Method for manufacturing a resilient rail support block assembly and resilient rail support block assembly

Abstract

The invention relates to a resilient rail support block assembly and a method for manufacturing thereof, to be mounted embedded in a railway substructure. The resilient rail support block assembly comprises a resilient tray member having sandwich type walls with an inner and an outer anchoring sheet, and a moulded block. The resilient tray member is manufactured by injection moulding a planar state cross-shaped monolithic core member of resilient foam material with fold grooves connecting the side portions to the bottom portion. Inner and outer anchoring sheets are secured to the monolithic core member. The monolithic core member is folded from the planar state into a tray shape and side portions are connected to form the resilient tray member.

Description

[0001] RESILIENT RAIL SUPPORT BLOCK ASSEMBLY AND MANUFACTURING THEREOF

[0002] The present invention relates to the field of resiliently supporting rails of a railway track, such as for trains, underground, trams, metro, subway, heavy rail, lightrail, long distance rail, etc.

[0003] In the field of railway track technology resilient rail support systems have been developed to reduce hinder, in particular noise and vibration, from passing railway vehicles.

[0004] In a known arrangement a rail of a railway track is supported on rail support blocks arranged at intervals under the rail. These blocks are embedded in a concrete slab. The slab is commonly poured around the blocks, but it is also known to place the blocks in corresponding cavities or pockets in a slab. To reduce noise and vibrations resulting from rail vehicles passing over the railway a resilient elastomeric boot or tray member is present between each block and the slab. In US6283383 such a crosstie shoe of styrene-butadiene rubber and / or butadiene rubber is described, having a sidewall which becomes wider in the upward direction.

[0005] In documents W02008 / 040549 and W02009 / 104948 of the same applicant resilient rail support block assemblies and manufacturing methods therefore are disclosed. These assemblies include a resilient tray member as well as a rail support block, wherein the resilient tray member has a bottom wall that extends under the moulded block and a raised side wall that extends at least along a lower region of the peripheral wall of the moulded block. For a railway installation project a large number of such block assemblies are needed. This causes the need for efficiency both in production of the assemblies and in the logistics. Also the cost price is relevant in view of the numbers of assemblies that are needed.

[0006] In W02013 / 036120 of the same applicant a method is described wherein the resilient tray member is manufactured by folding a bottom portion and side portions from a planar form into a tray shape. The bottom wall and the side wall is manufactured by providing a plate of resilient foam, cut to shape with well known tooling, e.g. using a waterjet cutting tool. The plate of resilient foam is commonly produced by slab stock foam production creating continuous blocks, i.e. slabs of foam. The present invention aims to provide yet another improved resilient rail support block assembly and manufacturing method for resilient rail support block assemblies to achieve one or more of the above objects or to at least provide an alternative to prior art solutions.

[0007] According to the present invention a method according to claim 1 is envisaged for manufacturing a resilient rail support block assembly.

[0008] The method of the invention includes the step of injection moulding a monolithic core member of resilient foam material in a planar state in an injection mould defining a cross-shaped mould cavity such that the moulded monolithic core member has a cross-shape with: o a rectangular bottom portion, and integrally formed o four side portions, and integrally formed o fold grooves connecting the side portions to the bottom portion.

[0009] An advantage of injection moulding the monolithic core member in a planar state having fold grooves so that it is readily foldable allows for a significant reduction of waste material. Less anchoring sheet material and less resilient foam material is required, compared to the rectangular blank of monolithic plate applied in WO2013 / 036120. This prior art concept requires cutting out the cross-shape and the grooves, to make it suitable to fold the plate into an erected resilient tray member. This is far less desirable than the invention from an environmental perspective.

[0010] It will be appreciated that the production step for making the monolithic core member according to the inventive method can be efficiently performed with a relatively simple tooling, as additional steps such as cutting to obtain the cross-shape can be refrained from. It has been experienced that the production time for a resilient tray member is significantly reduced to 2-10, preferably 3-5 minutes per resilient tray member.

[0011] An injection mould for injection moulding a monolithic core member of resilient foam material for a resilient gray member for a resilient rai support block assembly according to the invention comprises multiple injection moulding points: at least one injection moulding point for the bottom portion and at least one injection moulding point for each side portion. The present invention also relates to such an injection mould. It is desired to have multiple injection points to injection mould a foam material, because the foaming process during injection moulding restricts the flow of mouldable material. In addition, an injection mould providing fold grooves has narrow passages forming these grooves. Such a narrow passage forms a resistance for moulding material to flow within the mould cavity, in particular for foam material. In view hereof, the compartments of the mould at both sides of the passage are provided with an injection moulding point. Hence, at least five injection moulding points are provided: at least one for the bottom and at least one for all four side portions. In embodiments, each of the bottom portion and elongated side portions are provided with multiple injection moulding points.

