Embedded Rail Track Manufacturing with Segmented Elastic Support
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Solution Overview
Problem
Existing methods for manufacturing embedded rail tracks with continuous elastic support in concrete track beds are inefficient in terms of material usage and cost, as they often require expensive resilient compounds for both vertical and lateral support, and do not adequately address electrical insulation needs.
Innovation Solution
The method involves providing pre-aligned rails with filler blocks and an elastic strip, where the filler blocks are machined to create voids that are then filled with a pourable resilient compound, allowing for reduced use of expensive materials and enhanced electrical insulation by using a polyurethane-based compound with cork granules, which provides primary lateral support and vertical support from the elastic strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive resilient compound is used to provide both vertical and lateral elastic support, then the rail receives adequate support in both directions, but the material cost increases significantly
Solution Approach 1:
The support function is segmented between two different components: filler blocks provide vertical support and electrical insulation, while a limited amount of resilient compound provides lateral support. This division allows each component to be optimized for its specific function rather than requiring comprehensive support in all directions from a single material.
Solution Approach 2:
The filler blocks act as an intermediary element between the rail and the resilient compound. They occupy the space that would otherwise require expensive resilient compound to provide vertical support, thereby reducing the quantity of costly material needed while maintaining the required elastic support properties.
2Quantity of substance
If filler blocks are used to reduce the volume of resilient compound, then material costs decrease, but the electrical insulation between the rail and concrete track bed may be compromised
Solution Approach 1:
The filler blocks are positioned specifically at the critical locations where electrical insulation is needed - between the rail head and the concrete track bed. This localized placement provides electrical insulation precisely where required, while allowing the resilient compound to be used only where lateral support is needed, optimizing both cost and functional performance.
3Reliability
If the top portions of filler blocks are removed after concrete hardening, then the voids can be filled with resilient compound, but the manufacturing process becomes more complex
Solution Approach 1:
The filler blocks are installed with their top portions extending above the concrete track bed level before the concrete is poured. This preliminary positioning allows the concrete to harden around the lower portions of the filler blocks, creating a stable foundation. The top portions are then removed and the voids filled with resilient compound in a subsequent step, enabling a modular and manageable manufacturing process.
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
This method achieves cost-effective and reliable elastic support for rail tracks with improved electrical insulation, reducing the volume of expensive resilient compound needed and ensuring effective lateral and vertical support, while minimizing material costs and preventing water ingress.
Implementation Method 1
an elastic strip underneath the foot... provides continuous vertical and horizontal elastic support to the rail
Implementation Method 2
the compound bonds to the rail and in cured state provides continuous vertical and horizontal elastic support to the rail
Implementation Method 3
enhanced electrical insulation by using a polyurethane-based compound with cork granules
Data Source
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Figure 7~9
AI summary
A method for manufacturing an embedded rail track with a continuous and elastically supported rail embedded in a continuous concrete track bed, wherein a rail has a head, a web and a foot, which method comprises the steps of: - providing one or more pre-aligned rails provided with filler blocks on opposed sides of the web as well as with an elastic strip underneath the foot, - pouring the concrete track bed and allowing said concrete to harden thereby embedding said one or more pre-aligned rails in the concrete track bed. At the boundary between each filler block and the hardened concrete track bed a layer of the filler block is removed by machining to create a void to the level of the elastic strip. These voids created by said machining are filled by pouring into the voids a pourable resilient compound which cures over time and has permanent elasticity.