Perforated Polyurethane Track Bed Mat for Railway Resilience
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing railway superstructures with resilient track bed mats made of rubber bonded with polyurethane face indeterminate suspension behavior, leading to high production costs and inadequate flexibility for load-bearing capacity.
Innovation Solution
The use of perforated mats or panels made from recycled rubber material bonded with polyurethane, featuring perforations that allow material displacement under dynamic loads, achieving the desired spring properties and load capacity with a range of diameters from 5 to 30 mm, and a bedding modulus of 0.005 to 0.1 N/mm² for static and dynamic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid mat made of recycled rubber material bonded with polyurethane is used, then load-bearing capacity is achieved, but flexibility and spring properties are insufficient
Solution Approach 1:
The patent applies porous materials by incorporating perforations through the entire thickness of the resilient track bed mat. These perforations create void spaces that allow the material to deform and recover, providing spring properties while maintaining load-bearing capacity. The porous structure enables the mat to exhibit resilient behavior under dynamic loads from passing trains, solving the contradiction between strength and flexibility.
2Reliability
If rubber material bonded with polyurethane is used, then resilient properties are achieved, but suspension behavior becomes indeterminate
Solution Approach 1:
The patent applies parameter changes by specifying precise geometric parameters for the perforations (diameter, spacing, distribution) and material properties (rubber composition, polyurethane bonding) to achieve deterministic suspension behavior. By controlling these parameters, the mat's resilient properties become predictable and measurable, with suspension characteristics that can be optimized for specific track conditions while maintaining reliability.
3Adaptability or versatility
If perforated mats are used to achieve spring properties, then flexibility and resilient behavior are improved, but production complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the mat into regions with different perforation patterns or densities to optimize spring properties in different areas. This segmented approach allows tailored resilient behavior where needed while maintaining simpler construction in other areas, balancing performance requirements with production complexity.
4Object-affected harmful factors
If standard resilient track bed mats are used, then noise and vibration reduction is achieved, but production costs increase
Solution Approach 1:
The patent applies porous materials as a cost-effective solution for noise and vibration reduction. The perforated structure of the resilient track bed mat provides acoustic absorption and vibration damping properties without requiring expensive specialized materials or complex manufacturing processes, making noise control economically viable.
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 a resilient track bed mat with optimal suspension behavior, achieving a soft spring effect while maintaining sufficient load-bearing capacity, reducing noise and vibration, and offering a cost-effective production method.
Implementation Method 1
the material displaced into the hole space returns resiliently to its original position. Overall, the mat exhibits the behavior of a soft spring
Implementation Method 2
the task of this resilient mat is, among other things, to hinder the generation and propagation of low-frequency sound
Implementation Method 3
A two-layer, resilient mat is used as a base, the upper layer of which consists of rubber granules bonded with polyurethane and the lower layer of a rock wool plate. The task of this resilient mat is, among other things, to hinder the generation and propagation of low-frequency sound.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a railway superstructure comprising a track bed mat (10) as a continuous support of a track carrier system. The track bed mat (10) either consists of rubber recycling material having a polyurethane bond, or of polyurethane having a special specification, and has holes that run transversely to the mat plane such that a particular resilience effect with a static bed module between 0.005 to 0.08 N/mm2 and a dynamic bed module between 0.02 to 0.1 N/mm2 is achieved.