TECHNICAL FIELD:

[0001] The present invention relates to an applicator insert, and an applicator, for a solid stick composition for lubricating or modifying the coefficient of friction between metal surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact.

BACKGROUND:

[0002] The control of friction and wear of metal mechanical components that are in sliding, slipping, rolling and sliding, or rolling and slipping contact is of great importance in the design and operation of many machines and mechanical systems. For example, many steel-rail and steel-wheel transportation systems including freight, passenger and mass transit systems suffer from the emission of high noise levels and extensive wear of mechanical components such as wheels, rails and other rail components such as ties. The origin of such noise emission, and the wear of mechanical components may be directly attributed to the frictional forces and behaviour that are generated between the wheel and the rail during operation of the system.

[0003] Systems are known for lubricating or otherwise modifying the coefficient of friction between steel surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact, for example, the flanges of rail car wheels and a track, or fifth-wheels. Friction modifying systems may use liquid lubricants, such as oil, grease or friction enhancing compositions, or solid stick friction modifiers, to lubricate, enhance, or modify the coefficient of friction of surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact, for example flanges of a rail car wheels and a track.

[0004] For example, US 6,136,757, US 5,308,516, and US 5,173,204 (each of which is incorporated herein by reference) describe solid stick compositions for application to surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact, for example the flanges of rail car wheels. These solid stick compositions are used to control the friction between the wheel and rail interface. Solid stick compositions applied to wheel flanges help control flange wear and can reduce the potential for low speed wheel climb derailments. Solid stick compositions or friction modifying compositions applied to wheel treads help control tread wear and can reduce corrugations on wheel and rail surfaces. [0005] US 2003/0101897 and WO 2006/027859 (which are incorporated herein by reference) provide examples of solid stick applicators that may be used for application of friction modifying compositions to steel surfaces. These applicators comprise a removable insert that can be loaded with the solid stick and inserted within the applicator body.

[0006] Solid stick compositions are typically made of hard, brittle materials. The applicators that house the solid stick, and the solid stick lubricant compositions or friction modifying compositions, need to be able to withstand the severe vibration and shock conditions experienced during operation. Vibrational energy from the rotating wheel is transferred from the lubricant-wheel interface to the solid stick and then to the applicator and associated hardware. Energy from the truck frame housing a set of wheels can also be transferred to the applicator via the bracket mounted on the truck frame. Because of the variations in hardware designs, each system responds to input vibrations differently, for some applicators, a significant level of induced vibration can occur, leading to excessive noise, hardware fatigue and failure.

[0007] The vibrations transferred to the stick hardware (for example, the applicator, the insert and the applicator bracket) can result in a chattering or rattling noise in the applicator. Stick chatter is understood to be a non-linear vibration and is related to an unstable system where under certain parameters, instability and self-excited vibrations may occur. Similar problems occur in machining operations, such as lathes, where sudden rattling noises develop as the cutting tool is fed into the work piece. This chatter and rattle can result in high stress and strain values induced in the applicators, leading to broken solid sticks, pre-mature spring failures within the applicator, and fatigue failure of the applicator insert, and/or the applicator.

SUMMARY

[0008] The present invention relates to an applicator insert and an applicator for solid stick compositions for modifying the co-efficient of friction between metal surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact.

