Composite fittings plate

Abstract

According to some embodiments, a fittings plate for attaching railcar fittings to a railcar comprises: a plate consisting of a non-metallic, fiber reinforced polymer (FRP) composite material. The plate comprises: a first set of one or more openings for attaching railcar fittings to the plate and a second set of one or more openings for attaching the plate to a railcar.

Description

[0001] COMPOSITE FITTINGS PLATE

[0002] RELATED APPLICATION

[0003] This application claims priority to United States Provisional Application Serial No. 63 / 635,731, entitled “COMPOSITE FITTINGS PLATE,” filed April 18, 2024. TECHNICAL FIELD OF THE INVENTION

[0004] This disclosure generally relates to a composite fittings plate, and more particularly to a composite fittings plate for a railcar, such as a tank car.

[0005] BACKGROUND

[0006] Tank cars transport a wide variety of commodities including liquids, gases and other fluids. Tank cars may be equipped with various fittings for loading, unloading, monitoring, pressure relief, etc. Conventional top fittings include: fill holes; eduction pipes; safety vents; valves, such as pressure release valves; gauges; and the like. Bottom fittings may include a bottom outlet valve, as one example. A fittings plate joins the service equipment (i.e., fittings) to the tank car. The fittings plate is typically a circular shaped plate bolted to the tank to which the fittings are mounted. The fittings plate may be in contact with the lading.

[0007] SUMMARY OF THE INVENTION

[0008] The embodiments described herein include a composite fittings plate for a railcar, such as a tank car. Particular embodiments include non-metallic, fiber reinforced polymer (FRP) composite fittings plate for rail tank cars. Some embodiments use 100 percent FRP composite material, and FRP composite composition may be altered based on design intent and service application. The FRP composite fittings plate replaces existing rubber- lined metallic fittings plate or any other fittings plate in a retrofit program and / or new car production.

[0009] According to some embodiments, a fittings plate for attaching railcar fittings to a railcar comprises: a plate consisting of a non-metallic, FRP composite material. The plate comprises: a first set of one or more openings for attaching railcar fittings to the plate and a second set of one or more openings for attaching the plate to a railcar. In particular embodiments, an opening of the first set of one or more openings comprises an integral spool and flange. The integral spool may be bonded to the plate. The integral spool may comprise one or more keyways.

[0010] In particular embodiments, the plate, spool and flange are integrally fused as a single piece. In particular embodiments, the integral spool is coupled to the fittings plate via a secondary overlay. In particular embodiments, the integral spool is coupled to the fittings plate via a grout ring.

[0011] In particular embodiments, the composition of the FRP material is based on a use of the railcar. In particular embodiments, the composition of the FRP material is based on a corrosiveness associated with an intended lading of the railcar. In particular embodiments, the FRP material is resistant to ultraviolet (UV) rays.

[0012] According to some embodiments, railway tank car comprises a tank for transporting a commodity, a nozzle coupled to the tank and providing access to the tank, and a fittings plate coupled to the nozzle for attaching railcar fittings to the railcar. The fittings plate comprises a plate consisting of a non-metallic, FRP composite material. The plate comprises a first set of one or more openings for attaching railcar fittings to the plate and a second set of one or more openings for attaching the plate to the nozzle.

[0013] Particular embodiments include one or more of the following advantages. In particular embodiments, the FRP composite fittings plate may last longer than current designs, such as traditional rubber lined metallic fittings plates that last about five years. This amounts to a significant cost reduction throughout the life of the railcar. An additional benefit is an improved customer experience and improved operations due to less down time because of the extended life span.

[0014] Another advantage is reduced manufacturing time compared to a traditional rubber coated fittings plate because applying the rubber coating is time and labor intensive.

[0015] Particular embodiments may reduce static electricity conductivity due to use of non-conductive material. Some embodiments may include improved heat transfer properties and provide a thermal break. Some embodiments include improved ergonomics and ease of use during shop or maintenance operations because, for example, an FRP composite fittings plate may be approximately 1 / 3 the weight of a metallic design.

