Steel monoblock sleeper and method for producing same

Abstract

Steel monoblock sleeper comprising a steel sleeper trough body made of a hollow profile with head caps at opposite ends of the steel sleeper trough body, wherein the steel sleeper trough body is filled in a profile-filling manner, at least in sections intended for rail fastening. A preferred method for manufacturing a steel monoblock sleeper comprising the following steps: (a) providing or manufacturing a steel sleeper trough body from a hollow profile with head caps at opposite ends; and (b) arranging or forming at least one moulded body in at least one section of the steel sleeper trough body, and connecting it to the steel sleeper trough body so that the at least one section of the steel sleeper trough body is filled by the at least one moulded body in a profile-filling manner.

Description

BACKGROUND OF THE INVENTION1. Field of the Invention

[0001] The invention relates to railroad sleepers and more particularly to railroad sleepers manufactured on the basis of a steel trough sleeper. The invention further relates to a method for producing such railroad sleepers which are intended for use both in the master track and under points and intersections.2. Brief Description of the Related Art

[0002] Railroad sleepers are part of the track body of railway, tram and / or subway trains and have been used in railroad construction for centuries. The track body generally consists of rubble, railroad sleepers and rails which are mounted on the sleepers.

[0003] Historically, wooden sleepers have been used. Nowadays, prestressed concrete sleepers are mainly used in the construction of track systems. Prior to the emergence of such prestressed-concrete sleepers, steel sleepers were frequently also used. Since the 1970's, so-called FFU artificial wood sleepers have also been used, wherein FFU stands for fiber reinforced foamed urethane. Such sleepers are used mainly in the area of railway bridges, switch stations and at locations where sleepers with a small overall height are required.

[0004] Steel trough sleepers which have been used since the 18th century are distinguished by a very long service life in the track. The railroad sleepers serve primarily for receiving loads from running rails and for fastening them. In this case, a load is transferred both in the vertical direction and in the transverse direction to the track body. In the case of steel trough sleepers, a removal of the transverse load is achieved in particular in that the steel trough sleepers, which are manufactured from a hollow profile, have bent-over head caps which project significantly beyond a profile thickness. This means that the lower edges of the bent-over head caps project beyond the longitudinal edges or profile edges of the hollow profile of the steel trough sleepers in the fastening region of the rails. When laying in the track bed, this means that, for the incorporation of the head caps in the rubble, corresponding grooves or recesses must first be present during the laying.

[0005] In addition to the load transfer, the railroad sleepers serve for fastening the rails and thus guarantee a track width. In this case, it is also desirable to have the greatest possible resistance to track narrowing caused by derailments. In this regard, steel trough sleepers often perform worse than, for example, sleepers made of wood.

[0006] From the Chinese patent application CN 107 313 313 A a method for producing a track bed is known, in which sleepers are arranged and fastened at a manufacturing location on blocks foamed from polyurethane and are transported to a track bed in this arrangement. In the track bed to be created, the polyurethane blocks with the track sleeper or the track sleepers fastened thereon are deposited and aligned and the track bed is finished by adding rubble around the polyurethane blocks. This is intended to speed up the production and to avoid pouring and foaming the polyurethane blocks in the same place where the track bed is formed.

[0007] DE 26 36 853 A1 describes a railroad cross sleeper for supporting rails on a bedding with at least two rail support blocks at a distance that corresponds to the distance between the rails to be supported by the cross sleeper, whereby each rail support block has a base surface and a rail surface and a stiffening system that connects the support blocks and is attached to them. The stiffening system has a self-supporting plate-shaped component which, when the cross sleeper is arranged on the ballast, is designed for embedding in particulate subgrade, wherein this plate-shaped component is corrugated in the longitudinal direction, forming a plurality of vertical waves which substrate, and is arranged vertically when the cross sleeper is installed on the substrate.

[0008] JP 2 954366 A describes a sleeper that is equipped with a rail fastening part on the top near both ends in the longitudinal direction. An underside is formed at both end parts by concrete filled in and hardened on the inside. The end parts each correspond to the rail fastening part of the sleeper body, and an intermediate part of the sleeper body, which is located between the two end parts, is formed into a hollow shape with an open bottom part

[0009] Further sleeper types are shown in JP 2007 120044 A and JP S4 984804 U.

[0010] DE 10 2019 210 289 A1 describes a rubble plastic composite body comprising gravel stones, wherein the rubble plastic composite body has the shape of a plate, a track bed and track bodies comprising the rubble plastic composite body, as well as a method for producing the rubble plastic composite body and a method for producing a track bed.SUMMARY OF THE INVENTION

[0011] The technical object of the present invention is to provide railroad sleepers and a method for the production thereof, wherein the railroad sleepers achieve a service life similar to or better than steel trough sleepers, but are easier to lay and exhibit a high stability and flexibility during use and an improved behavior compared to conventional steel trough sleepers with respect to a possible track narrowing due to derailments and with respect to the load transfer behavior and have a lower tendency to corrosion and exhibit a better resonance behavior, in particular on account of avoiding undesired hollow layers.

[0012] According to the invention, the task is solved by a steel monoblock sleeper with the features of patent claim 1 and a method for manufacturing a steel monoblock sleeper with the features of patent claim 12. Advantageous designs result from the subclaims.

[0013] The invention is based on the idea of creating novel sleepers based on a steel profile, which is preferably known and tested, in which the hollow profile is filled at least in sections by a moulded body in a volume-filling manner. This creates a larger support surface in order to be able to dissipate transverse forces that occur transversely to a rail direction to a track bed. At the same time, this increases the sleeper weight compared to the steel trough sleepers known from the prior art, which are frequently considered in specialist circles to be too light compared to different concrete sleeper types.

[0014] In a preferred embodiment, it is thus provided that a steel monoblock sleeper is created, which comprises a steel sleeper trough body made of a hollow profile with head caps bent at opposite ends of the steel sleeper trough body, wherein the steel sleeper trough body is filled in a profile-filling manner at least in sections provided for rail fastening by means of at least one moulded body formed from reacted reactive material.

[0015] A corresponding preferred method for producing a steel monoblock sleeper comprises the method steps of (a) providing or producing a steel sleeper trough body from a hollow profile with bent head caps at opposite ends; (b) arranging or forming at least one moulded body in at least one section of the steel sleeper trough body and connecting it to the steel sleeper trough body, so that the at least one section of the steel sleeper trough body is filled in a profile-filling manner by the at least one moulded body.

[0016] Because the steel sleeper trough body is filled with the moulded body in a volume-filling manner at least in sections, unintentional cavities during laying, which occur in the prior art with steel trough sleepers that are not correctly underfed with ballast, are avoided. As a result, the resonance behavior is also significantly improved compared to the known steel trough sleepers.

[0017] A moulded body is a body having a defined outer shape. The outer shape is adapted to a section of a hollow profile of a steel sleeper trough body respectively and can fill this section in a volume-filling manner.

