Block assembly and kit for laying rails and method of installing block assembly thereof

Abstract

The disclosed technical solution relates to a modular assembly configured for directly securing railway track components. The modular assembly is configured to be operably connected to rail fasteners via a plurality of cast-in threaded fasteners. The modular assembly can be placed on a concrete slab. Furthermore, the modular assembly can be partially embedded in the poured concrete. The modular assembly includes a plurality of grooves that engage with the poured concrete to maintain the position of the modular assembly. The modular assembly includes reinforcing steel fittings contained within it, thereby increasing the overall integrity of the modular assembly without causing problems typically associated with extended steel reinforcement. Additionally, the reinforcing steel fittings are configured with an optimized number of bends and welds to further increase integrity and reduce manufacturing costs.

Description

Technical Field

[0001] A railway track, particularly a block assembly and a kit for laying the track, and a method for installing the block assembly. Prior Technology

[0002] Traditional railway tracks are secured using sleepers and rail fasteners. Sleepers provide support, and rail fasteners secure the rails to them; typically, monolithic sleepers are used. Typically, a monolithic sleeper spans the width of the track, that is, the distance between the rails (perpendicular to the direction of travel).

[0003] Railway sleepers necessarily require two pairs of rail fasteners to be installed parallel to each of the two rails. For certain rail configurations, more flexibility in track layout is needed. For example, subway tracks have a unique gauge and a more compact turning radius (among other considerations). Therefore, direct-fixing blocks are often used.

[0004] Direct-fixed blocks provide similar support to integral railway sleepers. However, unlike integral railway sleepers, direct-fixed blocks are arranged in pairs, with each pair providing the ability to adjust track width (gauge) and different turning radii.

[0005] The direct-fixing blocks are initially placed on a concrete slab and then partially embedded in the poured concrete (or other material). Rail fasteners can then be attached to the embedded direct-fixing blocks. This arrangement provides configurability and stable fixation.

[0006] However, as disclosed herein, existing direct fasteners have many problems. To address these problems, this paper discloses a technical solution involving direct fasteners. Summary of the Invention

[0007] This application claims priority to the following: U.S. Provisional Patent Application No. 63 / 669,087, filed July 9, 2024, entitled “DIRECT FIXATION BLOCK ASSEMBLY”, and U.S. Non-Provisional Patent Application No. 19 / 015,461, filed January 9, 2025, entitled “DIRECT FIXATION BLOCK ASSEMBLY”.

[0008] All referenced applications are incorporated herein by reference in their entirety.

[0009] The technical solution disclosed herein includes a modular assembly comprising a plurality of grooves having multiple edges, wherein the plurality of grooves may include grooves having a first edge and a second edge, both the first edge and the second edge belonging to the plurality of edges. The modular assembly may further include a plurality of cast-in threaded fasteners partially disposed within the modular assembly. The modular assembly may further include reinforcing steel fittings integrally disposed within the modular assembly.

[0010] The block assembly may further include a first back side surface having a second back side surface and a plurality of back side surfaces, wherein the second back side surface may be straight at a first periphery of the block assembly, and the plurality of back side surfaces may be curved at the first periphery of the block assembly. The block assembly may further include a first ventral side surface having a second ventral side surface and a plurality of ventral side surfaces, wherein the second ventral side surface may intersect with a plurality of grooves at a second periphery of the block assembly, and the plurality of ventral side surfaces may be curved at the second periphery of the block assembly. The first back side surface may be smaller than the first ventral side surface. The first periphery may be shorter than the second periphery.

[0011] The grooves may intersect at the center of the straight segments of the second periphery. The grooves may be defined by a first distance, a first plurality of distances, a second distance, a third distance, a first plurality of angles, and a second plurality of angles. The cast-in threaded fastener may be selected from a plurality of cast-in threaded fasteners and may have a raised cylindrical portion, a plurality of holes, a recess, a shaft, and a plurality of bell-shaped portions. The shaft may be partially disposed within the reinforcing bar assembly. The raised cylindrical portion may be configured to mate within a hole in the fastener base. The reinforcing bar assembly may have a first reinforcing bar segment, a first plurality of reinforcing bar segments, a second plurality of reinforcing bar segments, a third plurality of reinforcing bar segments, a fourth plurality of reinforcing bar segments, and a fifth plurality of reinforcing bar segments. The block assembly may be configured to be operably connected to the fastener assembly, which is configured to be fastened to the rail. The fastener assembly may have a fastener base. A first back surface at the block assembly may support the entire front surface of the fastener base.

[0012] The technical solution disclosed herein includes a kit for laying rails with modular assemblies, the modular assemblies including multiple grooves having multiple edges. The multiple grooves may include grooves having a first edge and a second edge, wherein the first edge and the second edge belong to the multiple edges. The modular assemblies may include multiple cast-in threaded fasteners partially disposed within the modular assemblies. The modular assemblies may include reinforcing steel assemblies integrally disposed within the modular assemblies. The modular assemblies may further include fastener assemblies for fastening to the rails. The grooves may be defined by a first distance, a first plurality of distances, a second distance, a third distance, a first plurality of angles, and a second plurality of angles.