[0009] As described herein, the applicators comprise an insert having an elongate base, and a flange comprising a resilient bent portion which exerts a lateral force against a solid stick composition to reduce or dampen vibrations transferred to the solid stick composition, applicator or applicator hardware. The applicator hardware includes, for example, an insert, a housing and an applicator bracket. [0010] The applicators as described herein may comprise an insert having an elongate base, the elongate base having a first and a second elongate edge, and a first and a second end, a first flange affixed along a length of the first elongate edge, and an end plate affixed to the second end of the elongate base and to an adjacent end of the first flange, the first flange and the end plate extending outwards from the elongate base in a same direction, the elongate base, the first flange and the end plate configured to receive the solid stick composition when the solid stick composition is placed within the insert, the first flange defining one or more first slots through a thickness of the first flange and extending from: (i) an end of the first flange opposite the end plate and along about 1% to about 35% of a length of the first flange, (ii) an edge of the first flange opposite the elongate base and along a width of the first flange, (iii) a combination of i) and ii), or (iv) an end of the first flange opposite the end plate along a length of the first flange and continuous to a slot extending from an edge of the first flange adjacent the first elongate edge of the elongate base, to form a resilient bent portion of the first flange, for example, the resilient bent portion of the first flange may be bendable in a direction perpendicular to a surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the first flange exerts a force against the solid stick composition; a housing defining an internal cavity operatively configured to receive the insert, the resilient bent portion of the first flange being angled towards the internal cavity; and a biasing member attached to either the insert or the housing, the biasing member for advancing the solid stick composition, when placed within the insert, towards the first end.

[0011] As described herein the applicators may also comprise an insert having an elongate base, the elongate base having a first and a second elongate edge, and a first and a second end, a first flange affixed along a length of the first elongate edge, a second flange affixed along a length of the second elongate edge, and an end plate affixed to the second end of the elongate base and to adjacent ends of the first flange and the second flange, the first flange, the second flange and the end plate extending outwards from the elongate base in a same direction, the elongate base, the first flange, the second flange and the end plate configured to receive the solid stick composition when the solid stick composition is placed within the insert, the first flange defining one or more first slots through a thickness of the first flange and extending from: (i) an end of the first flange opposite the end plate and along a length of the first flange, (ii) an edge of the first flange opposite the elongate base and along a width of the first flange, (iii) a combination of (i) and (ii), or (iv) an end of the first flange opposite the end plate and along a length of the first flange and continuous to a slot extending from an edge of the first flange adjacent the first elongate edge of the elongate base, to form a resilient bent portion of the first flange, for example, the resilient bent portion of the first flange may be bendable in a direction perpendicular to a surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the first flange exerts a force against the solid stick composition; the second flange defining one or more second slots through a thickness of the second flange and extending from: (i) an end of the second flange opposite the end plate and along a length of the second flange, (ii) an edge of the second flange opposite the elongate base and along a width of the second flange, (iii) a combination of (i) and (ii), or (iv) an end of the second flange opposite the end plate and along a length of the second flange and continuous to a slot extending from an edge of the second flange adjacent the second elongate edge of the elongate base, to form a resilient bent portion of the second flange, for example, the resilient bent portion of the second flange may be bendable in a direction perpendicular to the surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the second flange exerts a force against the solid stick composition; a housing defining an internal cavity operatively configured to receive the insert, the resilient bent portions of the first flange and the second flange being angled toward the internal cavity; and a biasing member attached to either the insert or the housing, the biasing member for advancing the solid stick composition, when placed within the insert, towards the first end.

[0012] Also described herein are inserts for use in a solid stick composition applicator. The inserts comprise an elongate base, the elongate base having a first and a second elongate edge, and a first and a second end; and a first flange affixed along a length of the first elongate edge, and an end plate affixed to the second end of the elongate base and to an adjacent end of the first flange, the first flange and the end plate extending outwards from the elongate base in a same direction, the elongate base, the first flange and the end plate configured to receive the solid stick composition when the solid stick composition is placed within the insert, the first flange defining one or more first slots through a thickness of the first flange and extending from: (i) an end of the first flange opposite the end plate and along about 1% to about 35% of a length of the first flange, (ii) an edge of the first flange opposite the elongate base and along a width of the first flange, (iii) a combination of i) and ii), or (iv) an end of the first flange opposite the end plate along a length of the first flange and continuous to a slot extending from an edge of the first flange adjacent the first elongate edge of the elongate base, to form a resilient bent portion of the first flange, for example, the resilient bent portion of the first flange may be bendable in a direction perpendicular to a surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the first flange exerts a force against the solid stick composition.