[0018] According to the invention, a further process step is provided for: filling reactive material into a hollow profile mould, 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 moulded body filling the hollow profile mould.

[0019] Preferably, a foaming plastic is selected as the reactive material. Polyurethanes are preferably suitable for this purpose, since they exhibit high strength and rapid reaction kinetics and are recyclable, as described, for example, in application DE 10 2021 211 499, which has not yet been disclosed at the time of this application. Thus, it is possible to produce the moulded bodies in a short time. The moulded bodies produced can be processed and / or finished in a time period corresponding to the requirements. Polyurethanes moreover offer a high durability against environmental influences. They offer a sufficiently high stability and longevity. However, on the other hand, they also offer a certain elasticity, so that when laying in a ballast bed, edges and tips of ballast stones can press into the lower surface and thus in particular transverse forces, i.e. forces acting transversely to the mounted rails, can be transmitted well from the steel monoblock sleeper to the ballast bed. Polyurethanes are also suitable because they bond to and coat or enclose a wide variety of materials and form a firm adhering bond.

[0020] In order to be able to influence a strength and also a mass of the moulded bodies, the at least one moulded body is produced as a solid-foam composite according to the invention, preferably as a gravel-foam composite. The gravel used preferably has a grain size between 31 mm and 62 mm, as is customary, for example, for track ballast. Particularly preferably is gravel track ballast. However, other embodiments may also use other loose solid bodies in the form of plastic parts, plastic rods or other materials, but also other grain sizes.

[0021] The method according to the invention thus provides that before the filling or timely with the filling of the reactive material into the hollow profile mould, the hollow profile mould is additionally filled with loose solid bodies and the loose solid bodies are preferably compacted by vibrating. A compaction can also be effected and / or supported alternatively or additionally by evacuating the hollow profile mould. The filling and reacting of the reactive material is preferably carried out in such a way that the reactive material surrounds the loose solid bodies and forms the moulded body as a composite body, the outer contour of which is adapted at least to a section of the contour of the hollow profile mould. A moulded body produced in this way has a high strength and is capable of transferring and removing high loads both in the vertical and horizontal plane from the rails fastened thereon to the track bed.

[0022] The reactive material is preferably introduced via injection nozzles which are located above the preferably compacted filler material consisting of loose solids. Alternatively, the injection nozzles may be inserted into the preferably compacted loose solid filler material and withdrawn after injection of the reactive material. As a result, the reactive material can be applied into the interior of the hollow profile mould and a uniform distribution of the reactive material can be achieved. However, other forms of application of the reactive material during filling are also possible.

[0023] For example, reactive material may be poured or sprayed into the hollow profile mould or applied by means of a coating. It is also possible to dip the hollow profile mould into reactive material.

[0024] It has been found that by selecting an exact input time and weight and a composition or ratio of the components (e.g. polyol, catalyst and isocyanate) of the material, moulded bodies can be reproduced repeatably. Thus, a moulding time and a weight of the shot / feedstock must be predetermined and set. The reactive material can be selected and / or adjusted in such a way, in particular if it is composed of two components, that the reaction only begins with a time delay after the introduction. Thus, a liquid mixture can be applied from above into the filling material or onto the filling material, first essentially due to its flow behavior and gravity distribute itself in the filling material, i.e. in the intermediate spaces of the dissolved solids and / or wet them and only then completely react, i.e. foam up, and preferably completely fill the intermediate spaces between the loose solids / cavities of the filling material.

[0025] The amount of introduced reactive material is selected to be adapted to the volume of the solid bodies introduced into the hollow profile mould such that, when the reactive material is fully reacted, preferably the entire volume of the hollow profile mould, at least in the section in which the at least one moulded body is formed, is completely filled by the solid bodies and the fully reacted reactive material, i.e. the foam. Thus, preferably no or only small gas inclusions remain in the moulded body, namely such that, for example, a previously loose solid body in the form of a stone cannot twist out of its compacted position.

[0026] In order to avoid or minimize the solid-state compaction existing before the reactive material has reacted as little as possible, and / or in order to avoid or minimize the formation of gas inclusions and voids in the formed moulded body, the open side of the hollow profile mould is closed with a force-loaded cover during the reaction of the reactive material. Forces in the range of 5,000N / m2 , which can be achieved, for example, by a weight of approximately 500 kg / m2 being applied, are generally sufficient here.

[0027] This preferably also prevents the reactive material from escaping from the hollow profile mould. This also allows efficient use of the material to be used. For this purpose, the cover has, on sides facing the hollow shape of the hollow profile mould, for example, a silicone coating which prevents a force-fit or firmly bonded connection from being formed between the cover and the reactive material. Other release coatings and release systems may also be used.

[0028] In order to be able to influence, for example, sound transmission properties and / or mechanical vibration properties of the monoblock sleeper, a mass of the reactive material can be changed by additions and fillers and the density can also vary. In the case of polyurethane foams, different properties can be achieved depending on the choice and proportion of the isocyanate and of the polyol. In order, for example, to increase the mass of the foam formed by the reactive material, fillers and additives, for example barium sulfate or calcium carbonate, each in powder form, can be added to this material.

[0029] To influence the acoustic properties and / or vibration properties, the loose solid material can also be varied and selected accordingly. In addition to track ballast, other materials such as flushing cinder or the like can also be used, as long as they have sufficient stability with respect to pressure loads. This allows the carbon footprint of the produced sleepers to be improved, since an otherwise occurring waste product of steel production is used.

[0030] The moulded body of an unclaimed alternative is produced by means of a pure concrete filling. The moulded body made of concrete is connected by connecting elements, e.g. of iron, which are spot welded, for example, to the steel sleeper trough body, and is thus held in the trough formed by the hollow profile. Prestressing the concrete is not necessary. Damping materials can be placed in the concrete on the underside in the wet state or subsequently glued on, so that a soft layer directed to the ballast grain structure of the stuffed track is thereby produced, which increases the transverse displacement resistance and reduces vibrations and sound radiation.

[0031] A great advantage of the manufactured steel monoblock sleepers compared to known steel trough sleepers is that the top edges can be designed variably, since the transverse displacement resistance is defined primarily by the moulded body. In a preferred embodiment, it is provided that the bent-over head caps terminate with longitudinal edges or profile edges of the hollow profile or do not protrude beyond the latter at least on a trough side of the hollow profile. The end caps of the steel sleepers of the hollow profile to be formed can therefore be bent or cut to length at most such that the bent head caps end with longitudinal edges or profile edges of the hollow profile. A height or thickness of the steel monoblock sleeper and of the steel sleeper trough body is thus determined by the height or thickness of the hollow profile and not by the head caps. The head caps do not project beyond the profile edges. This eliminates the complicated work during laying which is necessary in the case of conventional steel trough sleepers and which makes it necessary to insert the projecting head caps into the ballast material. In the steel monoblock sleepers now created, in which the head caps of the steel sleeper trough body do not project beyond the longitudinal edges of the hollow profile from which they are formed, the transverse forces are thus transmitted over the entire surface of the at least one moulded body, which is filled with the steel sleeper trough body at least in sections. The transverse force dissipation is thus distributed more uniformly and prevents stresses in the ballast bed.

