Resilient Rail Support Block Assembly Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing resilient rail support block assemblies for railway tracks are inefficient and require additional adhesive steps, increasing complexity and potential for errors during installation.
Innovation Solution
A manufacturing method involving a prefabricated resilient member with an outer and inner tray, where the resilient intermediate structure is bonded to both, allowing the concrete block to adhere directly to the inner tray during hardening, eliminating the need for separate adhesives and simplifying the installation process by integrating transverse tie bars and enhancing anchoring with specific tray designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate adhesive step is used to fix the block to the resilient member, then the block can be securely attached, but the manufacturing process becomes more complex and less efficient
Solution Approach 1:
The patent combines the block attachment function with the resilient member structure itself. The resilient member is designed with an integrated bonding interface that directly bonds to the block during the concrete pouring process, eliminating the need for separate adhesive application steps and tools.
Solution Approach 2:
The resilient member is pre-fabricated with built-in bonding characteristics before the block is assembled. The bonding surface and adhesive properties are prepared in advance during resilient member manufacturing, so no additional adhesive preparation is needed at the assembly stage.
2Manufacturing precision
If multiple separate steps are used for assembly, then each step can be optimized, but the overall installation time and complexity increase
Solution Approach 1:
The patent merges multiple assembly operations into a single integrated process. The resilient member, block, and anchoring elements are combined into one assembly operation where the concrete is poured directly over the pre-assembled resilient member and block combination, achieving both precision and efficiency.
3Strength
If additional adhesives and materials are used, then the bonding strength is improved, but the material cost and potential for errors increase
Solution Approach 1:
The resilient member is designed to be self-sufficient with built-in bonding capabilities. The material itself provides the necessary adhesive properties through its composition and structure, eliminating the need for additional adhesive materials and reducing the quantity of substances required.
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 increases manufacturing efficiency, ensures reliable adherence of the block to the resilient member, and simplifies the installation process by eliminating the need for additional adhesives, while providing improved vibration and noise attenuation properties.
Implementation Method 1
the resilient material adheres to the concrete block and concrete tray and thus bonds said tray to the block
Implementation Method 2
Upon polymerisation (while maintaining its resilient property) the resilient material adheres to the concrete block and concrete tray
Data Source
Figure 1~2
Figure 3~4
AI summary
A method for manufacturing a resilient rail support block assembly (1), which assembly is adapted to be mounted embedded in or mounted on a railway substructure and which assembly comprises a prefabricated resilient member (10) as well as a moulded block (20) of a suitable mouldable material, preferably of concrete, having a top, a bottom and peripheral wall, said block being adapted for fastening one or more rails on the top of said block. The prefabricated resilient member (10) has an outer tray (12) and inner tray (13) arranged within said outer tray, and comprises a resilient intermediate structure (15) arranged between said outer and inner trays (12, 13). The prefabricated resilient member (10) is used to form a part of the block mould, so that one or more additional mould members combined with said prefabricated resilient member delimit the mould for the block, the mouldable material being introduced into said block mould and thereby adhering directly to the inner tray (13) of the prefabricated resilient member (10).