[0013] As described herein the inserts may also comprise an elongate base, the elongate base having a first and a second elongate edge, and a first and a second end; a first flange affixed along a length of the first elongate edge; a second flange affixed along a length of the second elongate edge; and an end plate affixed to the second end of the elongate base and to adjacent ends of the first flange and the second flange, the first flange, the second flange and the end plate extending outwards from the elongate base in a same direction, the elongate base, the first flange, the second flange and the end plate configured to receive the solid stick composition when the solid stick composition is placed within the insert, the first flange defining one or more first slots through a thickness of the first flange and extending from: (i) an end of the first flange opposite the end plate and along a length of the first flange, (ii) an edge of the first flange opposite the elongate base and along a width of the first flange, (iii) a combination of (i) and (ii), or (iv) an end of the first flange opposite the end plate and along a length of the first flange and continuous to a slot extending from an edge of the first flange adjacent the first elongate edge of the elongate base, to form a resilient bent portion of the first flange, for example, the resilient bent portion of the first flange may be bendable in a direction perpendicular to a surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the first flange exerts a force against the solid stick composition; the second flange defining one or more second slots through a thickness of the second flange and extending from: (i) an end of the second flange opposite the end plate and along a length of the second flange, (ii) an edge of the second flange opposite the elongate base and along a width of the second flange, (iii) a combination of (i) and (ii), or (iv) an end of the second flange opposite the end plate and along a length of the second flange and continuous to a slot extending from an edge of the second flange adjacent the second elongate edge of the elongate base, to form a resilient bent portion of the second flange, for example, the resilient bent portion of the second flange may be bendable in a direction perpendicular to the surface defined by the elongate base, wherein when the solid stick composition is placed within the insert, the resilient bent portion of the second flange exerts a force against the solid stick composition.

[0014] Any solid stick composition as known to a person of ordinary skill in the art may be used with the applicators and inserts as described herein.

[0015] In use, the resilient bent portion of the first, the second, or both the first and the second flange press against the solid stick when the solid stick is loaded within the insert or housing thereby reducing vibration of the stick that is generated when the stick is rubbing against the metal surface. As a result, there is reduced breakage of the solid stick, reduced wear, stress or breakage of the insert and housing, or both reduced breakage of the solid stick and reduced wear, stress or breakage of the insert and housing. Furthermore, the field life of the solid stick, the insert, the housing or a combination thereof is increased.

[0016] The modified inserts as described herein reduce the severity of vibrations experienced in the applicator during use, and they apply a side stiffness to the solid stick composition without affecting the axial application pressure required to be applied by the spring so that stick movement within the insert or applicator is not restricted. The modified inserts as described herein can be manufactured using existing manufacturing processes and equipment and are lightweight, for example, the mass of the insert is not increased by more than 20%. The modified inserts as described herein are also cost effective to produce and are easy to use and to maintain. Furthermore, the modified inserts as described herein may be used within existing applicators.

[0017] This summary does not necessarily describe the entire scope of all aspects of the disclosure. Other aspects, features and advantages will be apparent to those of ordinary skill in the art upon review of the following description of specific embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features of the present disclosure will become more apparent from the following description in which reference is made to the appended drawings:

[0019] Figure 1 shows a prior art applicator in operative communication with a wheel.

[0020] Figure 2 shows an exploded view of an example of a prior art applicator comprising an applicator body and an insert for receiving a solid stick composition. In this example the insert comprises one flange.

[0021] Figure 3 shows an exploded view of an example of a prior art applicator comprising an applicator body and an insert for receiving a solid stick composition. In this example, the insert comprises two flanges.

[0022] Figure 4 shows inserts according to various aspects of the invention (Figures 4C, “Top bend insert”; and 4D, “Short bend insert”) and inserts of prior art applicators for a solid stick composition (Figures 4A, “Standard, or Regular, insert”; and 4B, “Standard Bend, or Regular curved, Insert”). The inserts shown in Figures 4A-4D each comprise one first flange.

[0023] Figures 5A - 5L show non-limiting examples of side elevations of flanges of an insert as described herein.