[0012] The fold groove preferably has a V-shape, preferably including an angle of 70-90 degrees. An angle of about 70° is preferred. In embodiments, the orientation of the V is slanted outwards to arrive at an outward inclining position of the side wall portion. This shape may more resemble an L-shape.

[0013] The monolithic core member of resilient foam material is preferably made from a closed-cell foam. Preferably a thermoplastic foamed elastomer is used, e.g. polyurethane foam material, TPU, TPE-ll, foamed styrene ethylene butylene styrene, TPE-S, or a thermoplastic vulcanizate such as TPV or TPE-V. The use of thermoplastic material has advantages in view of recyclability over thermosetting materials. Suitable thermoplastic elastomers advantageously have appropriate elastic properties, are UV-resistant, are sustainable and should maintain the required elastic properties over a temperature range of -30°C up to 80°C. Foaming the thermoplastic elastomer reduces the density, resulting in a lower weight of the resilient tray member. E.g. the density of thermoplastic polyurethanes can be reduced from about 1 kg / l to 0,2-0, 9 kg / l.

[0014] The resilient tray member has a rectangular bottom wall and raised side walls extending upwards from the bottom. The resilient tray member is open from above, in particular to receive the mouldable material for the moulded block. The bottom wall and the side wall of the resilient tray member have a sandwich type wall with a resilient core and an inner and an outer anchoring sheet, wherein the outer anchoring sheet is configured to be integrally attached to the railway substructure.

[0015] Common dimensions for such a resilient tray member are a length of 500-1000 mm, preferably 500-700 mm; a width of 100-500 mm, preferably 150-300 mm, and a height of 40- 200 mm, preferably 50-150 mm.

[0016] The method according to the invention includes securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member. Preferably, the outer anchoring sheet is made of one-piece. Alternatively, as is preferred for the inner anchoring sheet, the anchoring sheet is made of multiple sheet portions. In embodiments, five inner anchoring sheet portions are provided.

[0017] In embodiments, the step of securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member comprises the positioning of at least a sheet portion of the inner and / or outer anchoring sheet in the injection mould prior to the step of injection moulding the monolithic core member, thereby creating a monolithic core member of resilient foam material with the inner and / or outer anchoring sheet secured thereto. The injection moulding technique allows securing an anchoring sheet to the monolithic core member, by positioning the inner and / or outer anchoring sheet or sheet portion(s) thereof in an injection mould, and injection moulding a monolithic core member of resilient foam material in the injection mould, thereby creating a monolithic core member of resilient foam material with the inner and / or outer anchoring sheet secured thereto. As such, an anchoring sheet is in-mould labelled (secured) to said monolithic core member of resilient foam material. This securing technique is referred to as an in-mould labelling or in-mould decoration technique. In case of in-mould labelling, cutouts in an anchoring sheet may be required for the injection nozzle points.

[0018] It is conceivable that both the inner anchoring sheet / inner anchoring sheet (portions) and the outer anchoring sheet is / are secured to the monolithic core member by in-mould labelling / inmould decoration. This method provides the inner and outer anchoring sheet in the injection mould prior to the step of injection moulding the monolithic core member, thereby creating a monolithic core member of resilient foam material with both the outer and the inner anchoring sheet secured thereto.

[0019] Alternatively, the inner and / or outer anchoring sheet or sheet portion(s) thereof is secured to the monolithic core member in a different method. The step of securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member may also comprise the securing of at least a sheet portion of the inner and / or outer anchoring sheet to the monolithic core member after injection moulding the monolithic core member, preferably prior to folding the monolithic core member. It is also conceivable that the anchoring sheet or anchoring sheet portions are secured to the resilient tray member after folding the monolithic core member into a tray shape, possibly even after connecting the side portions of resilient foam material together The step of securing possibly includes melting the surface of the resilient foam material, e.g. by heating, e.g. by infrared heating. The resilient foam material is heated to allow anchoring of the anchoring sheet to the wall. Preferably, the monolithic core member is held flat, heated, e.g. by infrared heating, and the anchoring sheet is pressed onto the monolithic core member. Alternatively, an adhesive is applied.