[0013] The cast-in threaded fastener can be selected from multiple cast-in threaded fasteners having a raised cylindrical portion, multiple holes, recesses, a shaft, and multiple bell-shaped portions. The block assembly may further include a first back surface, which includes a second back surface and multiple back surfaces, wherein the second back surface may be straight at a first periphery of the block assembly, and wherein the multiple back surfaces may be curved at the first periphery of the block assembly. The block assembly may include a second ventral surface and multiple ventral surfaces, wherein the second ventral surface may intersect with multiple grooves at a second periphery of the block assembly, and wherein the multiple ventral surfaces may be curved at the second periphery of the block assembly. The fastener assembly may further include a fastener base configured to be disposed on the first back surface, wherein the ventral surface of the fastener base may be integrally in contact with the first back surface. The first back surface may be smaller than the first ventral surface, and the first periphery may be shorter than the second periphery.

[0014] The technical solution disclosed herein also includes a method for installing a block assembly on a concrete slab. The method may include placing the block assembly on the surface of the concrete slab. The block assembly may include a plurality of grooves having a plurality of edges. The plurality of grooves may include recesses, wherein each recess includes a first edge and a second edge. The first edge and the second edge belong to the plurality of edges. The block assembly may further include a plurality of cast-in-place threaded fasteners partially disposed within the block assembly. The block assembly may further include reinforcing steel fittings integrally disposed within the block assembly. The method may further include pouring a layer of concrete around the block assembly that contacts the plurality of grooves. The plurality of cast-in-place threaded fasteners may be accessible above the poured concrete layer. Simple Explanation of the Diagram

[0015] The accompanying drawings, which are incorporated herein and form part of this specification, illustrate exemplary aspects of the claims and, together with the general description given above and the detailed description given below, serve to interpret the features of the claims. Figure 1A is a perspective view of the fixed assembly from a top view. Figure 1B is a perspective view of the fixed assembly from the bottom. Figure 1C is a plan view of the fixed assembly from a top perspective. Figure 1D is a plan view of the fixed assembly from a frontal perspective. Figure 1E is a plan view of the fixed assembly from a side view. Figure 1F is a plan view of the fixed assembly shown from the bottom. Figure 2A is a perspective view of the block assembly from a top view. Figure 2B is a perspective view of the block assembly from the bottom. Figure 2C is a plan view of the block assembly from a top perspective. Figure 2D is a plan view of the block assembly from a frontal perspective. Figure 2E is a plan view of the block assembly from a side view. Figure 2F is a plan view of the block assembly from the bottom perspective. Figure 2G is a perspective view of the hole from a top view. Figure 3A is a perspective view of the block assembly from a top view. Figure 3B is a perspective view of the block assembly from the bottom. Figure 3C is a plan view of the block assembly from a top perspective. Figure 3D is a plan view of the block assembly from a frontal perspective. Figure 3E is a plan view of the block assembly from a side view. Figure 3F is a plan view of the block assembly from the bottom perspective. Figure 3G is a plan view of the hole from a side view. Figure 4A is a perspective view of the block assembly from a top view. Figure 4B is a perspective view of the block assembly from a top view. Figure 4C is a perspective view of the block assembly from the bottom. Figure 4D is a plan view of the block assembly from a top perspective. Figure 4E is a plan view of the block assembly from a bottom perspective. Figure 5A is a perspective view of the block assembly from a top view. 5B is a three-dimensional view of the block fitting shown from the bottom perspective. Figure 5C is a plan view of the block fitting shown from the top perspective. 5D is a plan view of the block fitting shown from the front view. Figure 5E is a plan view of the block assembly from a side view. Figure 5F is a plan view of the block assembly from the bottom perspective. Implementation

[0016] The various aspects will be described in detail with reference to the accompanying figures. Where possible, the same drawing markings are used in all drawings to refer to the same or similar parts. References to particular examples and implementations are for illustrative purposes and are not intended to limit the scope of the claims.

[0017] As mentioned above, the integral layout used for railways is under-optimized for layouts that require more configurations. Typically, integral blocks are custom-made for the layout. However, this process increases the cost of setting up and introduces unnecessary construction delays. In addition, any adjustments to the arrangement often require rework of the integral blocks and other components of the rail. Therefore, direct fixed blocks can be used to address defects in integral block-related layouts.

[0018] Different gauge gauges can be adapted by direct fixed blocks spaced apart according to the desired rail moment. For example, subway rails can have narrower gauge than heavy freight rails. However, direct fixed blocks can be used in both configurations. Unlike integral blocks, the track can be adjusted in the field since each direct-fixed block is independent. Another motivation for the use of directly fixed blocks is to address configurations that require different turning radii. For example, subway rails can have a smaller turning radius than that of heavy freight rails.

[0019] An advantage of directly securing blocks is the ability to adjust the layout in the field. As mentioned above, custom gauge and turning radii may be required. To the extent these aspects are altered, direct fixed blocks often do not require customization for a specific block when compared to the arrangement associated with the integral block. In addition, furnishings associated with integral blocks often require brand new integral blocks, which need to be ordered and shipped to the site for furnishing.