[0032] In addition, at least one angle profile oriented transversely to a longitudinal direction of the hollow profile of the steel sleeper body can be welded or already be affixed by welding to an underside of the steel sleeper trough body. That is to say that directions of extension of the hollow profile and of the at least one angle profile are oriented transversely to one another, preferably perpendicularly to one another. At the same time, a leg of the at least one angle profile is preferably oriented parallel to the edges of the hollow profile of the steel trough body. The other leg of the angle profile is preferably oriented perpendicularly to the first leg and projects downwards. This makes it possible to achieve an improved load-bearing capacity of transverse 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 which is opposite the side which is provided for the fastening of rails.

[0033] Preferably, the at least one angle iron additionally protrudes laterally on one or preferably both sides of the steel sleeper trough body in the profile extension direction. This increases horizontal stability of the steel monoblock sleeper.

[0034] The at least one angle iron thus preferably spans the trough of the steel trough body filled with the moulded body and is fastened at the two profile edges to the one leg of the at least one angle iron. This creates a particularly stable fastening.

[0035] Preferably, the at least one angle iron comprises two angle irons which are fastened at a distance from one another to the underside of the steel trough body. The spacing preferably corresponds approximately to a track width for which the steel monoblock sleepers are formed. They are thus preferably fastened opposite the fastening devices for rails.

[0036] By arranging the angle profile in a rail axis, the installation of the steel monoblock sleeper during the track assembly is greatly simplified and travel under load by a travelling train is safe. Undesired deflection of the sleeper is effectively prevented.

[0037] Some embodiments may also include more than two angle irons.

[0038] The at least one angle profile can have openings or through-holes at opposite ends. This can be utilized with a suitable length of the at least one angle profile, which is adapted to a laying distance of the steel monoblock sleepers, in order to connect together steel monoblock sleepers provided for an adjacent laying or laid adjacent to one another by means of connecting plates. As a result, a joint frame can be created.

[0039] In some embodiments, ribbed plates are welded onto the steel monoblock sleeper and are provided for guiding the rails and securing them. Rail fastening devices can be attached directly to these welded-on ribbed plates. A ribbed plate comprises two strips placed on top, between which the strip-shaped foot of a rail placed on top is positioned transversely to it in a form-fitting manner. Fastening means connect the rail via the ribbed plate to the steel monoblock sleeper to form a track frame. This track frame is designed to be secure against rotation and push through, so that the rail is neither displaced in the longitudinal direction nor can it be tilted or rotated.

[0040] Other embodiments additionally or alternatively provide that the monoblock sleepers are manufactured with dowels or dowel recesses. The dowels are advantageously inserted and fixed at corresponding points before the moulded body is formed in the hollow profile mould. This fixing can be effected, for example, via pins or projections which project into the hollow profile mould and which optionally project into the hollow shape of the hollow profile mould through openings which are opposite the open side. For fixing the dowels, they can also be screwed to the hollow profile mould through such openings during the production of the moulded body. Alternatively or additionally, a dowel receiving block, also abbreviated to dowel block, can be arranged in the hollow profile mould at the corresponding points before the introduction of the reactive material and possibly additionally introduced loose solid bodies. Once again, fastening by fastening means projecting into the hollow shape of the hollow profile mould is advantageous.

[0041] A dowel receiving block preferably has one or more dowel recesses which are slightly larger in diameter than the dowel to be fitted later.

[0042] The hollow profile mould used for the production of the moulded body can be a mould formed separately from the steel sleeper trough body. Alternatively and preferably, however, the at least one moulded body is produced directly in the hollow mould formed by the trough of the steel sleeper trough body. In order to fix dowels or dowel receiving blocks during the production of the at least one moulded body, slot-like or round openings are preferably introduced into the steel sleeper trough body at corresponding positions at which dowels or screw connections of track fastening devices are to be made later. As a result of these, during the production of the moulded body, fixing means in the form of projecting pins and / or by means of screwing for sleeper screw studs, inserts and the like are then formed. Such inserted objects are referred to as functional elements.

[0043] The rail fastening to the steel monoblock sleeper can be designed as a fully insulated structure. It is appropriate to use a modification to the rail fastening of the type S15 known from the prior art in the case of Y steel sleepers for this purpose. For this purpose, openings are made in an 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 are considered to be the side which is provided for fastening rails. A lower side of the steel trough body is correspondingly the opposite open side in which the moulded body is located or into which it is introduced.

[0044] For example, four, preferably circular, openings are made in the upper side of the steel trough body. In addition, four cross wires are welded to the top side with which the rails are guided.

[0045] Precisely fitting sleeper screw dowels made of a plastic are pressed into these, preferably circular, openings. Preferably, two of these sleeper screw dowels are connected to one another to form a sleeper screw dowel pair. The distances of two of the four openings in each case are matched to a “dowel distance” of the sleeper pair of screw end dowels, so that a sleeper pair of screw end dowels fills two of the openings during pressing in.

[0046] Other embodiments may provide that openings are formed as slits (e.g., 48×62 mm). A sleeper screw dowel with lateral fastening projections is then inserted into each slit. The fastening projections each have a notch into which the upper side of the hollow profile of the steel sleeper trough body penetrates and is clamped when the sleeper screw dowel is rotated by 90° around the longitudinal axis. As a result, these sleeper screw dowels provided with fastening projections are fastened to the steel sleeper trough body, preferably before the forming of the moulded body.

[0047] The openings may be punched or formed by laser cutting or drilling and / or high pressure water cutting or drilling.

[0048] Sleeper dowel plastic suitable is known in the art.

[0049] The pressing-in of the sleeper screw dowels or of the sleeper screw dowel pairs is preferably effected before forming the moulded body, at least if the moulded body is formed in the hollow profile of the steel trough body itself. The sleeper screw dowels are preferably completely surrounded by the at least one moulded body.

[0050] Some embodiments may however provide that the sleeper screw dowels are prefabricated such that their length is adapted to a depth of the trough of the steel sleeper trough body. They are preferably dimensioned such that, in a state pressed into the openings, they end essentially flush with a plane defined by the profile edges of the hollow profile. The sleeper screw dowels themselves have a through hole which then ends in an outer surface of the formed moulded body, more precisely in the outer surface facing the underside of the steel monoblock sleeper or in the outer surface forming the underside of the steel monoblock sleeper. Thus, water penetrating into the sleeper screw dowel or dowels can drain downward. The sleeper screw dowels or sleeper screw dowel bodies of a sleeper screw dowel pair can also be correspondingly formed with a through-opening.

[0051] Embedding the sleeper screw dowels in the moulded body also offers the advantage that a damaged sleeper screw dowel can be drilled out during a repair and replaced with a new one in a simple manner.