[0020] Advantageously, the dimensions of the inner and outer anchoring sheet essentially match those of the monolithic core member. It may also be desired to have a smaller sheet surface than core member surface. In embodiments, the outer anchoring sheet may cover a relatively smaller area of the core member surface than the inner anchoring sheet.

[0021] The method according to the invention includes folding the monolithic core member from the planar state into a tray shape, the rectangular bottom portion thereby forming the resilient core of the bottom wall of the resilient tray member, and the side portions thereby forming the resilient core of the side walls of the resilient tray member.

[0022] The method further includes connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member.

[0023] In embodiments, in the step of connecting the side portions of resilient foam material of the folded monolithic core member together, edges of the side portions are melted to each other, e.g. by heat welding, e.g. by infrared heating, to form upstanding corners of the resilient tray member. Corners of resilient foam material are connected together to form the resilient tray core. Advantageously, the connection and the fold lines defined by the grooves make the tray watertight. This is e.g. relevant for electrical insulation properties of the tray member.

[0024] In embodiments, in the step of connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member, the bottom portion and the side portions of resilient foam material of the folded monolithic core member are not connected to each other along the fold grooves. This is not necessary for watertightness, and not to arrive at the tray shape.

[0025] The thickness of the bottom of the resilient tray member is preferably 10-30 mm, preferably 12-18 mm, to provide sufficient resilience to reduce hinder, in particular noise and noise and vibration. A large thickness is advantageous for the properties of the tray, but may require a longer manufacturing time, in particular in view of the cooling time after moulding. This is also dependent on the resilient foam material; hence, the thickness may differ from the type of material that is applied.

[0026] The thickness of a wall is important for anchoring, in particular of the moulded block into the resilient tray member, and for anchoring of the resilient rail support block assembly into a railway substructure. Improved anchoring will attribute to the lifetime of the resilient rail support block assembly and safety. In view hereof, a thickness of preferably 15-30 millimetres is desired.

[0027] In addition, a thickness of about 15-30 millimetres at an upper edge of the resilient tray member is desired to provide both electrical insulation and prevent the ingress of water.

[0028] It has been observed that in the injection moulding technique the resilient foam material is not homogeneous when comparing the area near the fold grooves to the bottom and side portions. In thicker wall parts there is more resilience, while there is more rigidity in the thinner parts at the grooves. This e.g. makes the connection between the bottom and side portions relatively strong.

[0029] In embodiments, at least two side portions of the monolithic core member have a decreasing wall thickness towards the fold groove. Accordingly, the tray is more rigid towards the bottom. In other words, the raised side walls of the resilient tray member have a thickness that increases in the upward direction, such that the resiliency of said side walls increases in the upward direction. This shape advantageously optimizes the stability of the rail by providing a stiffer bottom part, while maintaining the desired resilient behaviour at the upper part. As a result, despite the resilience of the tray member undesired motion of the rail is restricted.

[0030] In such embodiments, preferably, the thickness of the raised side walls in the vicinity of the bottom is small, e.g. 5-10 millimetres, and the thickness of the raised side walls at an upper edge of the resilient tray member is 15-30 millimetres.

[0031] In folded tray members having a uniform wall thickness, as known from the prior art, there is more resilience and accordingly less stability of the rail, e.g. resulting in torsion issues. Such a decrease in stability results in a decrease of lifetime and of safety of the rail system. Hence, to compensate for the thickness of the walls, it is known to use additional stoppers within and adjacent an embedded resilient rail support block assembly. Not having to provide such stoppers results in a further advantage of the invention of reduced weight of the resilient tray members. Such a reduction of weight is advantageous to optimize transportation from the tray manufacturing site to the project site, as well as for easier handling of the trays during track installation.

[0032] Advantageously, the raised side walls allow nestability of resilient tray members, e.g. the side walls are outwardly inclined. Considering the amounts of resilient tray members (tens to hundreds of thousands per project) that are required for rail tracks all over the world, it is a common desire to reduce transportation costs and corresponding environmental impact thereof. Hence, nestable tray members are highly preferred.

[0033] Embodiments are envisaged wherein the walls of the resilient tray member have a constant thickness and are nestable, as well as nestable resilient tray members having an upwardly increasing thickness, as well as non-nestable resilient tray members having an upwardly increasing thickness.