[0020] However, directly anchoring blocks is not without its challenges. When directly anchored blocks are placed on a concrete slab, they are subjected to numerous forces. These forces can damage, displace, and / or destroy the blocks (and any attached hardware components). If the blocks are subjected to such forces, there is a risk that the rails will lose support, potentially leading to derailment of locomotives and rolling stock. Such incidents can result in property damage and even loss of life.

[0021] To secure and protect the blocks, one or more layers of concrete are poured around them to anchor them to the concrete slab. The poured concrete typically reduces the forces required to move and / or remove the blocks from the base layer (i.e., the slab). Furthermore, the poured concrete protects the blocks from weather, mechanical damage, and other factors. However, existing direct-fixing block configurations lack sufficient design to properly secure the blocks in place.

[0022] There is also a risk that the extended sections of the reinforcing bars may corrode. When the reinforcing bars corrode, as the corrosion spreads throughout the metal, the internal reinforcing bars may also begin to corrode.

[0023] In stark contrast, as described above, the technical solution of this disclosure includes a reinforcing steel assembly that is completely contained within the block itself. By ensuring that the reinforcing steel is entirely within the block, there are no external components that could corrode the steel. Therefore, external corrosion will not penetrate into the block by traveling along the extension of the reinforcing steel.

[0024] External reinforcing bar extensions may be damaged and break directly. As mentioned above, corrosion is a factor that damages and / or weakens the reinforcing bar extensions. When the reinforcing bar extensions break, the block loses its integral connection with the poured concrete, resulting in unstable block support.

[0025] In stark contrast, the technical solution disclosed herein includes reinforcing steel assemblies that are entirely contained within the block itself. Therefore, the reinforcing steel assemblies will not break or lose their integral connection with the poured concrete. The block assemblies are designed so that, due to the unique characteristics of the technical solution disclosed herein (as disclosed below), the poured concrete firmly secures the block.

[0026] Furthermore, extended sections of reinforcing bars are difficult for installers to handle. These sections may be sharp, or even if in good condition, rough and prone to causing injury. Additionally, these extended sections must be carefully handled before pouring concrete to avoid any premature damage. Even when blocks with extended reinforcing bars have been placed, pouring concrete can still damage them. Even under ideal conditions, these factors slow down the installation process. Worse still, these problems pose a risk of injury to installers.

[0027] As described, the technical solution of this disclosure includes a reinforcing steel assembly completely contained within the block itself. Since no reinforcing steel extends from the disclosed solution, personnel will not be injured by the steel. Furthermore, personnel can easily handle the block without the risk of damaging any protruding portions of the reinforcing steel. Therefore, the technical solution of this disclosure protects personnel from unnecessary occupational hazards. Additionally, installation personnel do not need to worry about prematurely damaging the protruding portions of the reinforcing steel, because, as mentioned above, the reinforcing steel in the technical solution of this disclosure is completely contained within the block.

[0028] Additionally, there is a risk of interference between the extended steel reinforcement sections and other track components. For example, conduits for cables may be laid in the track before concrete is poured. When placing the extended steel reinforcement sections, the conduits need to be adjusted to prevent interference between them and the reinforcement. Other track-side components may include water pipes, heating elements, gas lines, sensors, etc. For subway construction, many other types of infrastructure may share space with the tunnels used for the subway tracks.

[0029] In stark contrast, the technical solution disclosed herein features a reinforcing steel assembly entirely contained within the block itself. Therefore, the block has no reinforcing steel extensions that could potentially interfere with other track components (such as conduits, other reinforcing bars, other supports, sensors, etc.). Even in the case of temporary additions to the track infrastructure, the technical solution disclosed herein completely avoids any interference with the track infrastructure based on the reinforcing steel. Therefore, designers are free to add components to the track without worrying about interfering with the reinforcing steel extensions (because the technical solution disclosed herein lacks reinforcing steel extensions).

[0030] Reinforcing bar extensions are not the only way to secure blocks in place to avoid stress. The shape of the blocks can be configured to allow the poured concrete to hold them more firmly in place. However, existing shapes for directly securing blocks are suboptimal.

[0031] Existing direct-fixing blocks are typically configured in a rectangular shape, with the block surface perpendicular to the base layer and / or rail fasteners. However, rectangular shapes can be prone to chipping at the corners. For example, installers might accidentally bump into a corner, causing it to break.

[0032] In stark contrast, the technical solution disclosed herein has a substantially circular perimeter at the base. Therefore, installers are less likely to damage the blocks before and / or during installation. An additional benefit is a reduced risk of injury to installers, as the block assembly has fewer sharp edges.

[0033] Regarding the shape of existing block assemblies, the existing rectangular directly fixed blocks are insufficient to resist vertical forces. When the blocks are pulled by the rails, because the periphery of the blocks is aligned with the direction of the force, the blocks can simply slide upwards and out of the poured concrete.

[0034] In stark contrast, the technical solution of this disclosure includes a configuration in which the back surface area is smaller than the ventral surface area. In other words, the technical solution of this disclosure has a more trapezoidal shape than existing rectangular blocks. Therefore, the base (with a larger ventral surface area) is larger than the top (with a smaller back surface area), thus the technical solution of this disclosure is held within the cast concrete. Furthermore, the non-coplanar surfaces of the technical solution of this disclosure firmly hold the block assembly within the cast concrete slab / substrate, with the block assembly acting strongly against the cast concrete slab / substrate. Therefore, the technical solution of this disclosure is more difficult to displace by forces (especially vertical forces / tensions).

