Elastic Insulating Rail Layer for Tramway Substructure
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Solution Overview
Problem
Existing rail systems face challenges in providing reliable electrical insulation, vibration damping, and noise reduction, especially in substructures like streets, where stray currents can cause corrosion and rail movements can damage the substructure.
Innovation Solution
A two-layered elastic rail mounting system with a flexible, volume-compressible inner layer and an outer layer that adheres securely to the rail and substructure, ensuring electrical insulation and absorbing movements without damaging the substructure, combined with a method of preparation involving blasting, priming, and spraying of a 2-component plastic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the rail is mounted rigidly in the substructure, then structural stability is improved, but electrical insulation deteriorates and corrosion occurs
Solution Approach 1:
An elastic mounting layer made of two-component plastic is introduced as an intermediary between the rail and the substructure. This layer provides both mechanical support and electrical insulation, preventing stray currents while maintaining structural stability. The layer has insulating properties that block electrical conduction between the rail and substructure, eliminating corrosion risks.
Solution Approach 2:
The mounting layer is made of composite material comprising a two-component plastic system that combines rigidity and elasticity. The composite structure allows the material to be rigid enough for structural support yet flexible enough to accommodate rail movements and maintain insulation properties over time.
2Object-affected harmful factors
If the rail is mounted elastically to dampen vibration and noise, then vibration damping is improved, but electrical insulation deteriorates due to movement and contact with substructure
Solution Approach 1:
The elastic mounting layer acts as a mediator that allows controlled rail movement for vibration damping while simultaneously serving as an electrical insulator. The two-component plastic material maintains its insulating properties even during elastic deformation, preventing electrical contact between the moving rail and the substructure.
Solution Approach 2:
The mounting layer's physical parameters (elasticity, thickness, density) are optimized to provide sufficient vibration damping while maintaining electrical insulation. The material properties are specifically selected to ensure that even under dynamic loads, the layer remains thick enough to prevent electrical conduction.
3Reliability
If the insulating layer is made thick to ensure electrical insulation, then electrical insulation is improved, but the rail's flexibility and ability to absorb movements deteriorates
Solution Approach 1:
The thickness and material properties of the two-component plastic layer are precisely optimized to achieve the minimum required electrical insulation while maintaining sufficient flexibility. The elastic mounting layer is thick enough to prevent electrical conduction but thin and flexible enough to accommodate rail movements without rigid constraint.
Solution Approach 2:
The composite nature of the two-component plastic allows tuning of the material's mechanical and electrical properties. By adjusting the formulation and thickness, the layer achieves optimal balance between electrical insulation (preventing stray currents) and mechanical flexibility (allowing rail movement absorption).
4Strength
If the outer skin of the layer is rigid to maintain structural integrity, then structural integrity is improved, but damage to the substructure from rail movements increases
Solution Approach 1:
The outer skin of the mounting layer is designed with specific mechanical parameters (modulus of elasticity, thickness, hardness) that allow it to maintain structural integrity while being soft enough to prevent damage to the substructure. The two-component plastic formulation enables the outer layer to be sufficiently strong for structural support yet compliant to avoid scratching or damaging the substructure surface during rail movements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable electrical insulation, effective vibration and noise damping, and protection against corrosion, ensuring the rail's longevity and preventing damage to both the rail and substructure during static and dynamic loads.
Implementation Method 1
spraying on a plastic layer which adheres to the rail and hardens in a flexible and volume-compressible manner
Implementation Method 2
They have air chambers running along the rail below the head of the rail, which are intended to make the profile in this area so compressible that they can absorb the vertical deflections
Implementation Method 3
it is necessary to insulate the running rails because these almost always form one pole of the railway's energy supply. Otherwise, very undesirable phenomena can occur due to stray currents
Implementation Method 4
The method according to the invention comprises the preparation of the rail surface by blasting and/or priming
Data Source
Figure 1
Figure 2
AI summary
A rail (11) for electric railways, in particular tramways, is elastically embedded in a substructure (40). The electric insulation of the rail (11) with respect to the substructure (40) is adhesively applied to the rail surface by spraying in the form of an elastic, flexibily curing and volume-compressible and shear-flexible layer (20). The total thickness (25) of the layer (20) is at least 4 mm. The outer face (30) of the layer (20) is structured in such a way that it is adhesively joined with the substructure by bonding or a form-fit connection.