[0034] The method for manufacturing a resilient rail support block assembly includes the step of moulding the mouldable material into the resilient tray member to form the moulded block and manufacture the resilient rail support block assembly. In a preferred method of the invention the resilient tray member is used as a block mould or at least as part of a block mould or is placed in a block mould, such that said resilient tray member, possibly with one or more additional block mould members combined with said resilient tray member, delimits a block mould cavity for the block, the mouldable material being introduced into said block mould cavity and thereby adhering directly to the inner anchoring sheet to form the moulded block and manufacture the resilient rail support block assembly.

[0035] In a preferred method of the invention manufacture is allowed at a first production location, e.g. in a company specialized in manufacturing of resilient railway support products, a shipment of resilient tray members. These resilient tray members are e.g. stacked, preferably nested, on a transport pallet, and then transported, e.g. by road, rail, or airfreight, to a second, remote location that is preferably close to the railway installation site. At said second location blocks are moulded to manufacture the resilient rail support block assembly.

[0036] Preferably a said second location a concrete facility is present, which is suitable to pour the blocks from concrete.

[0037] It is also conceivable that at a first production location a shipment of monolithic core members of resilient foam material with the inner and outer anchoring sheet secured thereto are manufactured. After shipment to a second, remote location, the steps are carried out of connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member and moulding the mouldable material into the resilient tray member to form the moulded block and manufacture the resilient rail support block assembly.

[0038] Preferably this second, remote location is close to the railway installation site. Preferably, at said second location a concrete facility is present, which is suitable to pour the blocks from concrete, such that at said second location also blocks are moulded to manufacture the resilient rail support block assembly.

[0039] It will be appreciated that shipping monolithic core members or resilient tray members greatly reduces transport volume and handling issues, compared to shipped prefabricated resilient rail support block assemblies. Advantageously, the inventive monolithic core members or resilient tray members have a reduced weight attributing to a reduction of transportation costs.

[0040] As indicated above, resilient rail support systems have been developed to reduce hinder, in particular noise and vibration, from passing railway vehicles. The resilient rail support block assembly is adapted to be mounted embedded in a railway substructure.

[0041] In embodiments, in particular for new rail systems, the resilient rail support block assembly is embedded in a concrete track bed. It is also conceivable to mount the resilient rail support block assembly into a concrete pocket to be placed in situ, e.g. using a cement-based binder comprising mortar or grout. In particular for renovation or refurbishment of resilient rail support block assemblies, it is known to mount the resilient rail support block assembly into a cavity, e.g. using a cement-based binder comprising mortar or grout.

[0042] In an embodiment, the moulded block is provided with one or more, preferably two, rail fastener members, adapted for fastening one or more rails on the top of said moulded block.

[0043] The moulded block can be made of any suitable mouldable material and is preferably made of concrete. Alternative materials that are envisaged include recycled plastics such as polyolefins, recycled PET, composites etc.

[0044] The moulded block has a top, a bottom and peripheral wall. The bottom wall of the resilient tray member extends under the bottom of the moulded block, and the raised side wall of the resilient tray member extends along at least a lower region of the peripheral wall of the moulded block. The dimensions of such a rail support block are commonly a length of 500- 1000 mm, preferably 600-800 mm; a width of 150-500 mm, preferably 200-400 mm, and a height of 150-500 mm, preferably 200-300 mm.

[0045] In embodiments, the resilient tray member is used as a block mould or at least as part of a block mould or is placed in a block mould, such that said resilient tray member, possibly with one or more additional block mould members combined with said resilient tray member, delimits a block mould cavity for the block, the mouldable material being introduced into said block mould cavity and thereby adhering directly to the inner anchoring sheet. As a result, the block is moulded so as to have a lower portion around which the resilient tray member side wall extends and an upper portion upwardly protruding from the resilient tray member. This method can e.g. be envisaged in the methods disclosed in W02009 / 104948, which is incorporated by reference herein.

[0046] In embodiments, prior to the pouring of the mouldable material one or more reinforcement elements, preferably of metal, such as steel reinforcement bars or stirrups, steel fibres, plastic fibres, basalt fibres, are positioned in the block mould cavity so as to obtain a reinforced block.

[0047] In embodiments, prior to the pouring of the mouldable material, one or more rail fastening members are positioned with at least a portion thereof within the block mould cavity, so that said one or more rail fastening members are directly integrated in the block and fixed to the block material.