[0035] Another problem with existing directly fixed blocks is the risk of rotational forces causing the blocks to move within the poured concrete. Many existing solutions have smooth peripheral surfaces. Therefore, when forces cause the block to rotate, the block's surface merely slides within the poured concrete, leading to displacement. In extreme cases, the block may damage the poured concrete slab / substrate under rotational forces.

[0036] In stark contrast, the technical solution disclosed herein features multiple grooves disposed on the peripheral surface of the block. These grooves cause the block to remain in the installed position because the poured concrete and the grooves abut against each other. The grooves are particularly well-suited to resist rotational forces. Thus, the integrity of the poured concrete slab / substrate is maintained.

[0037] Regarding internal steel reinforcement assemblies, existing direct-fixing blocks include under-optimized steel reinforcement assemblies. Steel reinforcement assemblies are designed to increase the overall integrity of the blocks. However, many steel reinforcement assemblies are configured with an excessive number of bends and / or welds. Therefore, these assemblies may be prone to failure. Furthermore, these steel reinforcement assemblies are more difficult to manufacture, thus incurring additional costs.

[0038] In contrast, the technical solution disclosed herein includes steel reinforcement assemblies configured with an optimized number of bends and / or welds. Therefore, the technical solution disclosed herein possesses a high level of integrity while not incurring excessive manufacturing costs.

[0039] Figure 1A is a perspective view of the fixed assembly 101 from a top view. Multiple axes are shown: a first axis 103X, a second axis 103Y, and a third axis 103Z. Axis 103X is perpendicular to the direction of travel of the locomotive and rolling stock along the rail 102. Axis 103Y is parallel to the direction of travel of the locomotive and rolling stock along the rail 102. Axis 103Z is vertical and is formed by the normal vectors of axes 103X and 103Y.

[0040] The fixing assembly 101 includes a fastener assembly 201 and a block assembly 301. The rail 102 is fastened to the block assembly 301 via the fastener assembly 201. The fastener assembly 201 includes a fastener base 205, a plurality of clamping members 206Z, a plurality of bolts 203Z, and a plurality of locking washers 204Z. The fastener base 205 is generally configured to align and support the rail 102, such that the plurality of clamping members 206Z can fasten the rail 102. The plurality of clamping members 206Z includes a first clamping member 206A and a second clamping member 206B, each of which can be positioned to contact the base of the rail 102.

[0041] The plurality of bolts 203Z includes a first bolt 203AA, a second bolt 203AB, a third bolt 203BA, and a fourth bolt 203BB. The plurality of bolts 203Z are typically configured to operatively connect the fastener base 205 to the block assembly 301. The plurality of bolts 203Z are operatively connected to a plurality of locking washers 204Z, which prevent the plurality of bolts 203Z from loosening. The plurality of locking washers 204Z includes a first locking washer 204AA, a second locking washer 204AB, a third locking washer 204BA, and a fourth locking washer 204BB.

[0042] Those skilled in the art will understand that the bell shape of the block assembly 301 provides stability when it is placed on a concrete slab. Specifically, more surface area (at the ventral surface of the block assembly 301) is in contact with the slab. Similarly, more mass is set closer to this surface, i.e., at the slab. Those skilled in the art will note that the rear surface area of ​​the block assembly 301 is smaller than the ventral surface area.

[0043] The block assembly 301 includes a plurality of recesses 308Z. The plurality of recesses 308Z includes a first recess 308A and a second recess 308B. The plurality of recesses 308Z are generally configured to engage with the poured concrete to further hold the block assembly 301 in place. Furthermore, the plurality of recesses 308Z provide keying engagement into the poured concrete to facilitate mechanical locking with surrounding materials. The bell-shaped shape of the block assembly 301 provides resistance to pulling the block assembly 301 out of the poured concrete. The plurality of recesses 308Z limit the block assembly 301 to vertical forces and provide its stability against rotational forces that cause the block assembly 301 to lift and / or rotate within the poured concrete (which is generally undesirable). Additionally, the plurality of recesses 308Z provide more surface area for adhesion to the poured concrete.

[0044] Those skilled in the art will understand that, due to the relationship between the two assemblies 201 and 301, the block assembly 301 and the fastener assembly 201 can be sold as a kit. For example, a railway operator or installer may expect faster railway deployment and require the two assemblies 201 and 301 to be pre-installed with each other. Therefore, the operator / installer can simply remove assemblies 201 and 301 from the kit and place the assembled assembly onto a concrete slab. Those skilled in the art will understand that fine-tuning may be required, such as checking torque values ​​and adjusting rail clamp components. However, the combined kit offers the advantage of rapid railway deployment.

[0045] Figure 1B is a perspective view of the mounting bracket 101 from a bottom view. The plurality of recesses 308Z include a plurality of recessed surfaces 307Z and a plurality of edges 309Z.