[0052] A further embodiment provides that one or more cladding tubes are permanently attached to the hollow profile of the steel sleeper trough body, preferably by welding or adhesive bonding / bonding, at those locations at which sleeper screw dowels are to be arranged. The cladding tube consists of a material, preferably steel, which offers the possibility of permanently receiving a sleeper screw dowel under dynamic load application and giving this hold against pulling out. A cross-sectional shape of the enclosed region of the cladding tube or tubes can be chosen suitably, and also differently in the case of a plurality of cladding tubes. 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 notches and / or protuberances. The one or more steel sheathing tubes are preferably formed concentrically with openings in the upper side of the steel sleeper trough body, which openings are provided for receiving the sleeper screws. Preferably, the openings are formed and dimensioned to also receive an upper end of a sleeper screw dowel. The sleeper screw (not shown) is thus insulated from the steel sleeper trough body in the screwed-in state via the sleeper screw dowel.

[0053] Preferred embodiments are those wherein the steel cladding tube has a larger inner diameter than the opening in the top of the steel sleeper trough body for receiving sleeper bolts and / or sleeper bolt dowels. Thereby, withdrawal of the sleeper screw dowel, which is adapted to an inner diameter of the steel cladding tube at least in the portion received in the steel cladding tube, can be prevented.

[0054] Preferably, a steel cladding tube edge facing away from the upper side of the steel sleeper trough body terminates with the side edges of the hollow profile of the steel sleeper trough body or at least does not project beyond the latter.

[0055] The moulded body or bodies enclose the steel cladding tube or the steel cladding tubes. These are welded or bonded to the steel sleeper trough body before the forming or inserting of the moulded body or bodies, for example by means of a 2-component adhesive. If the moulded body or bodies are formed in a hollow profile mould formed separately from the steel sleeper trough body, then this has one or more corresponding inserts which correspond to the steel sheathing tube or tubes which are welded on in the steel sleeper trough body.

[0056] Further fastening means for the rails can then be pre-assembled by means of the sleeper screw dowels or sleeper screw dowel pairs before transport to a laying location.

[0057] It is not desirable in every case for the at least one moulded body to fill the trough of a steel sleeper trough body in its full volume. Therefore, in some embodiments it is provided that dividing profiles, which divide the hollow shape of the steel sleeper trough body into different sections, are welded into the trough, i.e. the hollow shape of the steel sleeper trough body. Such dividing profiles are also called separating profiles. For example, a moulded body can thus be formed and produced between a head cap and such a welded-in separating profile in each case under the two end sections of the steel monoblock sleeper, which sections serve as fastening sections. Alternatively, correspondingly designed moulded bodies, which are referred to as separating bodies, can be inserted into these sections and connected to the steel sleeper trough body. A cavity thus remains in a central portion of the trough body. This offers an advantage in that a reiteration of the sleepers can be reduced as a result. In addition, the cavity can be used to accommodate signal or metrology devices and premount them before the steel monoblock sleeper is laid. This is also a possibility of saving filler material and weight.

[0058] Alternatively or additionally to the separating profiles, an insert block can also be used as a separating body in order to produce the sections for forming the at least one moulded body in the trough of the steel sleeper trough body. Such an insert body or separating body can be, for example, a plastic body which is manufactured, for example, from polyurethane or another plastic. Such an insert block or separating body can also have a recess in its middle, preferably toward the open side of the hollow shape of the steel sleeper trough body. This can also be used to avoid riding of the sleepers and / or to record other components such as signal and measurement technology. This also serves as opportunity to save filler material and weight. The insert block or separating body can in some embodiments also be integrated into the moulded body. It is also possible to use a plurality of insert blocks, but not in sections which are provided for track mounting. The separating body can also be fastened, for example glued, in the steel sleeper trough body before the filling of the portion or portions delimited and formed thereby.

[0059] In particular in the case in which separating profiles are inserted in the trough of the steel sleeper trough body, a closable inspection opening can be introduced into the steel sleeper trough body in order to allow access from above to the cavity formed between the separating profiles in the laid state.

[0060] In order to connect the moulded body to the steel sleeper trough body, adhesives are preferably used. In some embodiments, the reactive material itself can act as an adhesive and directly self-bond the moulded body formed in the trough of the steel sleeper trough body to the steel sleeper trough body during production. In other embodiments, regardless of whether the moulded body is formed in a separate hollow profile mould or the steel sleeper trough body itself has served as a hollow profile mould for producing the moulded body, the moulded body can be bonded to the steel sleeper trough body in a separate step.

[0061] For the application of the adhesive, dipping methods, spraying methods, pouring into the trough or the like are possible.

[0062] The adhesives used are phenoplasts (PF plastics, in particular PF resins) or urea-based resins (UF resin) and isocyanates, and also epoxide or urethanes and polyurea.

[0063] In order to achieve good adhesion of the moulded body and / or of a coating and / or of an adhesive to the steel sleeper trough body, a surface treatment can be provided which can comprise, for example, sandblasting and optionally additionally cleaning and degreasing.

[0064] Because the steel sleeper trough body is filled by the at least one moulded body on the trough side, no accumulation of condensate which has formed from moisture raised from the ballast bed takes place in the trough in the laid state in the region of the at least one moulded body. However, if regions are separated by separating profiles, cavities still remain in the trough of the steel sleeper trough body. In such an embodiment as well as in other embodiments, a partial or complete coating of the steel sleeper trough body can be carried out to improve the corrosion resistance. Particularly preferably, the trough side of the steel sleeper trough body is coated / treated.

[0065] Again suitable as coatings are preferably polyurethanes which form a short reaction time, high strength and optimum sealing. These do not tend to be brittle and are temperature-resistant in wide temperature ranges of, for example, −50° C. to 120° C. They also have acid resistance and resistance to a number of other chemicals. Moreover, no washing out or escape of substances hazardous to the environment takes place. Furthermore, polyurea coatings are UV-resistant and have a sound-absorbing effect. If necessary, they can also be made fire-resistant using flame-retardant additives.

[0066] In particular on a side facing away from the trough, a coating of the steel sleeper trough body can furthermore be carried out in such a way that inscriptions or markings are also visible on the basis of added dyes. The coating can be printed in this case, for example, in order to already apply escape route markings or the like to the monoblock sleepers during production. Moreover, the coating is preferably non-slip. The coating can also be used to embed a foil made of metal or a metal alloy, in particular a foil made of aluminum or an aluminum alloy, a so-called Neutrino or Ntrino foil as described in WO 2016 / 142056 A1, in the coating itself, in order to thereby generate energy on site and to use it at least for signal-or metrology devices embedded in the sleeper, if appropriate, in the cavities themselves or to feed it into the track network if there is an excess. This coating can also be used to embed these metamaterials and thus to achieve further frequency reductions of the eigenoscillations and to reduce body and / or airborne sound propagation. Metamaterials are man-made materials that have properties that do not occur in naturally occurring substances and materials. For sound propagation reduction, it is possible to use three-dimensional phonetic crystals with a very large band gap, as are described, for example, by L. D'Alessandro et al. in the article “Modeling and experimental verification of an ultra-wide bandgap in 3D phonetic crystal” in Applied Physics Letters 109, 221907 (2016). This coating can likewise also consist of two-dimensional polymer layers in order to achieve the greatest possible protection of the films located beneath it. A two-dimensional polymer layer is distinguished in that the polymer bonds are each or at least substantially only formed in a two-dimensional plane.