[0048] The sandwich type wall of the resilient tray member of the invention has an inner and an outer anchoring sheet, which anchoring sheet is preferably double-faced in that opposed faces thereof are each provided with a multitude of anchoring formations. The anchoring formations are provided to effect a mechanical interlock to the anchoring sheet, hence to the walls of the resilient tray member, by the moulded block on the one hand and by the railway substructure into which the resilient rail support block assembly is embedded on the other hand.

[0049] As disclosed in W02009 / 104948 an anchoring sheet is chosen for its ability to adhere to concrete, mortar, or another hardening compound in order to secure the resilient rail support block assembly to rail support block and to the railway substructure, e.g. a concrete railway bed. It is noted that different anchoring sheet materials may be used within a single resilient tray member. For reasons of efficiency it is preferred to use the same anchoring sheet material for the inner and outer faces of the resilient tray member. On the other hand, it may also be desired to have different material, in particular to be able to remove the resilient block assembly as a whole the outer anchoring sheet may be relatively weaker than the inner anchoring sheet.

[0050] The anchoring sheet can be a single layer sheet or a multilayer sheet. In embodiments wherein the anchoring sheet is a multilayer sheet, optionally a central layer is provided that is substantially impenetrable for the resilient foam material of the resilient tray member and / or the mouldable material of the moulded block. The anchoring sheet can be woven and / or nonwoven, e.g. a needle punched non-woven fabric, e.g. a geotextile, e.g. a sheet made of fibres, e.g. felt. Advantageously, the anchoring sheet is supplied from a roll of said sheet material. Preferably, the anchoring sheet is made of plastic, e.g. made of polypropylene (PP) which is strong, sustainable, durable, and relatively cheap. Other suitable materials are PE, HDPE, TPU, PA, PP, EVA, etc. The anchoring sheet advantageously has a thickness of 0,8-5 mm, e.g. 3,5 mm. An advantage of securing the anchoring sheet to injection moulded resilient foam material is that it has been experienced that thinner anchoring sheets could be applied, as little ingress of resilient foam material already provides sufficient anchoring. This also results in less material used.

[0051] Preferably, the anchoring sheet has a 3-dimensional open structure and is open on the outer and inner face. “Open” means openings therein allowing a compound to penetrate into the anchoring sheet, optionally also between layers of the anchoring sheet, thus effecting a mechanical interlock. It is conceivable that the anchoring sheet is a sheet with looped anchoring formations, e.g. plastic loops and / or hooks, e.g. similar to a hook-and-loop fastener system. A well-known alternative is the hook-and-mushroom fastener system.

[0052] As is preferred the anchoring sheet is supplied from a roll of such material. Sheet materials commonly used as geotextile, e.g. for draining, e.g. felt, may be employed as anchoring sheet. Such materials are readily available and can also be easily cut to the desired shape.

[0053] The invention will be discussed in more detail below referring to the drawings. In the drawings:

[0054] Figs. 1a, b shows an example of a resilient rail support block assembly according to the invention, provided in a concrete pocket and having a rail supported thereon, Fig. 1b shows the resilient rail support block assembly of fig. 1a,

[0055] Fig. 1c shows the resilient rail support block assembly of fig. 1b in a side view, Fig. 2a shows the resilient tray member of the resilient rail support block assembly of figs. 1a- c, Figs. 2b and 2c show the monolithic core member of resilient foam material with the outer anchoring sheet secured thereto, in planar state and ready to be folded into a tray shape to form a resilient tray member of fig. 2a,

[0056] Fig. 3 shows a railway system with two rails fastened to resilient rail support block assemblies of the invention,

[0057] Figs. 4a, 4b show cross sectional views of the resilient rail support block assemblies of fig. 1a,

[0058] Fig. 5a shows an alternative resilient rail support block assembly according to the invention, having a rail supported thereon,

[0059] Fig. 5b shows the monolithic core member of resilient foam material with the outer anchoring sheet secured thereto, in planar state and ready to be folded into a tray shape to form the resilient tray member of fig. 5a,

[0060] Fig. 6 shows a nested stack of resilient tray members in a perspective view.

[0061] In figures 1a-c an example of a resilient rail support block assembly 1 according to the invention and a rail 2 supported thereon is shown.

[0062] For example, and as depicted in this figure, the assembly 1 should be able to serve in railways lines as specified in UIC code 700, "Classification of lines and resulting load limits for wagons", a relevant code of the International Union of Railways.