[0046] The plurality of grooved surfaces 307Z include a first grooved surface 307A and a second grooved surface 307B. The plurality of edges 309Z include a first edge 309AA, a second edge 309AB, a third edge 309BA, and a fourth edge 309BB. The first grooved surface 307A is formed by the first edge 309AA and the second edge 309AB. The second grooved surface 307B is formed by the third edge 309BA and the fourth edge 309BB.

[0047] Figure 1C is a plan view of the fastener assembly 101 shown from a top perspective. The fastener base 205 includes a plurality of holes 209Z. The plurality of holes 209Z includes a first hole 209AA, a second hole 209AB, a third hole 209BA, and a fourth hole 209BB. The plurality of holes 209Z are generally configured such that a plurality of bolts 203Z can be inserted into fasteners (not shown) via a plurality of cast-in threads within the block assembly 301 to operably connect the fastener assembly 201 to the block assembly 301.

[0048] The groove 308B includes a first distance 310B measured between the back points of edges 309BA and 309BB. Multiple distances 312Z include the first distance 312BA and a second distance 312BB. Distance 312BA covers the length of edge 309BA. Distance 312BB covers the length of edge 309BB.

[0049] Distance 311B measures the distance between the ventral ends of edges 309BA and 309BB. Distance 324B measures the width of edges 309BA and 309BB at the ventral surface of the block assembly 301.

[0050] Figure 1D is a plan view of the fixing fitting 101 shown from the front. The groove 308B is defined by a first plurality of angles 313Z and a second plurality of angles 314Z.

[0051] The plurality of corners 313Z includes a first corner 313BA and a second corner 313BB. The first corner 313BA is formed between the edge 309AB and the back surface of the block assembly 301. The second corner 313BB is formed between the edge 309BB and the back surface of the block assembly 301.

[0052] The plurality of angles 314Z includes a first angle 314BA and a second angle 314BB. The first angle 314BA is formed between the edge 309AB and the ventral surface of the block assembly 301. The second angle 314BB is formed between the edge 309BB and the ventral surface of the block assembly 301. The plurality of angles 314Z includes a first angle 314BA and a second angle 314BB.

[0053] Figure 1E is a plan view of the fastener 101 from a side view. Figure 1F is a plan view of the fastener 101 from a bottom view.

[0054] Figure 2A is a perspective view of the block assembly 301 from a top view. The block assembly 301 includes a plurality of cast-in threaded fasteners 315Z. The plurality of cast-in threaded fasteners 315Z include a first cast-in threaded fastener 315AA, a second cast-in threaded fastener 315AB, a third cast-in threaded fastener 315BA, and a fourth cast-in threaded fastener 315BB. The plurality of cast-in threaded fasteners 315Z are generally configured to accommodate a plurality of bolts 203Z. In addition, the plurality of cast-in threaded fasteners 315Z are configured to align with a plurality of cast-in threaded fasteners 209Z of the fastener base 205.

[0055] Figure 2B is a perspective view of the block assembly 301 from a bottom view. Figure 2C is a plan view of the block assembly 301 from a top view. The plurality of cast-in threaded fasteners 315Z include a plurality of raised cylindrical portions 318Z. The plurality of raised cylindrical portions 318Z include a first raised cylindrical portion 318AA, a second raised cylindrical portion 318AB, a third raised cylindrical portion 318BA, and a fourth raised cylindrical portion 318BB. In one aspect, the plurality of cast-in threaded fasteners 315Z may not have the plurality of raised cylindrical portions 318Z.

[0056] Figure 2D is a plan view of the block assembly 301 from a front view. Figure 2E is a plan view of the block assembly 301 from a side view. Figure 2F is a plan view of the block assembly 301 from a bottom view.

[0057] Figure 2G is a perspective view of the cast-in threaded fastener 315BA from a top view. The cast-in threaded fastener 315BA includes multiple holes 317Z. The multiple holes 317Z include a first hole 317BAAA, a second hole 317BAAB, a third hole 317BABA, and a fourth hole 317BABB. The multiple holes 317Z are typically configured to allow the removal of a nylon plastic insert from the cast-in threaded fastener 315BA. This removal process can be performed using a special tool.

[0058] Figure 3A is a perspective view of the block assembly 301 shown from a top view. The block assembly 301 includes a reinforcing steel assembly 401. The reinforcing steel assembly 401 is generally configured to provide strength to the block assembly 301 and maintain the integrity of the concrete of the block assembly 301. Furthermore, the reinforcing steel assembly 401 is generally configured to work in conjunction with the geometry of the block assembly 301 to counteract bending forces caused by passing locomotives or rolling stock. The construction configuration shown minimizes reinforcing steel welding without compromising the integrity of the reinforcing steel assembly 401 (and the block assembly 301).

[0059] The reinforcing steel assembly includes a first reinforcing steel segment 405, multiple first reinforcing steel segments 406Z, multiple second reinforcing steel segments 407Z, multiple third reinforcing steel segments 409Z, multiple fourth reinforcing steel segments 410Z, and multiple fifth reinforcing steel segments 411Z. Multiple reinforcing steel segments 406Z include a first reinforcing steel segment 406A and a second reinforcing steel segment 406B. Multiple reinforcing steel segments 407Z include a first reinforcing steel segment 407A and a second reinforcing steel segment 407B. Multiple reinforcing steel segments 409Z include a first reinforcing steel segment 409A and a second reinforcing steel segment 409B. Multiple reinforcing steel segments 410Z include a first reinforcing steel segment 410A and a second reinforcing steel segment 410B. Multiple reinforcing steel segments 411Z include a first reinforcing steel segment 411A and a second reinforcing steel segment 411B.