[0067] Fully coated steel sleeper trough bodies are suitable in particular for laying sites with high moisture, as occurs, for example, in tunnels. A suitable coating material is, for example, the polyurea system, Polyresyst ® S6020-90W, which is marketed by the company Huntsman under the Internet address https: / / www.huntsman.com / contact / polyurethanes / customer-service. This system consists of a resin mixture formed from amines and isocyanates as curing agents. The fully reacted material preferably has a hardness of 45 Shore D according to DIN 53505, a tensile modulus of 24.2 MPa according to DIN 53504, an extensibility of 390% according to DIN 53504 and a tear strength of 73.9 N / mm according to DIN 53505. The DIN standards relate in each case to the valid or current version at the time of the application.

[0068] The moulded body can be produced in such a way that the hollow profile mould is open at the top and the reactive material and, if appropriate, the loose solid bodies or inserted dowels, dowel blocks or separators are inserted or introduced through the open side of the hollow mould. However, it is also possible to press the hollow profile mould, for example the steel sleeper trough body, into a layer consisting of loose solid bodies and to fill the trough, i.e. the hollow profile mould, in this way, virtually from below. In this case, too, the reactive plastic material can be injected via nozzles and the reactive material can preferably be fully reacted during a loading of the hollow profile mould from above.

[0069] The reactive material is preferably introduced and reacted out in such a way that the reaction takes place from the hollow profile forming the trough to the “open” side, generally closed off with the cover.

[0070] In any case, the moulded body is preferably formed in such a way that the at least one moulded body arranged in the hollow profile of the steel sleeper body terminates with a side surface with the longitudinal edges of the steel sleeper sleeper body. This ensures that a constant overall height for the steel monoblock sleepers is maintained and installation on any desired subgrade and different track bed constructions is possible.

[0071] In addition, it is possible, before the reactive material has fully reacted, to introduce measurement or signal elements into the hollow profile mould in order to enclose these in the moulded body formed.BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0072] The invention is explained in more detail below with reference to a drawing. The following are shown here:

[0073] FIG. 1 a schematic top view of a steel monoblock sleeper;

[0074] FIG. 2 a cross-sectional view of a steel monoblock sleeper;

[0075] FIG. 3 a side / partial longitudinal sectional view of a steel sleeper trough body;

[0076] FIG. 4 a longitudinal cross-section through an embodiment of a steel monoblock sleeper;

[0077] FIG. 5 a longitudinal cross section through another embodiment of a steel monoblock sleeper;

[0078] FIG. 6 a partial view of a cross section of a steel monoblock sleeper with a rail shown schematically;

[0079] FIGS. 7a-7j Schematic views for explaining the production of a steel monoblock sleeper;

[0080] FIGS. 8a-8j Schematic representations for explaining a further embodiment for producing steel monoblock sleepers;

[0081] FIG. 9 a schematic top view of a steel monoblock sleeper with laterally projecting angle profiles;

[0082] FIG. 10 a schematic side view of a steel monoblock sleeper with laterally projecting angle profiles;

[0083] FIG. 11 a schematic cross-sectional view of a steel monoblock sleeper with laterally projecting angle profiles;

[0084] FIG. 12 a schematic side view of a plurality of steel monoblock sleepers connected to one another with laterally projecting angle profiles;

[0085] FIG. 13 a schematic partial cross section of a steel monoblock sleeper with a sleeper screw dowel with fastening projections;

[0086] FIG. 14 a schematic drawing of a section of a steel monoblock sleeper with a sleeper screw dowel pair;

[0087] FIG. 15 a partial sectional side view of the steel monoblock sleeper of FIG. 14;

[0088] FIG. 16 a schematic enlarged sectional view of a portion of a press-fit sleeper screw dowel body of a sleeper screw dowel pair;

[0089] FIG. 17 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 side of a steel sleeper trough body;

[0090] FIG. 18 a schematic partial sectional view of an upper surface of a steel trough body to which a steel cladding tube having a sleeper screw dowel received therein is welded; and

[0091] FIG. 19 a further schematic partial sectional view of an upper side of a steel trough body to which a steel cladding tube with a sleeper screw dowel accommodated therein and secured against being pulled out is welded.DETAILED DESCRIPTION OF THE INVENTION

[0092] FIG. 1 schematically shows a top view of a steel monoblock sleeper 1. From the top side, a steel sleeper trough body 100 produced from a steel profile and the top side 110 thereof can be seen. 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 head caps 160. The steel sleeper trough body 100 forms a trough open at the bottom, in which a moulded body not visible in FIG. 1 is arranged at least in sections in a profile-filling manner and is connected to the steel sleeper trough body 100.

[0093] In FIG. 2, a cross section 140 along a line A-A (compare FIG. 1) through the steel monoblock sleeper 1 is illustrated. Identical technical features are identified by the same reference numerals in all figures. The hollow profile 130 of the steel sill trough body 100 can be seen, as well as the profile of the moulded body 400 fitted into it, which completely fills at least the section whose cross-section is shown, the hollow profile 130 of the steel sill trough body 100.

[0094] FIG. 3 schematically shows a side and partial longitudinal section view of a steel sleeper trough body 100 of the steel monoblock sleeper 1 according to FIG. 1. It can be seen that the head caps 160 of the hollow profile 130 are bent over in such a way that head cap edges 165 end with profile edges 170 of the hollow profile 130 from which the steel sleeper trough body 100 is formed.

[0095] Ribbed plates 250 are schematically shown welded onto the top side 110, which are provided for guiding and fastening rails. In the schematic illustration, no fastening means for fastening the rails are shown here.

[0096] The steel sleeper trough body 100 represents a hollow profile mould 1000 which is open on an underside 120. The hollow profile mould 1000 is thus formed by the trough formed by the steel sleeper trough body 100. Internally, 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 dashed lines in FIG. 3. A further separating profile is usually welded in symmetrically to a central axis 105 in the part of the steel sleeper trough body 100 shown in a not cut-away view. The steel sleeper trough body 100 is thus divided in such an embodiment into two fastening sections 190 in which the fastening of a rail is provided, and a middle section 195.