[0024] Figure 6 shows an applicator according to an embodiment of the invention comprising an insert within a housing, the insert comprising a resilient bent portion of a first flange which defines a deflection and exerts a force against a solid stick composition (Figure 6A), and examples of inserts according to various embodiments of the invention (Figure 6B) showing the resilient bent portion of the first flange overlapping a surface of the elongate base of the insert.

[0025] Figure 7 shows inserts according to various aspects of the invention (Figures 7B, 7C, and 7D), and an insert of a prior art applicator for a solid stick composition (Figure 7A). The inserts of Figures 7A-7D each comprise a first flange and a second flange.

[0026] Figure 8 shows a front-end view of an applicator according to an embodiment of the invention corresponding to the applicator shown in Figures 7B or 7D (Figure 8A), and an applicator according to an embodiment of the invention corresponding to the applicator shown in Figure 7C (Figure 8B). The applicators according to various embodiments of the invention comprise an insert with a resilient bent portion of the first and the second flanges both of which define a deflection.

[0027] Figure 9 shows results of in-lab vibration tests (in the vertical, lateral and axial directions) of a solid stick composition (upper panels; “stick”) and applicator housing (lower panels: “tube”) as a function of vertical shaking frequency for applicators comprising four different inserts comprising one first flange (as shown in Figures 4A - 4D). [0028] Figure 10 shows an experimental set-up for a full wheel design for testing vibration as a function of wheel speed in the vertical, lateral and axial directions on a solid stick composition and applicator housing for applicators comprising four different inserts.

[0029] Figure 11 shows vibration results obtained on a full wheel rig (in the vertical, lateral and axial directions) of the solid stick composition (upper panels: “stick”) and applicator housing (lower panels; “tube”) as a function of wheel speed for applicators comprising four different inserts.

DETAILED DESCRIPTION:

[0030] The present invention relates to applicator inserts and applicators for delivering solid stick compositions to treat metal surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact. The metal surfaces to be treated may be any metal surfaces that require lubrication, for example, the flange of a rail car wheel, the rail guide of an elevator, or a fifth wheel. The inserts and applicators comprising the inserts described herein reduce vibrational effects on a solid stick composition housed within the applicator, and on the components of applicator hardware, thereby extending the operational life of the solid stick composition, and the applicator hardware, when used under field conditions.

[0031] Solid stick compositions are typically continuously applied to a wheel or other metal surface in sliding, slipping, rolling and sliding, or rolling and slipping contact by a spring-loaded applicator. As shown in Figure 1, applicators 10 are mounted to a bracket 12 which in turn is attached to a sprung portion of the truck frame 14. A film of the material of the solid stick composition 16 is deposited to the surface of a wheel 18 and influences and enhances the friction characteristics in the interface between metal surfaces that are in sliding, slipping, rolling and sliding, or rolling and slipping contact. During use, vibrational energy from the rotating wheel is transferred by friction at the stick-wheel interface to the solid stick composition and then to the applicator and associated hardware. Repeated exposure of the applicator and the components within the applicator to these vibrational forces results in fracturing or breakage of the solid stick, and increased wear or failure of the insert, and of the applicator.

[0032] The applicators as described herein reduce the induced vibrations transferred to the solid stick composition, applicator and associated hardware by applying a lateral force to the solid stick, thereby increasing the stiffness of the solid stick when the solid stick is loaded into the insert and placed within the applicator. The insert, a component of the applicator that receives and advances the solid stick composition within the applicator and towards the metal surface to be treated, can be modified to increase the lateral force or stiffness applied to the solid stick composition. By incorporating one or more slots into specific areas of a flange of the insert so as to define a resilient bent portion, a lateral force can be applied against the solid stick composition when placed within the insert, or in some cases when the insert is installed within the applicator. As a result, the inserts as described herein reduce or dampen the severity of vibrations experienced by the applicator and the components of the applicator (insert and solid stick), without affecting the axial application pressure to the solid stick composition and the movement of the solid stick composition along the insert and applicator. The insert design described herein was tested on a lab rig and showed significant reductions in induced vibrations when compared to the standard insert and standard bend designs. When tested on a full wheel rig, reductions in vibrations were also observed.

