Hollow structural members, a rail system and methods of manufacturing

• US 20090230205A1
• Filed: 03/12/2008
• Published: 09/17/2009
• Est. Priority Date: 03/12/2008
• Status: Active Grant

• Current Assignee: Hilltrac, Inc.
• Original Assignee: Hilltrac, Inc.
• Inventors: Hepner, Alan, Metivier, David
• Granted Patent: US 8,066,200 B2
• Time in Patent Office: Days
• US Class Current: 238/2
• CPC Class Codes: B23P 15/20 railroad requirements, e.g. buffers
• CPC Class Codes: B61B 5/00 Elevated railway systems without suspended vehicles with monorail B61B13/04; tracks therefor E01B25/00
• CPC Class Codes: E01B 25/08 Tracks for mono-rails with centre of gravity of vehicle above the load-bearing rail
• CPC Class Codes: E01B 25/10 Mono-rails; Auxiliary balancing rails; Supports or connections for rails
• CPC Class Codes: E01B 5/02 Rails
• CPC Class Codes: E04C 3/08 with apertured web, e.g. with a web consisting of bar-like components; Honeycomb girders E04C3/10, E04C3/11 take precedence
• CPC Class Codes: Y10T 29/49616 Structural member making

Abstract

The invention is hollow structural members, a rail system based thereon and method of manufacturing such hollow structural members. Embodiments of the structural members may be hollow triangular prism-shaped with a cross-section that is triangular, isosceles, hexagonal or otherwise. Embodiments of rail systems based on hollow structural members are also disclosed. Embodiments of the rail systems disclosed herein may also include reaction assemblies for local dissipation of stresses due to thermal expansion of track materials.

Claims

1. A method of forming a hollow triangular prism-shaped structural member, comprising:

forming a rectangular main panel having two long edges and two short edges and a first fold line bisecting the main panel along a lengthwise centerline between and parallel to the two long edges, the main panel further including second and third fold lines each disposed parallel to and a predetermined distance from each of the two long edges;

bending the main panel generally along the first fold line to form an inside angle of about 60°

to form a V-shaped cross-section;

bending the main panel generally along the second fold line to form a first lip having an inside angle of about 60°

, the first lip extending toward the third fold line and partially enclosing space inside the V-shaped cross-section;

bending the main panel generally along the third fold line to form a second lip having an inside angle of about 60°

, the second lip extending from the third fold line toward and generally parallel to the first lip and further partially enclosing the space inside the V-shaped cross-section;

forming an elongated rectangular base panel; and

connecting the elongated rectangular base panel to the first and second lips of the rectangular main panel to form a closed hollow triangular prism-shaped structural member.

2. The method according to claim 1, wherein forming the rectangular main panel further comprises forming cut-outs in the rectangular main panel between the fold lines.

3. The method according to claim 1, wherein forming the rectangular main panel further comprises forming mounting holes in the rectangular main panel.

4. The method according to claim 3, wherein the mounting holes are formed in rows parallel to the fold lines.

5. The method according to claim 1, wherein forming the elongated rectangular base panel further comprises forming cut-outs in the elongated rectangular base panel.

6. The method according to claim 1, wherein forming the elongated rectangular base panel further comprises forming mounting holes in the elongated rectangular base panel.

7. The method according to claim 1, wherein connecting the elongated rectangular base panel to the first and second lips of the rectangular main panel comprises bolting the panels together.

8. The method according to claim 1, wherein connecting the elongated rectangular base panel to the first and second lips of the rectangular main panel comprises welding the panels together.

9. A rail system formed by joining end-to-end a plurality of the hollow triangular prism-shaped structural members formed according to the method of claim 1.

10. A radio tower formed by joining end-to-end a plurality of the hollow triangular prism-shaped structural members formed according to the method of claim 1.

11. A rail system, comprising:

a plurality of hollow triangular prism-shaped rail segments, each rail segment comprising;

a triangular prism-shaped structural member having an equilateral triangle shaped cross-section, wherein one side of the equilateral triangle includes a gap between two opposed co-planar lips extending from adjacent vertices; and

an elongated rectangular base panel connected to the lips of the structural member thereby closing the gap; and

a plurality of coupling bars configured for attaching the plurality of rail segments end-to-end from inside adjacent vertices of adjacent end-to-end rail segments to form a track.

12. The rail system according to claim 11, further comprising a rack configured to be attached to a surface of the track, the rack configured with teeth for receiving and engaging a pinion gear.

13. The rail system according to claim 12, further comprising a plurality of rack brackets each configured for mounting the rack to the track.

14. The rail system according to claim 13, wherein each of the plurality of rack brackets is configured to hold the rack at a fixed distance parallel to the track.

15. The rail system according to claim 12, wherein the rack comprises a plurality of rack segments configured to be placed together serially to form a rack of arbitrary length.

16. The rail system according to claim 11, further comprising a plurality of vertical supports for supporting the track above ground.

17. The rail system according to claim 16, wherein each vertical support comprises:

a vertical beam;

a vertical support bracket configured to attach the vertical beam to the track;

a footing frame configured for placement into a concrete footing and configured for attachment to the vertical beam; and

wherein the length of the vertical beam is adjustable for precise placement of the track above ground.

18. The rail system according to claim 11, further comprising at least one reaction assembly for providing lateral support to a track, the reaction assembly comprising:

four reaction frames, each adjustable in length and configured with a first end attachable to vertical support brackets attached to the track; and

a lateral support bracket configured for placement in a concrete footing and for receiving a second end of each of the four reaction frames.

19. The rail system according to claim 11, wherein a centroid of the track traverses a non-linear path.

20. The rail system according to claim 19, wherein the path comprises traversing from point-to-point.

21. The rail system according to claim 19, wherein the path comprises a main trunk line with at least one spur.

22. The rail system according to claim 19, wherein the path comprises at least one loop.

23. The rail system according to claim 11, wherein each of the plurality of coupling bars may be configured to allow up to a specified amount of bend in the track at the coupling bar depending on center spacing between adjacent rows of mounting holes formed in the coupling bar.

24. A rail system, comprising:

a track formed of a plurality of elongated hollow structural members joined end-to-end;

a plurality of vertical supports for elevating the track above concrete foundations formed in ground; and

at least one reaction assembly placed between adjacent vertical supports, the track and the concrete foundations having pivot points near the track and having pivot points near the concrete foundations, the reaction assembly allowing for local containment of stresses due to thermal expansion of the track.

25. The rail system according to claim 24, wherein the elongated hollow structural member comprises a cross-section having an outline selected from the group consisting of:

equilateral triangle, isosceles triangle and hexagon.