[0060] Figure 3B is a perspective view of the block assembly 301 from a bottom view. Figure 3C is a plan view of the block assembly 301 from a top view. Figure 3D is a plan view of the block assembly 301 from a front view. Figure 3E is a plan view of the block assembly 301 from a side view. Figure 3F is a plan view of the block assembly 301 from a bottom view.

[0061] Figure 3G is a plan view of the cast-in threaded fastener 315BA from a side view. The cast-in threaded fastener 315BA includes a recess 321BA, a plurality of bell-shaped portions 320Z, and a shaft 319BA. The plurality of bell-shaped portions 320Z include a first bell-shaped portion 320BAA and a second bell-shaped portion 320BAB. The bell-shaped portions 320BAB are configured to retain the cast-in threaded fastener 315BA within the block assembly 301, wherein the tapered shape creates a shear cone that prevents axial pull-out.

[0062] Figure 4A is a perspective view of the block assembly 302 from a top view. The current view shows an alternative embodiment of the technical solution of this disclosure (i.e., the block assembly 302) in which the plurality of cast threaded fasteners 315Z include fewer cast threaded fasteners and are therefore labeled as a plurality of cast threaded fasteners 316Z. As shown, the cast threaded fasteners 316AA and 316BB are positioned at the same locations as shown in Figures 2A to 2F above, relative to the cast threaded fasteners 315AA and 315BB. Furthermore, the cast threaded fasteners 315AB and 315BA have been omitted relative to Figures 2A to 2F above.

[0063] Block assembly 302 is configured to accommodate an alternative fastener assembly including two holes. For example, the alternative fastener assembly will have a first hole and a second hole. Referring to fastener assembly 201, the first hole will be similar to hole 209AA, and the second hole will be similar to hole 209BB. In addition, holes 209AB and 209BA will be omitted.

[0064] For clarity, fastener assembly 201 can be used with an alternative embodiment shown in this view as block assembly 302. However, holes 209AB, 209BA will not have locking washers 204AB, 204BA and bolts 203AB, 203BA installed. Therefore, the shown alternative embodiment has the advantage of being more aesthetically pleasing while accommodating rail fastener assemblies with two or four holes.

[0065] Figure 4B is a perspective view of the block assembly 302 from a top view. The reinforcing bar assembly 401 is shown in more detail. Figure 4C is a perspective view of the block assembly 302 from a bottom view. The reinforcing bar assembly 401 is shown in more detail again. Figure 4D is a plan view of the block assembly 302 from a top view. The reinforcing bar assembly 401 is shown in more detail again. Figure 4E is a plan view of the block assembly 302 from a bottom view. Finally, the reinforcing bar assembly 401 is shown in more detail.

[0066] Figure 5A is a perspective view of the block assembly 301 from a top view. As described herein, the block assembly 301 includes a back surface 329 smaller than the ventral surface 333 (not shown in this view). The back surface 329 includes a plurality of back surfaces 326Z and a back surface 331. The plurality of back surfaces 330Z includes a first back surface 330A and a second back surface 330B. The plurality of back surfaces 330Z are curved at the periphery 341A of the block assembly 301. The back surface 331 is straight at the periphery of the block assembly 301. To highlight that the back surface 329 is smaller than the ventral surface 333, a plurality of distances 326Z are shown. The plurality of distances 326Z includes a first distance 326A and a second distance 326B.

[0067] Figure 5B is a perspective view of the block assembly 301 from a bottom view. This view shows the ventral surface 333 in full detail. As with Figure 5A above, the dorsal surface 329 is smaller than the ventral surface 333. Similarly, distance 326A highlights this relationship between the dorsal surface 329 and the ventral surface 333.

[0068] As shown in the figure, the ventral surface 333 includes multiple ventral surfaces 334Z and ventral surfaces 335. The multiple ventral surfaces 334Z include a first ventral surface 334A and a second ventral surface 334B. The multiple ventral surfaces 334Z are curved at the periphery 341B of the block assembly 301.

[0069] Unlike the back surface 331, the ventral surface 335 is not continuous at the periphery 341B of the block assembly 301. Multiple grooves 308Z are shown intersecting the ventral surface 335, as indicated by multiple distances 311Z. As described herein, the multiple grooves 308Z provide more stable positioning within the poured concrete without the need for reinforcement extensions.

[0070] Figure 5C is a plan view of the block assembly 301 from a top perspective. The current view shows a plurality of recessed surfaces 307Z extending from the back surface 331 to the front surface 335. Those skilled in the art will understand that the back surface 329 has no recesses, allowing the fastener base 205 (at the front surface) to be mounted on the block assembly 301 with sufficient support. This advantage allows any standard rail fastener to be attached to the block assembly 301 without problems of interference or insufficient support caused by the multiple recesses 308Z.

[0071] Figure 5D is a plan view of the block assembly 301 from a frontal perspective. Figure 5E is a plan view of the block assembly 301 from a side perspective.