[0033] The applicators described herein are stronger and stiffer than prior art applicators and exert more stiffness to the solid stick composition than prior art applicators. The improved stiffness reduces fatigue and vibrations and reduces wear on the applicator and the mounting hardware used to connect the housing of the applicator to the undercarriage of a rail car, and increases the vibrational stability of the applicator, compared to prior art applicators such as the standard insert and standard bend designs.

[0034] The applicators and inserts as described herein may be easily refilled and do not need to be disposable. They are easy to use and maintain, and can be manufactured with established manufacturing processes and equipment.

[0035] Non-limiting examples of standard prior art applicators are shown in Figures 2 and 3. As one of skill would appreciate, other applicators that comprise an insert may also be modified as described herein. The applicator 20 comprises an insert 22 which fits into housing 24. The insert 22 comprises an elongate base 26 and an end plate 28. The end plate 28 may act as a cover and as a handle. Affixed along a first edge of the elongate base 26 is a first flange 30. The elongate base 26 comprises a spring 32 for advancing a solid stick composition (when the solid stick is placed within the insert, the spring is extended along the length of the elongate base 26). A boss or nut 34 may be attached at the rear of the insert 22 to retain a lock pin or lock bolt 36 which passes through the housing 24 to fasten the insert 22 to the housing 24. As shown in Figure 3, the applicator 20 may also comprise an insert comprising a second flange 38 affixed along a second edge of the elongate base 26. The applicator 20 may be of varying lengths, depending on the length of the solid stick composition required.

[0036] A non-limiting example of a standard bend prior art insert is shown in Figure 4B (referred to as the “Standard Bend Insert”). The insert 22 comprises an elongate base 26. The elongate base 26 has a first elongate edge 27 and a second elongate edge 29, and a first end 31 and a second end 40. A first flange 30 is affixed along a length of the first elongate edge 27 and an end plate (not shown) is affixed to the second end 40 of the elongate base 26 and to an adjacent end of the first flange 30. The first flange 30 and the end plate extend outwards from the elongate base 26 in a same direction. The elongate base 26, the first flange 30 and the end plate are configured to receive the solid stick composition when the solid stick composition is placed within the insert 22.

[0037] The end plate may be of any size or shape so long as it is affixed to the elongate base 26 and the first flange 30. The end plate may be solid and cover the entire space between the first flange 30 and the elongate base 26 (as shown in Figure 2), the end plate may include a handle, or the end plate may be open and comprise a brace. The end plate may have any shape, such as rectangular or triangular, and may have curved or straight edges.

[0038] The first flange 30 defines one or more first slots 44 through a thickness of the first flange 30 and as shown in Figure 4B, may extend from an end of the first flange 30 opposite the end plate and along a length that is greater than 40% of the length of the first flange 30 to form a resilient bent portion 48 of the first flange. For comparison, Figure 4A shows the insert of a standard prior art applicator which does not have a slot in the first flange. In the prior art insert shown in Figure 4A, a significant level of induced vibration is observed, leading to excessive noise, hardware fatigue and/or failure. The vibration results in increased stress within the applicator and results in broken solid sticks, pre-mature spring failure within the applicator, and over time, fatigue failure of the applicator insert, and/or the applicator. Some induced vibration reduction was achieved with the prior art applicator shown in Figure 4B.

