Polypropylene Railroad Sleeper with Apertures for Rigidity and Weight Reduction

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Solution Overview

Problem

Conventional railroad sleepers made of wood, steel, concrete, and recycled plastic face issues such as limited lifespan, environmental concerns, high maintenance costs, and structural problems, while alternatives like virgin plastic and concrete sleepers have specific drawbacks, including high costs, weight, and installation challenges.

Innovation Solution

A railroad sleeper made from a polyolefin material like polypropylene with fiberglass, manufactured using an extrusion process, featuring a structural shape that mimics the rigidity of hardwood and allows for standard fixing devices and easy installation, with apertures or structural gaps to reduce material usage without compromising mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If concrete sleepers are used, then durability and load-bearing capacity are improved, but weight and transportation cost increase

Engineering Contradiction:

Improveload-bearing capacityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses composite materials (polymer concrete, fiberglass-reinforced polymers, or rubber-concrete composites) to create sleepers that combine the durability and load-bearing capacity of concrete with the lightweight properties of polymers and fibers, resolving the contradiction between strength and weight

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by incorporating polymers, rubber, and fibers into concrete matrices, modifying the density and mechanical properties to achieve reduced weight while maintaining or improving load-bearing capacity compared to traditional concrete sleepers

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If wooden sleepers are used, then cost and ease of installation are improved, but lifespan and environmental resistance deteriorate

Engineering Contradiction:

Improveease of installationVSAvoidlifespan

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent employs composite materials such as polymer-concrete composites and fiberglass-reinforced polymers that combine the ease of handling and installation of wood with the extended lifespan and environmental resistance of synthetic materials, eliminating the need for chemical treatments

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If recycled plastic sleepers are used, then environmental friendliness and cost are improved, but structural homogeneity and crack resistance worsen

Engineering Contradiction:

Improveenvironmental impactVSAvoidmaterial homogeneity

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The patent uses composite materials where recycled plastics are combined with polymers, rubber, or concrete matrices, and reinforced with fibers, to create a homogeneous composite structure that maintains structural integrity and crack resistance while utilizing recycled materials

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different materials or reinforcements to different regions of the sleeper, such as adding fiber reinforcement in high-stress areas or creating layered composite structures, to ensure uniform structural properties throughout the component

Inventive Principle:

Principle #3Local quality

4Strength

If steel sleepers are used, then lifespan and strength are improved, but corrosion resistance and maintenance requirements worsen

Engineering Contradiction:

ImprovestrengthVSAvoidcorrosion

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials such as polymer-concrete composites, fiberglass-reinforced polymers, and rubber-concrete composites that inherently resist corrosion while maintaining high strength properties, eliminating the corrosion issue associated with steel sleepers

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs materials with inherent corrosion resistance that eliminate the need for protective coatings and ongoing maintenance, providing a durable solution that replaces steel sleepers without the corrosion and maintenance problems

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 cost-effective, high-performance sleeper with improved rigidity and ease of installation, suitable for both passenger and load transport, while being recyclable and environmentally friendly, reducing maintenance and logistic costs.

Implementation Method 1

manufactured using an extrusion process

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS12071732B2Railway sleepers and methods thereof

Publication Date: 2024.08.27 BRASKEM SA

AI summary

A railroad sleeper for fixation of at least one pair of rails of a railroad network, the railroad sleeper may include a contact surface, wherein each rail of the pair of rails is fixed thereto spaced apart from each other; anchorage walls extending downward from the contact surface, and having a support point at a bottom surface thereof, the anchorage walls having at least one aperture formed therein; and a void delimited by the contact surface and anchorage walls.