[0063] In fig. 1a the resilient rail support block assembly according to the invention is provided in a concrete pocket 25 using a cement-based binder 26 and having a rail 2 supported thereon, which is shown in cross sectional views in figures 4a and 4b.

[0064] The assembly comprises a resilient tray member 10 and a rail support block 20. The resilient tray member 10 has a bottom wall 11, here as is preferred a rectangular bottom wall, and raised side walls 12 extending upwards from the bottom wall. As is preferred the side wall 12 is a peripheral side wall.

[0065] The resilient tray member 10 is open from above. The moulded block 20 is made of a suitable mouldable material, preferably of concrete, e.g. a polymer concrete. The block 20 has a top 21, a bottom and a peripheral wall 22. The block 20 is provided with one or more rail fastener members 23 adapted for fastening one or more rails on the top of said block. As will be appreciated the bottom wall 11 of the resilient tray member 10 extends under the bottom of the moulded block, and the raised side walls 12 of the resilient tray member 10 extend along at least a lower region of the peripheral wall of the block 20.

[0066] The skilled person will appreciate that other general shapes of the tray member are also possible, for instance depending on the shape of the block.

[0067] Figure 2a shows the resilient tray member 10, and figs. 2b and 2c the monolithic core member 10’ of resilient foam material with the outer anchoring sheet 14 secured thereto, in planar state and ready to be folded into a tray shape to form the resilient tray member 10 of fig. 2a. The monolithic core member 10’ of suitable resilient foam material, e.g. a polyurethane foam material, is injection moulded in a planar state in an injection mould defining a cross-shaped mould cavity such that the moulded monolithic core member has a cross-shape with: o a rectangular bottom portion 11 , and integrally formed o four side portions 12a-d, and integrally formed o fold grooves 16 connecting the side portions to the bottom portion.

[0068] The bottom wall and the side walls of the resilient tray member have a sandwich type wall with a resilient core and an inner and an outer anchoring sheet 14, 15. The inner and outer anchoring sheets are secured to the monolithic core member.

[0069] Possibly, at least a sheet portion of the inner and / or outer anchoring sheet 14, 15 is positioned in the injection mould prior to the step of injection moulding the monolithic core member, thereby creating a monolithic core member of resilient foam material with the inner and / or outer anchoring sheet secured thereto. This is preferred for the outer anchoring sheet 14, wherein, by folding the monolithic core member into a tray shape, the outer anchoring sheet 14 is provided at an outer face of the resilient tray member.

[0070] In addition thereto or instead thereof, at least a sheet portion of the inner and / or outer anchoring sheet 14, 15 is secured to the monolithic core member after injection moulding the monolithic core member, preferably prior to folding the monolithic core member, by melting the surface of the resilient foam material, e.g. by heating, e.g. by infrared heating. This is preferred for inner anchoring sheet portions. Advantageously, five inner anchoring sheet portions are provided for the bottom wall and each side wall.

[0071] The inner anchoring sheet 15, preferably made of multiple sheet portions, is preferably secured to the monolithic core member after injection moulding the monolithic core member, preferably prior to folding the monolithic core member. It will be more difficult to position and secure the inner anchoring sheet 15 after folding into the tray shape.

[0072] This sandwich structure can readily be recognized in the figures 4a and 4b where the resilient support block assembly 1 is shown in cross-section.

[0073] In figs. 2a-2c a total of 10 injection moulding points 19 are visible. The injection mould comprises multiple injection moulding points 19: at least one injection moulding point for the bottom portion and at least one injection moulding point for each side portion. Injection moulding a narrow fold groove of resilient foam material is achieved by the provision of a narrow passage in the injection mould. Such a narrow passage forms a resistance for moulding material to flow within the mould cavity. The resistance is in particular high for foam material. In view hereof, at least five injection moulding points for the bottom and all four side portions are desired.

[0074] A large number is in particular desired when anchoring sheets are secured to the monolithic core member by in-mould labelling, i.e. in the injection mould.

[0075] The side walls 12a, b, c, d, are formed integral with the bottom wall 11 via fold grooves 16. As visible in figs. 2b, 2c, 4a and 4b the side portions of the monolithic core member have a decreasing wall thickness towards the fold groove. Or in other words, the thickness of the side walls of the resilient tray member increases towards the open end. In figs. 4a and 4b the monolithic core member is folded into the resilient tray member 10, showing the increased thickness in the upward direction: from a small thickness D1 near the bottom to increased thickness D2 at an upper end of the resilient tray member 10.