[0072] Figure 5F is a plan view of the block assembly 301 from a bottom perspective. The current view shows more clearly the multiple grooves 308Z that cut into the perimeter 341B of the block assembly at multiple distances 311Z. One advantage of the block assembly 301 is that the multiple grooves 308Z gradually taper from the back surface 329 to the ventral surface 333, increasing the surface area of ​​the ventral surface 333. Therefore, the block assembly 301 can be adequately supported on the concrete slab before concrete pouring. This support at the ventral surface 333 enables stability to be maintained during installation and operation.

[0073] The foregoing method descriptions and schematic diagrams / figures are provided as illustrative examples only and are not intended to require or imply that the operations of the various aspects must be performed in the presented order. As those skilled in the art will understand, the order of operations in the aspects described herein can be performed in any order. Words such as “afterward,” “then,” “next,” etc., are not intended to limit the order of operations; such words are used to guide the reader through the description of the methods and systems described herein. Furthermore, any reference to an element of a claim in the singular form, such as the use of the articles “a,” “an,” or “the,” should not be construed as limiting the element to the singular.

[0074] The foregoing description of the aspects of this disclosure is provided to enable any person skilled in the art to make, implement, or use the claims. Various modifications to these aspects will be apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects without departing from the scope of the claims. Therefore, this disclosure is not intended to be limited to the aspects shown herein, but is given the widest scope consistent with the claims disclosed herein.

[0075] 101: Fixed components 102: Railway Track 103X: First axis 103Y: Second axis 103Z: Third axis 201: Fastener Assembly Accessories 203AA: First bolt 203AB: Second bolt 203BA: Third Bolt 203BB: Fourth Bolt 203Z: Multiple bolts 204AA: First locking washer 204AB: Second locking washer 204BA: Third locking washer 204BB: Fourth Locking Washer 204Z: Multiple locking washers 205: Fastener base 206A: First clamping component 206B: Second clamping member 206Z: Multiple clamping components 209AA: First hole 209AB: Second hole 209BA: Third hole 209BB: Fourth Hole 209Z: Multiple holes 301: Component Assembly 302: Component Assembly 307A: Surface of the first groove 307B: Second groove surface 307Z: Multiple grooved surfaces 308A: First Groove 308B: Second Groove 308Z: Multiple grooves 309AA: First Edge 309AB: Second Edge 309BA: Third Edge 309BB: Fourth Edge 309Z: Multiple Edges 310B: First Distance 331: Second back surface 311B: Third distance 311Z: Multiple distances 312BA: First Distance 312BB: Second distance 312Z: Multiple distances 313BA: First Corner 313BB: Second Corner 313Z: First Multiple Angles 314BA: First Corner 314BB: Second Corner 314Z: Second Multiple Angles 315AA: First type of cast-in threaded fastener 315AB: Second type of cast-in threaded fastener 315BA: Third type of cast-in threaded fastener 315BB: Fourth type of cast-in threaded fastener 315Z: Multiple cast-in threaded fasteners 316AA: Cast-in threaded fasteners 316BB: Cast-in threaded fasteners 316Z: Multiple cast-in threaded fasteners 317BAAA: First hole 317BAAB: Second hole 317BABA: Third hole 317BABB: Fourth Hole 317Z: Multiple holes 318AA: The first protruding cylindrical part 318AB: The cylindrical part of the second protrusion 318BA: The cylindrical part of the third protrusion 318BB: The cylindrical part of the fourth protrusion 318Z: Multiple protruding cylindrical sections 319BA: Axis 320BAA: First bell-shaped part 320BAB: Second bell-shaped part 320Z: Multiple bell-shaped sections 321BA: Depression 326A: First distance 326B: Second distance 326Z: Multiple distances 324B: Second distance 329: Backside surface 330A: First back surface 330B: Second back surface 330Z: Multiple backside surfaces 331: Second back surface 333: First ventral surface 334A: First ventral surface 334B: Second ventral surface 334Z: Multiple ventral surfaces 335: Ventral surface 341A: First Surrounding Area 341B: Second Surrounding Area 401: Rebar Assembly Fittings 405: First Reinforcing Steel Section 406A: First rebar segment 406B: Second reinforcing bar segment 406Z: First multiple rebar segments 407A: First Reinforcing Bar Section 407B: Second reinforcing bar segment 407Z: The second and multiple steel reinforcement segments 409A: First Reinforcing Bar Section 409B: Second Reinforcing Bar Section 409Z: The third and multiple rebar segments 410A: First rebar segment 410B: Second reinforcing bar segment 410Z: The fourth and multiple rebar segments 411A: First rebar segment 411B: Second reinforcing bar segment 411Z: The fifth and multiple rebar segments

Claims

1. A modular assembly (301), comprising: The assembly includes multiple recesses (308Z) comprising multiple edges (309Z), each recess (308Z) including a recess (308B) comprising an edge (309BA) and an edge (309BB) belonging to the multiple edges (309Z); and multiple cast-in threaded fasteners (315Z) partially disposed within the block assembly (301). The steel reinforcement assembly (401) is integrally disposed within the block assembly (301); and a back surface (329) including a back surface (331) and a plurality of back surfaces (330Z), the back surface (331) being straight at the periphery (341A) of the block assembly (301), and the plurality of back surfaces (330Z) being curved at the periphery (341A) of the block assembly (301).