[0097] In FIG. 4 a longitudinal cross-section through an embodiment of a steel monoblock sleeper 1 is schematically shown. The trough formed by the steel sleeper trough body 100 is filled by the moulded body 400 over the entire length in the embodiment shown, wherein the moulded body 400 shows a depression 470 in a middle section 195 on an underside 420. In this recess 470, on the one hand, signaling or measurement devices can be accommodated and, on the other hand, the free space resulting therefrom serves to prevent the steel monoblock sleeper 1 from re-wetting.

[0098] The moulded body 400 comprises a fully reacted reactive material 700. This is preferably a polyurethane. Particularly preferably, the moulded body 400 is a composite body which consists of loose solid bodies 600, particularly preferably rubble 610 and most preferably track ballast 620. The latter is surrounded by the reactive material 700 by foam and particularly preferably also directly connected to the steel sleeper trough body 100 in a force-fitting manner. As is indicated in FIG. 4, one or more sleeper screw dowels 510 and / or a dowel block 520 can also already be integrated into the moulded body 400. Sleeper screw dowel 510 are made of plastic and / or fiberglass concrete, for example. In the embodiment shown, a prefabricated separating body 540 is integrated into a central section. The separating body separates the fastening sections 190 from a central section 195 and has the recesses 470 of the formed moulded body 400. The moulded body 400 as a whole is a composite body including the inserted components such as the separating body 540, the sleeper screw dowel 510, or the dowel block 520. In the fastening sections 190, loose solid bodies 600 are preferably filled into the molded body before the reactive material has reacted, for example into the hollow profile mold formed by the steel sleeper trough body in which the molded body 400 was formed, and are compacted, for example by vibration. The gaps have then been filled with the reactive material 700 which has foamed up during the reaction and thus enclosed by the reactive material. The steel sleeper trough body 100 is thus filled from an inner side by the moulded body 400.

[0099] FIG. 5 schematically shows a further longitudinal sectional view of a steel monoblock sleeper 1. As in all figures, technically identical features are provided with identical reference numerals. In this embodiment, separating profiles 200 are welded into the trough formed by the steel sleeper trough body 100, said separating profiles separating the fastening sections 190 from the middle section 195. In each of the fastening sections 190, moulded bodies 400, 400′ are formed, which are preferably formed from rubble 610 and a fully reacted reactive material 700 in the form of, for example, polyurethane, which surrounds the oil.

[0100] By adding barium sulfate or calcium carbonate to the reactive material 700, its mass and thereby its sound and damping properties can be influenced. Likewise, by selecting the rubble 610 or the loose solid bodies 600, which can also consist of plastic material, recycled broken concrete or the like, the mass of the at least one moulded body or, in the embodiment shown in FIG. 5, of the two moulded bodies can be influenced.

[0101] FIG. 6 shows a schematic sectional view of a fastening section 190 of a steel monoblock sleeper 1 in enlarged form in a longitudinal section. In the embodiment shown, ribbed plates 250 are welded onto the top side 110, which are provided for guiding a rail 2000, which is not part of the steel monoblock sleeper 1. Openings 111, 112 are formed in the top side 110, under which dowel openings 525 with dowels 510 of a dowel block 520 arranged therein are formed. The dowel block 520 is surrounded by compacted track ballast with a grain size of 31-61 mm, i.e. a conventional grain size for track ballast 620, which is foam-coated with a polyurethane foam in the compacted state. As a result, the end section 180, which is a fastening section 190, is completely filled by the moulded body 400. On one side, the end portion is bounded by the head cap 160 and on the opposite side by the separating profile 200.

[0102] With reference to FIGS. 7a-7j, the production of a steel monoblock sleeper 1 is schematically explained by way of example. In the embodiment explained first, the moulded body 400 is initially formed separately from the steel sleeper trough 100 and both are subsequently connected to one another by adhesive bonding.

[0103] FIG. 7a shows a hollow profile mould 1000 schematically, the hollow shape of which corresponds to the hollow profile of the steel sleeper trough body 100. Fixing means 1010, 1020 designed as fixing pins protrude into the hollow mould. Furthermore, injection nozzles 1100 for the reactive material protrude into the hollow mould through closable openings 1050 of the hollow profile mould 1000.

[0104] As shown in FIG. 7b, objects inserted on the fastening means 1010, 1020, such as a sleeper screw dowel 510, a dowel block 520, and / or a separating body 540, for example, are fastened.

[0105] Subsequently, as shown in FIG. 7c, the remaining cavity is filled with loose solid bodies 600, preferably with rubble 610, particularly preferably with track ballast 620. These loose solid bodies 600 are compacted, for example by vibrating, which is schematically illustrated by double arrows for indicating a vibrating device 1200.

[0106] FIG. 7d illustrates that the open side of the hollow profile mould 1000 is closed by a cover 1300, which preferably has an anti-adhesion layer 1320 on a bottom side, which is applied to an elastic layer 1310. The cover 1300 is pressed against the steel profile form, so that the latter remains closed even when the reactive material expands. By means of a pressing device 1370, which is schematically shown as a weight, the cover is pressed against the hollow profile mould. Via the injection nozzles 1100, reactive material 700 is now injected into the intermediate spaces of the compacted track ballast 620.

[0107] The injection nozzles 1100 are retracted and the closures 1060 of the closable openings 1050 are closed, as is schematically illustrated in FIG. 7e. When the reactive material 700 reacts, it expands and, together with the compacted loose solid bodies 600, in this case the track ballast 620, and the inserted elements, form the moulded body 400 as a composite body, which is shown schematically in FIG. 7f.

[0108] At the same time or with a time delay, a hollow profile 13 made of steel is bent over at opposite ends 150 in order to form head caps 160 (FIG. 7g). This forms the steel sleeper trough body 100. In addition, ribbed plates 250 are welded onto the steel sleeper trough body for the subsequent guiding of rails. Additionally, openings are optionally punched and / or drilled into the steel sleeper trough body 100.

[0109] Subsequently, the steel sleeper trough body 100 is coated on an inner side or underside 120 in the trough and / or on an outer side, i.e. the top side 110 (FIG. 7h). In this case, a polyurea coating 800 is preferably carried out via coating nozzles 1400. Alternatively and / or additionally, the top side 110 can also be printed and provided with graphic markings. In this case, a printing device 1420 is used.

[0110] In order to connect the steel sleeper trough body 100 to the moulded body 400, an adhesive 850 is applied to the inner side of the steel sleeper trough body and / or an outer side of the moulded body 400 (FIG. 7i) and the moulded body 400 is inserted into the trough of the steel sleeper trough body 100 and connected thereto in a force-fit manner in order to form the steel monoblock sleeper 1 The steel monoblock sleeper 1 is schematically illustrated in FIG. 7j.

[0111] In the embodiment described above, a hollow profile mould 1000 is used, which is formed separately from the steel sleeper trough body 100. In other embodiments, the at least one moulded body or optionally the plurality of moulded bodies which fill the trough of the steel sleeper trough body 100 or sections 180 of the steel sleeper trough body 100 is produced in the steel sleeper trough body 100 itself.