[0076] In figures 2b and 2c the monolithic core member 10’ is shown prior to folding. Here also the increasing thickness is visible and indicated in fig. 2b: the thickness 12c’ of the side walls in the vicinity of the bottom is small, e.g. 5-10 millimetres, and the thickness 12c” of the raised side walls at an upper edge of the resilient tray member is 20-30 millimetres.

[0077] As shown in figures 2b and 2c the connection between the bottom wall and the integral side wall portion is formed by a fold groove 16. The groove 16 can be V -shaped in cross-section. An angle of about 70° is preferred. The orientation of the V is preferably slanted (more resembling an L-shape) to arrive at an outward inclining position of the side wall portion. It will be appreciated that the monolithic core member 10’ shown in figures 2b and 2c allows to easily erect a resilient tray member 10 so as to have a bottom wall and raised side walls.

[0078] According to the inventive method, the side portions of resilient foam material of the folded monolithic core member are connected together to form the resilient tray member. It is shown that corners 12x of resilient foam material are connected together, by connecting the edges 12x’ and 12x” together, as seen in fig. 2c. Connecting the corners 12x forms the resilient tray member with sandwich type walls having the outer anchoring sheet at an outer face of the resilient tray member and having the inner anchoring sheet at an inner face of the resilient tray member. Then both the bottom wall and the raised side wall are of the sandwich type with anchoring sheet portions on both the inner face and the outer face.

[0079] This erected tray member can be used as a block mould or at least as part of a block mould or be placed in a block mould, e.g. as explained in WO 2009 / 104948. This allows for the tray member, possibly with one or more additional block mould members combined with said resilient tray member 10, to delimit a mould cavity for the block 20. The mouldable material, e.g. concrete, is then introduced into said mould cavity and thereby adheres directly to the one or more anchoring sheet portions on the inner face of the resilient tray member 10.

[0080] Both the inner and outer anchoring sheet is preferably double-faced in that opposed faces thereof are each provided with a multitude of anchoring formations. As will be appreciated the anchoring formations allow the pourable material, e.g. of the rail support block when on the inside of the tray member, or e.g. of the railway bed when on the outside, to enter in openings / interstices provided by the anchoring sheet. Once said material hardens a strong and durable mechanical connection is obtained.

[0081] In figure 5a an alternative resilient rail support block assembly 101 is shown having a tray member 112 and a moulded block 120, here of concrete as is preferred in this invention. The top of the moulded block 120 is formed to accommodate a rail 102 thereon.

[0082] The tray member 110 is manufactured from a monolithic core member 110’ shown in fig. 5b, provided at least with an outer anchoring sheet. In fig. 5b, the portion 111 that forms the bottom and four portions 112a-d that form the raised sides are shown.

[0083] In figure 6 a nested stack 30 of resilient tray members 10, is shown, wherein the raised side walls 12, 12b of each resilient tray member 10 have an outwardly inclined inner face to allow nestability thereof.

Claims

CLAIMS1. Method for manufacturing a resilient rail support block assembly (1), which resilient rail support block assembly is adapted to be mounted embedded in a railway substructure, for example a concrete track bed, and which resilient rail support block assembly comprises: a resilient tray member (10) having a rectangular bottom wall (11) and raised side walls (12) extending upwards from the bottom wall, wherein the resilient tray member is open from above, wherein the bottom wall and the side walls of the resilient tray member have a sandwich type wall with a resilient core and an inner and an outer anchoring sheet (14, 15), wherein the outer anchoring sheet is configured to be integrally attached to the railway substructure; a moulded block (20) of a mouldable material, preferably of concrete, said moulded block having a top, a bottom, and peripheral wall, said moulded block being provided with one or more rail fastener members adapted for fastening one or more rails on the top of said moulded block, wherein the bottom wall of the resilient tray member extends under the bottom of the moulded block, and wherein the raised side walls of the resilient tray member extend along at least a lower region of the peripheral wall of the moulded block in order to be integrally attached thereto via the inner anchoring sheet, characterized in that the resilient tray member is manufactured by:• injection moulding a monolithic core member of resilient foam material in a planar state in an injection mould defining a cross-shaped mould cavity such that the moulded monolithic core member has a cross-shape with: o a rectangular bottom portion (11), and integrally formed o four side portions (12a-d), and integrally formed o fold grooves (16) connecting the side portions to the bottom portion;• securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member;• folding the monolithic core member from the planar state into a tray shape, the rectangular bottom portion thereby forming the resilient core of the bottom wall of the resilient tray member, and the side portions thereby forming the resilient core of the side walls of the resilient tray member;• connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member.

