Steel Monoblock Sleeper Structure for Stable Rail Load Transfer
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Solution Overview
Problem
Existing railway sleepers, particularly steel trough sleepers, face issues with service life, stability, flexibility, track narrowing, corrosion resistance, and resonance behavior, and require complex installation due to protruding end caps.
Innovation Solution
A steel monoblock sleeper is created by filling a hollow profile with a molded body, preferably using polyurethane, to enhance load transfer and stability, and incorporating angle irons and ribbed plates for improved shear force distribution and rail fastening, with optional coatings for corrosion resistance and sound damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If steel trough sleepers are used with hollow profiles, then manufacturing cost is reduced and weight is decreased, but service life and stability are compromised due to hollow layers
Solution Approach 1:
The patent applies composite materials by combining steel hollow profiles with concrete fill material. The steel provides structural framework and corrosion resistance, while the concrete fill eliminates hollow layers that cause instability. This composite construction achieves both weight reduction compared to solid concrete sleepers and improved service life through the protective steel outer shell.
Solution Approach 2:
The concrete shaped body is nested within the steel hollow profile. The steel trough body serves as a container that holds the concrete fill material, creating a nested structure where the inner concrete body is surrounded by the outer steel shell, eliminating hollow cavities while maintaining structural integrity.
2Ease of manufacture
If hollow steel trough sleepers are used, then production cost is reduced, but load transfer behavior and stability deteriorate
Solution Approach 1:
The composite structure combines steel and concrete materials to achieve superior load transfer behavior. The concrete fill material provides mass and stability for effective load transfer to the track bed, while the steel hollow profile provides structural integrity and corrosion resistance, together achieving better load transfer than hollow steel sleepers alone.
Solution Approach 2:
The concrete fill is strategically placed in specific sections of the steel hollow profile, particularly in areas requiring enhanced load transfer capability. This localized addition of mass and structural material improves load transfer behavior without requiring complete solidification of the entire sleeper.
3Adaptability or versatility
If conventional steel trough sleepers are used, then flexibility in use is limited, but resistance to track narrowing in derailments is insufficient
Solution Approach 1:
The composite steel-concrete structure provides enhanced resistance to track narrowing during derailments. The concrete fill material adds mass and structural rigidity, creating a more robust sleeper that better resists the forces generated during derailment events, while the steel outer shell maintains flexibility and adaptability in various track conditions.
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 enhanced durability, stability, reduced resonance, improved track gauge maintenance, and simplified installation by eliminating voids and optimizing force distribution, while minimizing corrosion and noise.
Implementation Method 1
at least one section of the steel sleeper trough body is filled to fill the profile with at least one molded body made of fully reacted reactive material
Implementation Method 2
This creates a larger contact surface in order to be able to transfer transverse forces that occur transversely to a rail direction to a track bed
Data Source
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Figure 6~7a
AI summary
The invention relates to a steel monoblock sleeper (1) comprising a steel sleeper trough body (100) made of a hollow profile (130) with end caps (160) bent at opposite ends (150) of the steel sleeper trough body (100), wherein the steel sleeper trough body (100) is filled to fill the profile at least in sections (190) which are provided for rail fastening by means of at least one shaped body (400).A preferred method for manufacturing a steel monoblock sleeper (1) comprises the process steps of: (a) providing or manufacturing a steel sleeper trough body (100) from a hollow profile (130) with bent end caps (160) at the opposite ends (150); and (b) arranging or forming at least one shaped body (400) in at least one section (180, 190) of the steel sleeper trough body (100), and connecting it to the steel sleeper trough body (100) such that the at least one section (180, 190) of the steel sleeper trough body (100) is filled by the at least one shaped body (400) to fill the profile.