2. The block assembly (301) as described in claim 1, the block assembly (301) further comprising: The ventral surface (333) includes a ventral surface (335) and a plurality of ventral surfaces (334Z), the ventral surface (335) intersecting the plurality of grooves (308Z) at the periphery (341B) of the block assembly (301), the plurality of ventral surfaces (334Z) being curved at the periphery (341B) of the block assembly (301).

3. The block assembly (301) as claimed in claim 2, wherein the back surface (329) is smaller than the ventral surface (333).

4. The block assembly (301) as described in claim 2, wherein the periphery (341A) is shorter than the periphery (341B).

5. The block assembly (301) as claimed in claim 2, wherein the groove (308B) intersects at the center of the straight segment of the periphery (341B).

6. The block assembly (301) as claimed in claim 1, wherein the groove (308B) is defined by a distance (310B), a plurality of distances (312Z), a distance (324B), a distance (311B), a plurality of angles (313Z) and a plurality of angles (314Z).

7. The block assembly (301) as claimed in claim 1, wherein the cast threaded fastener (315BA) selected from the plurality of cast threaded fasteners (315Z) includes a raised cylindrical portion (318BA), a plurality of holes (317Z), a recess (321BA), a shaft (319BA), and a plurality of bell-shaped portions (320Z).

8. The block assembly (301) as claimed in claim 7, wherein the shaft (319BA) is partially disposed within the steel reinforcement assembly (401).

9. The block assembly (301) as claimed in claim 7, wherein the raised cylindrical portion (318BA) is configured to fit into a hole (209BA) in the fastener base (205).

10. The block assembly (301) as claimed in claim 1, wherein the reinforcing bar assembly (401) comprises: Rebar segment (405); multiple rebar segments (406Z); multiple rebar segments (407Z); multiple rebar segments (409Z); multiple rebar segments (410Z); and multiple rebar segments (411Z).

11. The block assembly (301) as claimed in claim 1, wherein the block assembly (301) is configured to be operably connected to the fastener assembly (201), which is configured to be operably connected to the rail (102).

12. The block assembly (301) as claimed in claim 11, wherein the fastener assembly (201) includes a fastener base (205) and the block assembly (301) includes a back surface (329) configured to support the entire ventral surface of the fastener base (205).

13. A kit for laying railway tracks, the kit comprising: A block assembly (301) includes: a plurality of grooves (308Z) including a plurality of edges (309Z), the plurality of grooves (308Z) including a groove (308B), the groove (308B) including an edge (309BA) and an edge (309BB), the edge (309BA) and the edge (309BB) belonging to the plurality of edges (309Z); a plurality of cast-in threaded fasteners (315Z) partially disposed within the block assembly (301); and a reinforcing bar assembly (401) wholly disposed within the block assembly (301); A back surface (329) including a back surface (331) and a plurality of back surfaces (330Z), the back surface (331) being straight at the periphery (341A) of the block assembly (301), the plurality of back surfaces (330Z) being curved at the periphery (341A) of the block assembly (301); a ventral surface (333) including a ventral surface (335) and a plurality of ventral surfaces (334Z), the ventral surface (335) intersecting the plurality of grooves (308Z) at the periphery (341B) of the block assembly (301), the plurality of ventral surfaces (334Z) being curved at the periphery (341B) of the block assembly (301); and a fastener assembly (201) configured to be operably connected to a rail (102).

14. The kit as claimed in claim 13, wherein the recess (308B) is defined by a distance (310B), a plurality of distances (312Z), a distance (324B), a distance (311B), a plurality of angles (313Z), and a plurality of angles (314Z).

15. The kit as claimed in claim 13, wherein the cast threaded fastener (315BA) selected from the plurality of cast threaded fasteners (315Z) includes a raised cylindrical portion (318BA), a plurality of holes (317Z), a recess (321BA), a shaft (319BA), and a plurality of bell portions (320Z).

16. The kit as claimed in claim 13, wherein the fastener assembly (201) further comprises: Fastener base (205) configured to be disposed on the back side surface (329), wherein the ventral side surface of the fastener base (205) is in overall contact with the back side surface (329).

17. The kit as claimed in claim 13, wherein the back surface (329) is smaller than the ventral surface (333) and the periphery (341A) is shorter than the periphery (341B).

18. A method for installing a block assembly (301) at a concrete slab, the method comprising: The block assembly (301) is placed on the surface of the concrete slab. The block assembly (301) includes: a plurality of grooves (308Z) including a plurality of edges (309Z), the plurality of grooves (308Z) including a groove (308B), the groove (308B) including an edge (309BA) and an edge (309BB), the edge (309BA) and the edge (309BB) belonging to the plurality of edges (309Z); Multiple cast-in threaded fasteners (315Z) are partially disposed within the block assembly (301); and a reinforcing bar assembly (401) is integrally disposed within the block assembly (301); and a concrete layer is poured around the block assembly (301), the concrete layer contacting the multiple grooves (308Z), the multiple cast-in threaded fasteners (315Z) being accessible above the poured concrete layer.

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