Angled Polyurethane Seal for Railroad Hopper Car Gap Filling

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Solution Overview

Problem

Coal is lost during transportation in railroad hopper cars due to gaps between the sidewall and trough, leading to revenue loss and track degradation, and existing sealing methods are ineffective, especially in aluminum cars.

Innovation Solution

A polyurethane seal with angled sections is designed to fit between the sidewall and trough, providing a secure attachment via bolts or adhesive, and featuring angled surfaces to match the geometry of the car, ensuring a tight seal and resistance to sulfuric acid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If caulk is applied to fill the gaps, then the gap filling is simple, but the sealing strength is insufficient

Engineering Contradiction:

Improvegap filling simplicityVSAvoidsealing strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs a flexible polyurethane seal member that can be formed into various shapes and sizes to fit into the gaps between the sidewall and trough. This flexible seal member provides both ease of installation and sufficient sealing strength, resolving the contradiction between simple gap filling and adequate sealing capability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If welding is used to seal gaps in aluminum cars, then the sealing strength is high, but the structural integrity is compromised

Engineering Contradiction:

Improvesealing strengthVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a flexible polyurethane seal member that can be installed without welding, thereby maintaining the structural integrity of aluminum cars while providing sufficient sealing strength. The seal member's flexibility allows it to conform to the gap geometry and provide effective sealing without compromising the underlying structure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs a composite sealing system combining the polyurethane seal member with the aluminum car structure. This composite approach allows the seal to provide the necessary sealing strength while the aluminum structure maintains its structural integrity, avoiding the need for welding that would compromise either property.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the seal is made rigid to withstand loading and unloading forces, then the structural stability is high, but the adaptability to gap geometry is reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to gap geometry

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS8925467B2Railroad car seal for railroad hopper cars

Publication Date: 2015.01.06 STUCKI A CO

AI summary

A seal is disclosed for retrofitting to an existing railroad hopper car having opposing sidewalls and at least one trough extending between the opposing sidewalls. The seal includes a first member configured to mate against a surface of a trough adjacent a sidewall, the first member including a first edge having angled sections corresponding to angled sections of where the sidewall meets the trough, and a second member integral with the first member and extending substantially upright from the first edge of the first member, the second member configured to mate against a surface of the sidewall adjacent the trough, wherein the second member is angled relative to the first member at each of the angled sections corresponding to angled sections of the sidewall adjacent the trough.