2. Method according to claim 1 , wherein the step of securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member comprises the positioning of at least a sheet portion of the inner and / or outer anchoring sheet in the injection mould prior to the step of injection moulding the monolithic core member, thereby creating a monolithic core member of resilient foam material with the inner and / or outer anchoring sheet secured thereto.

3. Method according to claim 1 or 2, wherein the step of securing the inner and outer anchoring sheets or sheet portion(s) thereof to the monolithic core member comprises the securing of at least a sheet portion of the inner and / or outer anchoring sheet to the monolithic core member after injection moulding the monolithic core member, preferably prior to folding the monolithic core member, by melting a surface of the resilient foam material, e.g. by heating, e.g. by infrared heating.

4. Method according to one or more of the preceding claims, wherein in the step of connecting the side portions of resilient foam material of the folded monolithic core member together, edges of the side portions are melted to each other, e.g. by heating, e.g. by infrared heating, to form upstanding corners of the resilient tray member.

5. Method according to one or more of the preceding claims, wherein in the step of connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member, the bottom portion and the side portions of resilient foam material of the folded monolithic core member are not connected to each other along the fold grooves.

6. Method according to one or more of the preceding claims, wherein at least two side portions of the monolithic core member have a decreasing wall thickness towards the fold groove.

7. Method according to one or more of the preceding claims, wherein the resilient tray member (10) is used as a block mould or at least as part of a block mould or is placed in a block mould, such that said resilient tray member, possibly with one or more additional block mould members combined with said resilient tray member (10), delimits a block mould cavity for the block (20), the mouldable material being introduced into said block mould cavity and thereby adhering directly to the inner anchoring sheet to form the moulded block and manufacture the resilient rail support block assembly.- 17 -8. Method according to one or more of the preceding claims comprising the step of moulding the mouldable material into the resilient tray member to form the moulded block and manufacture the resilient rail support block assembly, wherein preferably at a first production location a shipment, e.g. a nested stack (30) of said resilient tray members, is manufactured, and wherein said shipment is transported to a second remote production location, preferably close to the railway installation site, wherein at said second location the step is carried out of moulding the mouldable material into the resilient tray member.

9. Method according to one or more of the preceding claims, wherein at a first production location a shipment comprising stacks of monolithic core members in planar state with inner and outer anchoring sheets secured thereto is manufactured, and wherein said shipment is transported to a second remote production location, preferably close to the railway installation site, wherein at said second location the steps are carried out of:• connecting the side portions of resilient foam material of the folded monolithic core member together to form the resilient tray member,• moulding the mouldable material into the resilient tray member to form the moulded block and manufacture the resilient rail support block assembly.

10. Resilient rail support block assembly (1) manufactured by a method according to one or more of the preceding claims.

11. Resilient rail support block assembly according to claim 10, wherein the raised side walls of the resilient tray member are outwardly inclined to allow nestability of resilient tray members.

12. Resilient rail support block assembly (1) according to claim 10 or 11 , wherein there are two elongated side portions and two shorter side portions integrally formed to the rectangular bottom portion, and at least the elongated side portions of the monolithic core member have a decreasing wall thickness towards the fold groove, such that the elongated raised side walls of the resilient tray member have a thickness that increases in the upward direction, and such that the resiliency of said side walls increases in the upward direction.

13. Resilient rail support block assembly according to claim 12, wherein the thickness of the raised side walls in the vicinity of the bottom is small, e.g. 5-10 millimetres, and the thickness of the raised side walls at an upper edge of the resilient tray member is 20-30 millimetres.- 18 -14. Injection mould for injection moulding a monolithic core member of resilient foam material for a resilient tray member for a resilient rail support block assembly according to claim 10, the injection mould defining a cross-shaped mould cavity such that the moulded monolithic core member has a cross-shape with: o a rectangular bottom portion (11), and integrally formed o four side portions (12a-d), and integrally formed o fold grooves (16) connecting the side portions to the bottom portion; the injection mould comprising multiple injection moulding points (19): at least one injection moulding point for the bottom portion and at least one injection moulding point for each side portion.

15. Railway system including one or more rails fastened to a resilient rail support block assembly according to one or more of the preceding claims 10-13.

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