[0016] In some embodiments, exterior or interior coating or painting is not required because of the corrosion and ultra-violet resistance properties of the composite material. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] A more complete and thorough understanding of the particular embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:

[0018] FIGURE 1 is a schematic drawing illustrating a side view of a railway tank car having a fittings plate;

[0019] FIGURE 2 is a schematic top view of a fittings arrangement, that includes a fittings plate;

[0020] FIGURE 3 is a schematic cross-section view of a fittings plate;

[0021] FIGURE 4A is a schematic top view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0022] FIGURE 4B is a schematic isometric view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0023] FIGURE 4C is a schematic cross-section view of a bonded joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments;

[0024] FIGURE 4D is a schematic cross-section detail view of the bonded joint in FIGURE 4D;

[0025] FIGURE 5A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0026] FIGURE 5B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments; FIGURE 5C is a schematic cross-section view of a grout ring between a composite fittings plate and integral fitting spool and flange, according to particular embodiments;

[0027] FIGURE 5D is a schematic cross-section detail view of the grout ring in FIGURE 5D;

[0028] FIGURE 6A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0029] FIGURE 6B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0030] FIGURE 6C is a schematic cross-section view of a keyway lock between a composite fittings plate and integral fitting spool and flange, according to particular embodiments;

[0031] FIGURE 6D is a schematic cross-section detail view of the keyway lock in FIGURE 6D;

[0032] FIGURE 6E is a schematic isometric view of a fitting spool and flange with keyway lock, according to particular embodiments;

[0033] FIGURE 7A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0034] FIGURE 7B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0035] FIGURE 7C is a schematic section view of an integral composite fittings plate, fitting spool and flange, according to particular embodiments;

[0036] FIGURE 7D is a schematic cross-section detail view of the joint in FIGURE 7C;

[0037] FIGURE 8A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0038] FIGURE 8B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments;

[0039] FIGURE 8C is a schematic cross-section view of a secondary overlay joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments; and FIGURE 8D is a schematic cross-section detail view of the secondary overlay joint in FIGURE 8C.

[0040] DETAILED DESCRIPTION

[0041] Tank railcars transport a wide variety of commodities. To accommodate this, different types of fittings and number of fittings are used on the railcar, depending on the commodity and customer preferences, to load, unload, and check on the commodity. A fittings plate joins the fittings to the tank car. The fittings plate is typically a circular shaped plate bolted to the tank to which the fittings are mounted.

[0042] FIGURE 1 is a schematic drawing illustrating a side view of a railway tank car having a fittings plate. A customary railway tank car 10 includes a tank 12. Tank 12 includes a generally elongated hollow cylinder 18 enclosed at a first end 20 and a second end 22.

[0043] Tank car 10 may be used to transport a variety of hazardous and non-hazardous liquid commodities. Fluid commodities may be loaded into tank 12 through a variety of tank fittings attached to fittings plate 40 (typical within a protective housing 46).

[0044] A head 42 is coupled to cylinder 18 at first end 20. Similarly, a head 44 is coupled to cylinder 18 at second end 22. Cylinder 18 and heads 42 and 44 at least partially define tank 12.

[0045] Fittings plate 40 (located inside protective housing 46) joins the fittings to tank 12 via nozzle 48. Fittings plate 40 is typically a circular shaped plate bolted to tank 12 via nozzle 48. Fittings plate 40 may be in contact with the lading.

[0046] FIGURE 2 is a schematic top view of a fittings arrangement, that includes a fittings plate. The illustrated fittings plate is an example of fittings plate 40, illustrated in FIGURE 1.

[0047] Fittings plate 40 is illustrated with a particular bolt pattern for attachment to a railcar, such as tank car 10 illustrated in FIGURE 1. FIGURE 2 also illustrates various fittings 52 joined to fittings plate 40. Fittings 52 may include fill holes; eduction pipes; safety vents; valves, such as pressure release valves; gauges; and the like. Fittings plate 40 may be coupled to tank 12 via nozzle 48 via a plurality of bolts

[0048] 53.

[0049] FIGURE 3 is a schematic cross-section view of a fittings plate. This illustrated example is a cross section of fittings plate 40 illustrated in FIGURE 2. Fittings plate 40 includes one or more openings 54, which provide a means of commodity transfer and may also facilitate attachment of fittings 52.

[0050] A traditional fittings plate comprises a metallic (e.g., steel) plate. A fittings plate for tank car with corrosive lading may have a rubber lining or other linings applied on the surface of the metallic material. Rubber or other lining is used with reactive or corrosive commodities including, but not limited to, hydrochloric acid and bleach (sodium hypochlorite), so that the lading does not degrade the fittings plate nor does the metallic plate contaminate the lading. The aggressive commodities require the rubber lining application to typically be replaced every five years, which is expensive throughout the life of the railcar. When the rubber lining application is replaced, the fittings plate may also be replaced.