[0112] Such an embodiment is exemplarily shown in FIGS. 8a-8h. First, the steel sleeper trough body 100 is again produced from a hollow profile 130 made of steel, FIG. 8a.

[0113] In addition, separating profiles are optionally welded into the trough of the steel sleeper trough body. Furthermore, openings 111, 112 are optionally introduced into the steel sleeper trough body 100 (FIG. 8b), through which sleeper screw dowels 510 or dowel blocks 520 inserted therethrough can be fixed in the trough (FIG. 8d).

[0114] If appropriate, the steel sleeper trough body 100 is coated with a coating 800 on the open trough side and / or the top side 110 (at the bottom in the figure) before the introduction of inserts such as sleeper screw dowels 510 or a dowel block 520 etc. (FIG. 8c).

[0115] Injection nozzles 1100 for the reactive material are introduced into the hollow mould or the open trough (FIG. 8d). The remaining cavity is then filled with rubble 610, for example track ballast 620 made of basalt, and compacted by vibrating (FIG. 8e). In the embodiment shown, this takes place only in the fastening sections 190 in which moulded bodies are formed.

[0116] The trough of the steel sleeper trough body is then closed and sealed with a cover 1300, which is pressed with a closing pressure from a pressing device 1370 onto the opening of the hollow profile mould 1000 formed by the steel sleeper trough body 100. The cover 1300 has closable openings 1350, through which the injection nozzles 1100 project.

[0117] After reactive material 700 is injected into the fastening section 190 (FIG. 8f), the injection nozzles 1100 are retracted through the cover 1300, which is pressed against the open side of the tray with a pressing force, 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 on the one hand and encloses the loose solid bodies 600 preferably selected as track ballast 620 and at the same time enters into a force-fit connection with the steel sleeper trough body 100, so that the two formed moulded bodies 400, 400′ are connected with the steel sleeper trough body 100 to form the steel monoblock sleeper 1. The finished steel monoblock sleeper 1 turned into orientation for installing is schematically shown in FIG. 8h.

[0118] In each of the variants shown, the hollow profile mould is open at the top. In alternative embodiments, however, the hollow trough of the steel sleeper trough body can also be pressed into a layer of loose solid bodies, for example track ballast, and then reactive material can be injected into the interior of the trough of the steel sleeper trough body, also in the track. In this way, too, a suitable moulded body is formed. In this case, the steel sleeper trough body is subjected to force loading from the upper side during the reaction, in order not to impair the compaction of the oil in the interior of the trough and to prevent a lifting of the hollow profile mould formed by the steel sleeper trough body.

[0119] FIG. 9 shows a schematic plan view of a steel monoblock sleeper 1 with laterally projecting angle profiles 900. In FIG. 10, a corresponding side view is shown and in FIG. 11, a schematic cross-sectional view is shown. Two angle profiles 900 are welded onto the steel sleeper trough body 100 from below, which angle profiles project laterally on both sides 105, 106 of the steel sleeper trough body 100.

[0120] 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. A 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 side 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.

[0121] Another leg 920 of the angle profile 900, which is preferably oriented perpendicularly to the one leg 910, protrudes downward from the underside 120 of the steel sleeper trough body 100. The angle profiles 900 improve the horizontal stability of the steel monoblock sleeper 1. Furthermore, transverse forces can be better dissipated to a ballast bed into which the other legs 920 project in the installed state.

[0122] As shown in FIG. 12, the angle profiles 900 can have openings 921 in the other leg 902 and / or in the one leg 910 at one end 901 and at the other end 902 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 in order to form a joint frame.

[0123] In FIG. 13 there is shown a schematic partial cross-section of a steel monoblock sleeper 1 with a sleeper screw dowel 510 having 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 thereto.

[0124] Such a sleeper screw dowel 510 is inserted into a slot-like opening 111 of the upper side of the steel sleeper trough body 100. The extension of the slot-like opening 111 is longer perpendicular to the plane of the drawing than in the plane of the drawing. The sleeper screw dowel 510 is inserted or pressed in a position rotated through 90° about a central axis 514 relative to the position shown and then brought through 90° into the position shown. In a notch 516 formed between a clamping collar 515 and the fastening projections 512, a wall 113 of the steel sleeper trough body 100 is clamped on its top side 110 and the sleeper screw dowel 510 is fastened to the steel sleeper trough body via this.

[0125] The sleeper screw dowel 510 preferably has a through hole 517 in the interior thereof, said through hole preferably ending at the underside 420 of the moulded body 400 which surrounds the sleeper screw dowel 510 and is preferably formed around said sleeper screw dowel. Nevertheless, water entering the sleeper screw dowel can drain down through the through hole 517.

[0126] FIG. 14 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 which are connected to one another via a web 568 and on which fastening projections 562 are preferably respectively formed. The sleeper screw dowel bodies 561 each have a clamping collar 565 preferably formed peripherally. Between the clamping collar 565 and the fastening projections, a notch 566, which is likewise preferably formed in a circumferential manner, is formed in each case in the sleeper screw dowel body, in which notch the top side 110 of the steel trough body 100 of a steel monoblock sleeper 1 is received when the sleeper screw dowel bodies 561 are pressed into preferably circular openings 111, 112 of the steel trough body 100.

[0127] A length 563 of the sleeper screw dowel bodies 561 is adapted to a height of the steel trough body 100 and the moulded body 400 such that a through hole 567 around the central axis 564 of each sleeper screw dowel body 561 ends at the underside 420 of the moulded body 400.

[0128] The crossbar 260, guide parts 270, clamps 280 and the sleeper screws 290 for fastening a rail 2000 are visible, which are welded onto the top side 110 of the steel sleeper trough body 100. On the left is the operating state, on the right the delivery state of the fastening means pre-assembled on the steel monoblock sleeper 1 is shown

[0129] FIG. 15 is a partial sectional side view of the steel monoblock sleeper 1 of FIG. 14.

[0130] FIG. 16 shows a schematic enlarged sectional view of a part of a pressed-in sleeper screw dowel body of a sleeper screw dowel pair.

[0131] FIG. 17 shows a schematic sectional view of a sleeper screw dowel body 561 of a sleeper screw dowel pair 560 at the level of a notch 566 for receiving the top side 110 of a steel sleeper trough body 1. A circumferential notch edge 569, which is formed in a serrated manner and the serrations of which act as an elastic clamping element in the radial direction, can be seen when the top side 110 of the steel sleeper trough body is received in the notch.

[0132] In FIG. 18, there is shown a schematic partial sectional view of an upper surface of a steel sleeper trough body 100 to which a steel cladding tube 210 having a sleeper screw dowel 510 received therein is welded. The steel cladding tube 210 is arranged concentrically with an opening 111 in the top side 110. An inner diameter 215 of the steel cladding tube 210 and an inner diameter 115 of the opening 111 for receiving the sleeper bolt (not shown) are substantially identical in this embodiment.

