain downwards. Reference sign

[0118] 1 Steel monoblock sleeper 100 Steel sleeper trough body 105 Side 106 Side 110 Top 111 Opening 112 Opening 113 Wall 115 Inner diameter 120 Bottom 130 Hollow profile 135 Profile direction 140 Cross-section of the hollow profile 150 Ends 160 Head caps 165 Head cap edge 170 Profile edge / longitudinal edge 180 End sections 190 Fastening sections 195 Middle section 200 Dividing profile / rib 210 Steel sheathing tube 215 Inner diameter 220 Weld seam 250 Rib plate 260 Crossbar 270 Guide parts 280 Tension clamps 290 Sleeper screw 400 Shaped body 410 Top 420 Bottom 470 Recesses 510 Sill screw dowel 511 Body 512 Fastening projection 513 Extension 514 Central axis 515 Clamping collar 516 Notch 517 Circumferential projection 520 Dowel block 525 Dowel opening 540 Separating body 550 Sensor element 560 Sill screw dowel pair 561 Sill screw dowel body 562 Fastening projection 563 Length 564 Central axis 565 Clamping collar 566 Notch 567 Through hole 568 Web 569 Notch edge 600 Loose solids 610 Gravel 620 Crushed stone 700 ReactiveMaterial 800 Coating 850 Adhesive 900 Angle profile 901 End 902 Other end 905 Profile direction 910 Leg 911 Top 920 Other leg 921 Openings 930 Connecting plate 935 Connecting screws 1000 Hollow profile shape 1010 Fixing element 1020 Fixing element 1050 Lockable openings 1060 Closures 1100 Injection nozzles for reactive material 1200 Vibrating device 1300 Cover 1310 Rubber layer 1320 Anti-stick layer 1350 Lockable openings 1360 Closures 1370 Pressing device 1400 Coating nozzles 1420 Pressure device 2000 Rail

Claims

1. Steel monoblock sleeper (1) comprising a steel sleeper trough body (100) made of a hollow profile (130), wherein the steel sleeper trough body (100) is filled in a profile-filling manner, at least in sections (190) intended for rail fastening, by means of at least one moulded body (400) which is connected to the steel sleeper trough body (100), wherein the at least one moulded body (400) is a solid-foam-composite material.

2. Steel monoblock sleeper (1) according to claim 1, wherein the hollow profile (130) is bent over at opposite ends (150) of the steel sleeper trough body (100) to form head caps (160) or the hollow profile has end profiles welded into or onto the opposite ends.

3. Steel monoblock sleeper (1) according to claim 1 or 2, wherein the at least one moulded body (400) is a rubble-foam composite material.

4. Steel monoblock sleeper (1) according to claim 3, wherein a component of the composite material is selected from the group comprising polyurea and polyurethane.

5. Steel monoblock sleeper (1) according to any of claims 2 to 4, wherein the bent head caps (160) or end profiles do not protrude beyond the longitudinal edges (170) of the hollow profile (130), preferably ending flush with the longitudinal edges (170) of the hollow profile (130).

6. Steel monoblock sleeper (1) according to one of the preceding claims, wherein the at least one moulded body (400) is connected in a force-fitting manner to the steel sleeper trough body (100).

7. Steel monoblock sleeper (1) according to one of the preceding claims, wherein at least one separating profile or separating body in the hollow profile (130) of the steel sleeper trough body (100) delimits one of the sections (190) intended for track fastening.

8. Steel monoblock sleeper according to one of the preceding claims, wherein at least one dowel block (520) with at least one dowel recess (525) and / or at least one sleeper screw dowel (510) is integrated in the at least one moulded body (400).

9. Steel monoblock sleeper (1) according to one of the preceding claims, wherein the steel sleeper trough body (100) has at least one rib plate on a side facing away from the hollow profile (130) for guiding a track fastening arrangement or the track.

10. Steel monoblock sleeper (1) according to one of the preceding claims, wherein the at least one composite body (400) arranged in the hollow profile (130) of the steel sleeper trough body (100) ends flush with a side surface with the longitudinal edges (170) of the steel sleeper trough body (100).

11. Steel monoblock sleeper (1) according to one of the preceding claims, wherein the steel sleeper trough body (100) is coated in whole or in part.

12. Method for manufacturing a steel monoblock sleeper (1) comprising the following steps: (a) providing or manufacturing a steel sleeper trough body (100) from a hollow profile (130); (b) arranging or forming at least one moulded body (400) in at least one section (180, 190) of the steel sleeper trough body (100), and connecting it to the steel sleeper trough body (100) so that the at least one section (180, 190) of the steel sleeper trough body (100) is filled by the at least one moulded body (400) in a profile-filling manner, wherein the following further process steps are provided: Filling a hollow profile mould (1000), the hollow shape of which corresponds at least to a section (180, 190) of the hollow profile (130) of the steel sleeper trough body (100), with reactive material (700), and allowing the reactive material (700) to react to form the at least one moulded body (400) filling the hollow profile mould (1000) in a profile filling manner wherein before filling or simultaneously with filling the reactive material (700) into the hollow profile shape (1000) , the hollow profile shape (1000) is additionally filled with loose solids (600), and the loose solids (600) are compacted, and the filling and reaction of the reactive material (700) is carried out in such a way that the reacted reactive material (700) surrounds the loose solids (600) and forms the moulded body (400) as a composite body whose outer contour is adapted at least to a section (180, 190) of the contour of the hollow profile mould.

13. Method according to claims 12, wherein the hollow profile (130) is provided with bent head caps (160) at the opposite ends (150) or, alternatively, the hollow profile (130) is bent at the opposite ends (150) to form the head caps (160), or alternatively, end profiles are inserted into or welded to the hollow profile at the opposite ends.

14. Method according to claim 13, wherein rubble (610) is used as loose solid material (600), preferably track ballast (620).

15. Method according to one of claims 12 to 14, wherein a separating body (540) is inserted into a middle third of the hollow profile mould (1000) before filling, so that the at least one composite body (400) is formed by means of the reactive material (700) only in at least one section (180, 190) of the hollow profile mould (1000).

16. Method according to one of claims 12 to 15, wherein the steel sleeper trough body (100) is used as the hollow profile mould (1000).

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