[0051] Particular embodiments replace, for example, the rubber-lined fittings plate described above with non-metallic, fiber reinforced polymer (FRP) composite fittings plate for tank cars. Particular embodiments may fit up to the same existing metallic tank nozzle and protective housing. Some embodiments use 100 percent FRP composite material, and FRP composite composition may be altered based on design intent and service application.

[0052] Particular embodiments and their advantages are best understood by reference to FIGURES 4A through 8D, wherein like reference numbers indicate like features. Particular embodiments include an FRP composite fittings plate with integral spools and flanges.

[0053] FIGURES 4A-4D illustrate a composite fittings plate where the integral fitting spool and flange are bonded to the composite fittings plate. FIGURE 4A is a schematic top view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments. Fittings plate 40 comprises a non-metallic FRP composite material.

[0054] Fittings plate 40 may also include a set of one or more openings (not illustrated) for receiving fasteners (e.g., bolts, illustrated in FIGURE 2) to attach fittings plate 40 to railcar 10. In other embodiments, fittings plate 40 may be coupled to railcar 10 via any other suitable fastener.

[0055] FIGURE 4B is a schematic isometric view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments. The composite fitting plate comprises one or more integral spools 56 with flanges 58. Spool 56 and flange 58 may be used to join the various fittings (e.g., valves) to fittings plate 40. Spool 56 and flange 58 may comprise a non-metallic FRP composite material. Spools 56 may be inserted into fittings plate 40 as part of a composite layering process.

[0056] In some embodiments, the spool and flange may comprise the same non-metallic FRP composite material as fittings plate 40. In other embodiments, the spool and flange may comprise a different non-metallic composite material than fittings plate 40. For example, fittings plate 40 may comprise a fiber-reinforced composite material and the spool and flange composite may not contain fiber reinforcement.

[0057] Although a single spool and flange is illustrated, this is for example purposes, and particular embodiments may include any suitable number and arrangement based on the requirements for a particular tank car type, service type, lading type, and / or customer specific requirements.

[0058] In particular embodiments the non-metallic FRP composite material may vary based on requirements for a particular tank car type, service type, lading type, and / or customer specific requirements.

[0059] FIGURE 4C is a schematic cross-section view of a bonded joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. As illustrated, fittings plate 40 may comprise a recessed portion into which spool 56 may be inserted. FIGURE 4D is a schematic cross-section detail view of the bonded joint in FIGURE 4C. As illustrated, the surfaces between spool 56 and the recessed portion of fittings plate 40 may be bonded via adhesive 59.

[0060] Adhesive 59 may comprise any suitable adhesive for bonding the two composite materials.

[0061] FIGURES 5A-5D illustrate a composite fittings plate where the integral fitting spool and flange are coupled to the composite fittings plate via a grout ring and overmolding.

[0062] FIGURE 5A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 5B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.

[0063] FIGURE 5C is a schematic cross-section view of a grout ring between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. The illustrated example includes a composite grout ring integrally attached to the wall of spool 56 to aid in structural support both in a horizontal and / or vertical loading scenario. The grout ring may be overmolded when infusing the cover plate to create an integral part. The grout ring is used as a composite embedment ring.

[0064] FIGURE 5D is a schematic cross-section detail view of the grout ring in FIGURE 5C. The detail view illustrates grout ring 60 and gusset plate 62. In some embodiments, gusset plate 62 provides structural support for the spool neck.

[0065] FIGURES 6A-6E illustrate a composite fittings plate where the integral fitting spool and flange include a keyway for additional bonding strength.

[0066] FIGURE 6A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 6B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 6C is a schematic crosssection view of a key way lock between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. As illustrated, spool 56 comprises a plurality of keyways 64 around its circumference. The keyways provide more area for adhesive between spool 56 and fittings plate 40, facilitating a stronger bond. Some embodiments also include one or more grooves 65.

[0067] FIGURE 6D is a schematic cross-section detail view of the keyway lock in FIGURE 6C. FIGURE 6E is a schematic isometric view of a fitting spool and flange with keyway lock, according to particular embodiments.

[0068] FIGURES 7A-7D illustrate a composite fittings plate where the integral fitting spool and flange are integrally infused with the composite fittings plate as one piece.

[0069] FIGURE 7A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 7B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 7C is a schematic section view of an integral composite fittings plate, fitting spool and flange, according to particular embodiments. FIGURE 7D is a schematic cross-section detail view of the joint in FIGURE 7C. As illustrated, fittings plate 40, spool 56 and flange 58 are all formed as part of the same process and created as a single unit. A particular advantage is improved manufacturing efficiency because of fewer manufacturing steps.