[0039] An insert of an embodiment of the present invention is shown in Figure 4C (referred to as the “Top Bend Insert”). The insert 60 comprises an elongate base 62. The elongate base 62 has a first elongate edge 64 and a second elongate edge 66, and a first end 68 and a second end 70. A first flange 72 is affixed along a length of the first elongate edge 64 and an end plate (not shown) is affixed to the second end 70 of the elongate base and to an adjacent end of the first flange 72. The first flange 72 and the end plate extend outwards from the elongate base 62 in a same direction. The first flange 72 defines a first slot 76 through a thickness of the first flange 72 and extending from an edge of the first flange 72 opposite the elongate base 62 and along a width of the first flange 72 to form a resilient bent portion 78 of the first flange 72. The resilient bent portion 78 of the first flange 72 is bendable away from a plane defined by the first flange 72. The resilient bent portion 78 of the first flange 72 may be bendable in a direction (or plane) that is perpendicular to a surface 80 defined by the elongate base 62. When the solid stick composition is placed within the insert 60, and the insert installed within housing 24, the resilient bent portion of the first flange 78 exerts a force against the solid stick composition, pressing the solid stick against an internal wall of the housing.

[0040] As discussed below, the inserts shown in Figures 4C and 4D, exhibit a reduced level of vibration (see Figures 9 and 11), which results in reduced or no noise, and increased field-life of the hardware. The reduced vibration reduces stress within the applicator, resulting in increased solid stick integrity during use, and increased field-life of the insert, spring and applicator.

[0041] For example, the resilient bent portion 78 of the first flange 72 (e.g. as shown in Figure 4C) may be bendable away from a plane defined by the first flange 72, with the bendable portion overlapping elongate base 62. When the lubricating solid stick is placed within the insert 60, and the insert installed within the housing 24, the resilient bent portion 78 of the first flange 72 exerts a force against the solid stick composition. This force acts to increase the lateral stiffness of the solid stick composition, thereby minimizing the vibrations, including the lateral vibration, of the solid stick composition when in use. The amount of force applied to increase the lateral stiffness of the stick is such that it should not affect movement of the stick along the insert and applicator. A second embodiment of this aspect of the invention is shown in Figure 4D (referred to as the “Short Bend Insert”) where the slot 76 extends from the end of the first flange opposite the end plate and along about 1% to about 35%, or any amount therebetween, of a length of the first flange. The slot in this embodiment is shorter than that for the standard bend insert shown in Figure 4B.

[0042] As described herein, the first flange 72 may define one or more first slots through a thickness of the first flange 72 and extending from: (i) an end of the first flange opposite the end plate and along about 1% to about 35%, or any amount therebetween, of a length of the first flange (e.g. Figures 4D, 5A-5E), (ii) an edge of the first flange opposite the elongate base and along a width of the first flange (e.g. Figures 4C, 5G), as discussed in more detail below, (iii) a combination of (i) and (ii) as shown in Figures 5F, 5H, 5I, (iv) an end of the first flange opposite the end plate along a length of the first flange and continuous to a slot extending from an edge of the first flange adjacent the first elongate edge of the base (Figures 5J - 5K), or (v) the slots may form cuts through a thickness of the first flange 72 to define a hole (Figure 5L).

[0043] There are a number of possible configurations for the one or more slots in order to form the resilient bent portion, a sample of which are shown in Figures 5A-5L. These examples are not intended to limit the invention in any way, but merely illustrate to a person of ordinary skill in the art the numerous ways in which the slot can be formed to define the resilient bent portion of the flange. The one or more slots may be perpendicular to an end or an edge of the flange, or the one or more slots may be angular, straight, curved or comprise compound angles. These modifications to the shape and/or angles of the one or more slots result in the formation of a resilient bent portion with reduced or increased surface area exerting a force against the solid stick composition. Thus, a person of ordinary skill in the art may adjust the size and shape of the resilient bent portion in order to increase or decrease the vibrational stiffness provided by the insert.

