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 Railway car with composite box structure formed from molded components

Details
Inventors: Thoman, Mell R.; Smith, Stephen W.;
Assignee: TRN Business Trust (Dallas, TX)
Primary Examiner: Morano; S. Joseph
Assistant Examiner: McCarry, Jr.; Robert J.
Attorney, Agent or Firm: Baker Botts L.L.P.

A composite box structure is formed from individually manufactured components such as a pair of endwalls, a pair of sidewalls, a floor and a roof. One or more components preferably include a core encapsulated in multiple layers of fiber reinforced plastic. The core may be formed from various materials which provide improved resistance to heat transfer between the interior and the exterior of the composite box structure. The composite box structure may include one or more components manufactured at least in part from steel alloys, aluminum alloys, wood and/or other materials associated with conventional railway boxcars. An opening is provided in each sidewall to allow access to the interior of the composite box structure. An opening may be formed in one of the endwalls of the composite box structure to allow installation of a temperature control system. An airflow management system may also be incorporated into selected interior portions of the roof, sidewalls, endwalls, and floor. The individual components may be mounted on a railway car underframe and connected with each other to form a box structure for various types of railway cars such as a railway boxcar or a temperature controlled railway car.

DETAILED DESCRIPTION In accordance with the present invention, disadvantages and problems associated with previous composite box structures used to manufacture various types of railway cars have been substantially reduced or eliminated.
The present invention provides composite box structures for various types of railway cars including, but not limited to, railway boxcars and temperature controlled railway cars.
The composite box structure provides enhanced insulation, reduced weight, increased load carrying capacity and increased service life as compared to conventional railway cars.
A composite box structure formed from individually molded components incorporating teachings of the present invention allows manufacture and assembly of the resulting railway boxcar with substantially reduced costs as compared to conventional railway cars with the same performance characteristics and as compared to composite box structures formed by integrally molding several components as one or more composite units.
A composite box structure formed from individually molded components incorporating teachings of the present invention allows combining a temperature control system with an airflow management system to provide a temperature controlled boxcar with substantially reduced total lifetime costs as compared to conventional refrigerated boxcars with substantially the same performance characteristics.
The composite box structure provides enhanced insulation, reduced weight, increased load carrying capacity, better temperature regulation and increased service life as compared to a typical refrigerated boxcar.
One aspect of the present invention includes a composite box structure having a roof, sidewalls, endwalls and a floor fabricated as individual components using vacuum bagging techniques along with dry layup of selected material layers and an enhanced resin delivery system.
The individual components may then be assembled with each other using adhesives and/or mechanical fasteners to form the desired composite box structure


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