[0133] It is also possible to form the opening 111 so as to correspond to an outer diameter of the steel cladding tube 210. In such an embodiment, the steel cladding tube 210 may be welded to the top 110 from above.

[0134] In the embodiment according to FIG. 18, the sleeper screw dowel 510 has a circumferential protrusion 517, which protects the sleeper screw dowel 510 against “pressing through” when the steel cladding tube 210 protrudes through the moulded body 400 or terminates flush with the underside 420 thereof.

[0135] In FIG. 19 another schematic partial sectional view of a top side 110 of a steel sleeper trough body 100 is shown to which a steel cladding tube 210 with a sleeper screw dowel 510 received therein is welded, but which is secured against being pulled out upwards. In this embodiment, an inner diameter 115 of the opening 111 in the top 110 of the steel sleeper trough body 100 is less than the inner diameter 215 of the steel cladding tube 210. The sleeper screw dowel 510 in this embodiment has a notch 516 and a clamping collar 515. Like the circumferential protrusion 517 in the embodiment of FIG. 18, the clamping collar 515 prevents the sleeper screw dowel 510 from “pressing” downward out of the steel cladding tube 210.

[0136] In both embodiments, a weld seam 220 can be embodied to be circumferentially closed or circumferentially sectional.

[0137] In these embodiments as well, the sleeper screw dowel preferably has a through hole 567, so that liquids penetrating from above or forming in the interior can drain downward.

[0138] The features of the various embodiments described above may be combined to form new embodiments of the manufacturing method and the steel monoblock sleeper.Reference numerals1 Steel monoblock sleeper

[0140] 100 Steel sleeper trough body

[0141] 105 Side

[0142] 106 Side

[0143] 110 Top side

[0144] 111 Opening

[0145] 112 Opening

[0146] 113 Wall

[0147] 115 Inner diameter

[0148] 120 Underside

[0149] 130 Hollow profile

[0150] 135 Profile direction

[0151] 140 Cross section of the hollow profile

[0152] 150 Ends

[0153] 160 Head caps

[0154] 165 Head cap edge

[0155] 170 Profile edge / longitudinal edge

[0156] 180 End section

[0157] 190 Fastening section

[0158] 195 Middle section

[0159] 200 Separating profile / rib

[0160] 210 Steel cladding tube

[0161] 215 Inner diameter

[0162] 220 Weld seam

[0163] 250 Ribbed plate

[0164] 260 Crossbar

[0165] 270 Guide Parts

[0166] 280 Clamps

[0167] 290 Sleeper screw

[0168] 400 Moulded body

[0169] 410 Top side

[0170] 420 Underside

[0171] 470 Recesses

[0172] 510 Sleeper screw dowel

[0173] 511 Body

[0174] 512 Fastening projections

[0175] 513 Extension

[0176] 514 Central axis

[0177] 515 Clamping collar

[0178] 516 Notch

[0179] 517 Circumferential protrusion

[0180] 520 Dowel block

[0181] 525 Dowel opening

[0182] 540 Separating body

[0183] 550 Sensor element

[0184] 560 Sleeper screw dowel pair

[0185] 561 Sleeper screw dowel body

[0186] 562 Fastening projection

[0187] 563 Length

[0188] 564 Central axis

[0189] 565 Clamping collar

[0190] 566 Notch

[0191] 567 Through hole

[0192] 568 Web

[0193] 569 Notch edge

[0194] 600 Loose solid bodies

[0195] 610 Rubble

[0196] 620 Ballast

[0197] 700 Reactive material

[0198] 800 Coating

[0199] 850 Adhesive

[0200] 900 Angle profile

[0201] 901 End

[0202] 902 Another end

[0203] 905 Profile direction

[0204] 910 Leg

[0205] 911 Upper side

[0206] 920 Other leg

[0207] 921 Openings

[0208] 930 Connecting plate

[0209] 935 Connecting screws

[0210] 1000 Hollow profile mould

[0211] 1010 Fixing means

[0212] 1020 Fixing means

[0213] 1050 Closable openings

[0214] 1060 Closures

[0215] 1100 Injection nozzles for reactive material

[0216] 1200 Vibrating Device

[0217] 1300 Cover

[0218] 1310 Rubber layer

[0219] 1320 Anti-adhesion layer

[0220] 1350 Closable openings

[0221] 1360 Closures

[0222] 1370 Pressing device

[0223] 1400 Coating nozzles

[0224] 1420 Printing device

[0225] 2000 Rail

Claims

1. A steel monoblock sleeper comprisinga steel sleeper trough body made of a hollow profile,wherein the steel sleeper trough body is filled in a profile-filling manner, at least in sections intended for rail fastening, by means of at least one moulded body which is connected to the steel sleeper trough body,wherein the at least one moulded body is a solid-foam-composite material.

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

3. The steel monoblock sleeper according to claim 1, wherein the at least one moulded body is a rubble-foam composite material.

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

5. The steel monoblock sleeper according to claim 2, wherein the bent head caps or end profiles do not protrude beyond the longitudinal edges of the hollow profile, and wherein the bent head caps or end profiles are flush with the longitudinal edges of the hollow profile.

6. The steel monoblock sleeper according to claim 1, one wherein the at least one moulded body is connected in a force-fitting manner to the steel sleeper trough body.

7. The steel monoblock sleeper according to claim 1, wherein at least one separating profile or separating body in the hollow profile of the steel sleeper trough body delimits one of the sections intended for track fastening.

8. The steel monoblock sleeper according to claim 1, wherein at least one dowel block with at least one dowel recess and / or at least one sleeper screw dowel is integrated in the at least one moulded body.

9. The steel monoblock sleeper according to claim 1, wherein the steel sleeper trough body has at least one rib plate on a side facing away from the hollow profile for guiding a track fastening arrangement or the track.

10. The steel monoblock sleeper according to claim 1, one wherein the at least one composite body arranged in the hollow profile of the steel sleeper trough body ends flush with a side surface with the longitudinal edges of the steel sleeper trough body.

11. The steel monoblock sleeper according to claim 1, wherein the steel sleeper trough body is coated in whole or in part.

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

13. (canceled)14. The method according to claim 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.

15. (canceled)16. The method according to claim 14, wherein rubble is used as loose solid material preferably track ballast.

17. The method according to claim 12. wherein a separating body is inserted into a middle third of the hollow profile mould before filling, so that the at least one composite body is formed by means of the reactive material only in at least one section of the hollow profile mould.

18. The method according to claim 12, wherein the steel sleeper trough body is used as the hollow profile mould.

19. The steel monoblock sleeper according to claim 3, wherein the bent head caps or end profiles do not protrude beyond the longitudinal edges of the hollow profile, preferably ending flush with the longitudinal edges of the hollow profile.

20. The steel monoblock sleeper according to claim 3, wherein at least one dowel block with at least one dowel recess and / or at least one sleeper screw dowel is integrated in the at least one moulded body.

Images