[0044] Figures 5A to 5L show side views of the first flange (72) with the dashed lines indicating the slot (76) and are not necessarily drawn to scale. Figure 5A shows a side flange having a horizontal slot extending from an end of the flange and along about 1% to about 35% of a length of the flange. Figure 5B shows a side flange having a horizontal slot extending from an end of the flange and continuous with an angular slot. Figure 5C shows a side flange having a horizontal slot extending from an end of the flange and continuous with a vertical slot. Figure 5D shows a side flange having a slot extending from an end of the flange at an angle. Figure 5E shows a side flange having two horizontal slots extending from an end of the flange. Figure 5F shows a side flange having a horizontal slot extending from an end of the flange and a vertical slot extending from an edge of the flange. Figure 5G shows a side flange having a vertical slot extending from an edge of the flange. Figure 5H shows a side flange having a vertical slot extending from an edge of the flange and continuous with a horizontal slot. Figure 5I shows a side flange having a vertical slot extending from an edge of the flange and continuous with an angular slot. Figure 5J shows a side flange having a vertical slot extending from a first elongate edge of the flange adjacent the base of the insert, the vertical slot continuous with a horizontal slot extending along a lower edge of the flange and extending to an end of the flange. Figure 5K shows a side flange having a vertical slot extending from a first elongate edge of the flange adjacent the base of the insert, the vertical slot continuous with a horizontal slot extending to an end of the flange. Figure 5L shows a side flange having a hole defined by a vertical cut extending from a first elongate edge of the flange adjacent the base of the insert and continuous with a horizontal cut extending to an end of the flange.

[0045] The one or more first slots of the first flange may extend from the first end of the flange to about 1% to about 35%, or any amount therebetween, along the length of the first flange, about 10% to about 80%, or any amount therebetween, along the width of the first flange, or a combination thereof, or any amount therebetween. For example, the one or more first slots may extend from about 5% to about 30% along the length of the first flange, about 15% to about 65%, or any amount therebetween, along the width of the first flange, or a combination thereof, or any amount therebetween. The one or more slots may extend from about 10% to about 30%, or any amount therebetween, along the length of the first flange, about 30% to about 65%, or any amount therebetween, along the width of the first flange, or a combination thereof, or any amount therebetween. The one or more slots may extend from 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21 , 23, 25, 27, 29, 31 , 33 35%, or any amount therebetween, along the length of the first flange;

10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58,

60, 62, 64, 68, 70, 72, 74, 76, 78, 80%, or any amount therebetween, along the width of the first flange, or a combination thereof, or any amount therebetween. For example, which is not to be considered limiting, in the “Short Bend Insert”, the slot may extend approx. 30% along the length of the flange. Without wishing to be bound by theory, by reducing the length of the one or more first slot to from 1 to 35% of the length of the first flange (when compared to a prior art insert comprising a slot of more than 40% the flange length, as shown in Figure 4B), an increased force is applied to the solid stick thereby increasing the lateral stiffness of the stick. The increase in lateral stiffness reduces the severity of vibrations experienced by the solid stick and the applicator during use, when compared to prior art applicators that do not comprise a bent flange (Figure 4A) and do not increase the lateral stiffness of the stick and do not reduce vibrations at the stick or applicator, and when compared to applicators that comprise an elongate bent flange (i.e. greater than 40% the length of the length of the flange; Figure 4B) that is flexible and which does not increase the lateral stiffness of the stick as significantly or reduce vibrations at the stick or applicator as significantly.

[0046] The resilient bent portion of the first flange is bendable away from a plane defined by the first flange. For example, the resilient bent portion of the first flange may be bendable in a plane that is perpendicular to a surface defined by the elongate base, defining a deflection of the resilient bent portion of the first flange relative to a surface defined by the elongate base. When the insert is placed within the housing, the resilient bent portion of the first flange is deflected towards an interior space of the housing. This deflection is shown in Figures 6A and 6B. As shown in Figure 6A and 6B, depending upon the orientation of the housing when mounted, the height of the resilient bent portion of the first flange may be either less or greater than the width of the base.

[0047] Figure 6A shows an insert 90 contained within a housing 92 and a solid stick composition 94 in the insert 90. The vertical lines in Figure 6A show the deflection of the resilient bent portion of the flange relative to an edge of the elongate base 96. As shown in Figure 6A, the resilient bent portion exerts a force against the solid stick composition, pressing the solid stick against the internal wall of the housing and increasing the lateral stiffness applied to the stick, thereby reducing vibrations of the solid stick composition when in use. As described above, reducing or dampening the vibrations of the solid stick composition in turn reduces the vibrations in the applicator and associated hardware, thereby extending the useable life of the applicator and associated hardware.