[0070] FIGURES 8A-8D illustrate a composite fittings plate where the integral fitting spool and flange are coupled with the composite fittings plate via a secondary overlay. FIGURE 8A is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 8B is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments. FIGURE 8C is a schematic cross-section view of a secondary overlay joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. FIGURE 8D is a schematic cross-section detail view of the secondary overlay joint in FIGURE 8C. In the illustrated example, the secondary overlay includes exterior nozzle attachment overlay 66 coupling the exterior of spool 56 to the top of fittings plate 40, interior nozzle tie in 68 coupling the interior of spool 56 to the underside of fittings plate 40, and exterior nozzle repad 70 coupling exterior nozzle attachment overlay 66 to fittings plate 40.

[0071] The FRP composite fittings plate is designed to last longer than current designs in the same service, facilitating a significant reduction in the total cost of ownership per railcar. The FRP composite fittings plate does not require an exterior or interior coating or rubber lining and thus reduces time spent in a maintenance shop throughout the life of the railcar. Reduced time in the maintenance shop also benefits the end customers because their railcar assets are not taken out of service as often, reducing down time. Additional benefits include light weight design as well as strong corrosion resistance.

[0072] Particular embodiments may target cars used in hydrochloric acid and bleach (sodium hypochlorite) service, but the embodiments described herein apply to other commodities and provide similar benefits such as reducing the total cost of ownership of the car and extend the useful life of the fittings plate.

[0073] The FRP composite fittings plate replaces existing rubber-lined metallic fittings plate or any other fittings plate in a retrofit program and / or new car production.

[0074] Modifications, additions, or omissions may be made to the systems and apparatuses disclosed herein without departing from the scope of the invention. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components.

[0075] Although embodiments of the present disclosure and their advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the following example embodiments.

Claims

CLAIMS:

1. A fittings plate for attaching railcar fittings to a railcar comprising: a plate consisting of a non-metallic, fiber reinforced polymer (FRP) composite material, wherein the plate comprises: a first set of one or more openings for attaching railcar fittings to the plate; and a second set of one or more openings for attaching the plate to a railcar.

2. The fittings plate of claim 1, wherein an opening of the first set of one or more openings comprises an integral spool and flange.

3. The fittings plate of claim 2, wherein the integral spool is bonded to the plate.

4. The fittings plate of claim 3, wherein the integral spool comprises one or more keyways.

5. The fittings plate of claim 2, wherein the plate, spool and flange are integrally fused as a single piece.

6. The fittings plate of claim 2, wherein the integral spool is coupled to the fittings plate via a secondary overlay.

7. The fittings plate of claim 2, wherein the integral spool is coupled to the fittings plate via a grout ring.

8. The fittings plate of claim 2, wherein the integral spool and flange facilitate joining of a fitting to the fittings plate.

9. The fittings plate of claim 1, wherein the composition of the FRP material is based on a use of the railcar.

10. The fittings plate of claim 1, wherein the composition of the FRP material is based on a corrosiveness associated with an intended lading of the railcar.

11. The fittings plate of claim 1, wherein the FRP material is resistant to ultraviolet (UV) rays.12 The fittings plate of claim 1, wherein the fittings plate is coupled to the railcar via bolts.

13. A railway tank car comprising: a tank for transporting a commodity, and a nozzle coupled to the tank and providing access to the tank, and a fittings plate coupled to the nozzle for attaching railcar fittings to the railcar, the fittings plate comprising: a plate consisting of a non-metallic, fiber reinforced polymer (FRP) composite material, wherein the plate comprises: a first set of one or more openings for attaching railcar fittings to the plate; and a second set of one or more openings for attaching the plate to the nozzle.

14. The railway tank car of claim 12, wherein an opening of the first set of one or more openings comprises an integral spool and flange.

15. The railway tank car of claim 14, wherein the integral spool is bonded to the plate.

16. The railway tank car of claim 15, wherein the integral spool comprises one or more keyways.

17. The railway tank car of claim 14, wherein the plate, spool and flange are integrally fused as a single piece.

18. The railway tank car of claim 14, wherein the integral spool is coupled to the fittings plate via a secondary overlay.

19. The railway tank car of claim 14, wherein the integral spool is coupled to the fittings plate via a grout ring.

20. The railway tank car of claim 14, wherein the integral spool and flange facilitate joining of a fitting to the fittings plate.

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