[0048] Figure 6B shows two inserts according to different embodiments of the invention described herein, with the biasing member attached to the elongate base (either a narrow or wide base relative the width of the flange). In both embodiments, the resilient bent portion is bent away from a plane defined by the flange to create a deflection. The deflection overlaps with the elongate base.

[0049] In various embodiments, the deflection may be about 0.10 mm to about 10 mm relative to the edge of the elongate base, or any measurement therebetween. For example, the deflection may be about 0.2 mm to about 9 mm, about 0.25 mm to about 8 mm, about 0.25 mm to about 7 mm, about 0.25 mm to about 6 mm, about 0.25 mm to about 5 mm, about 0.25 mm to about 4 mm, or about 0.25 mm to about 3 mm. For example, the deflection may be from 0.10, 0.2, 0.4, 0.6, 0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, to 10.0 mm relative to the edge of the elongate base, or any measurement therebetween.

[0050] The inserts as described herein may include a second flange 52 affixed along a length of the second elongate edge of the elongate base (Figure 7B). In a manner similar to the first flange 72, the second flange 52, extends outwards from the elongate base and is affixed to the end plate. The insert 60 may comprise one or more slots through a thickness of the first, the second, or both the first and second flanges. Embodiments according to this aspect of the invention are shown in Figures 7B-7D. For comparison, the prior art insert is shown in Figure 7A.

[0051] Figure 7B shows an insert with both first and second flanges with resilient bent portions bendable away from a plane defined by the first and second flanges, respectively. For example, the first and second flanges may be bendable in a plane that is perpendicular to a surface 80 defined by the elongate base 62. However, it is also to be understood that inserts may comprise two flanges and only one of the flanges may be slotted and bendable as described herein. The insert 60, Figure 7B, comprises an elongate base 62. The elongate base 62 has a first elongate edge 64 and second elongate edge 66, and a first end 68 and a second end 70. A first flange 72 is affixed along a length of the first elongate edge 27. A second flange 52 is affixed along a length of the second elongate edge 66. An end plate (not shown) is affixed to the second end 70 of the elongate base 62, the first flange 72 and the second flange 52. The first flange 72, the second flange 52 and the end plate extend from the base in the same direction. The elongate base 62, the first flange 72, the second flange 52 and the end plate are configured to receive the solid stick composition when the solid stick composition is placed within the insert 60 so that the one, or both, resilient end presses against the solid stick composition, pressing the solid stick against the other flange of the insert.

[0052] The second flange 52 defines one or more first (if only one flange is slotted) or second (if both flanges are slotted) slots 54 through a thickness of the second flange 52 and as shown in Figures 7B and 7D, may extend from end 38 of the second flange 52 opposite the end plate and along a length of the second flange 52 to form a resilient bent portion 56 of the second flange 52. The second flange 52 may define one or more second slots through a thickness of the second flange and extending from: (i) an end of the second flange opposite the end plate and along a length of the second flange (e.g. Figures 7B, 7D), (ii) an edge of the second flange opposite the elongate base and along a width of the second flange (Figures 7C), (iii) a combination of (i) and (ii), (iv) an end of the second flange opposite the end plate along a length of the second flange and continuous to a slot extending from an edge of the second flange adjacent the first elongate base (e.g. as shown in Figure 5J-5K), or (v) the slots may form cuts through a thickness of the second flange 52 to define a hole (Figure 5L).

[0053] The resilient bent portion 56 of the second flange 52 is bendable away from a plane defined by the second flange 52. For example, the resilient bent portion 56 of the second flange 52 may be bendable in a plane that is perpendicular to a surface 80 defined by the elongate base 62. When the solid stick composition is placed within the insert, the resilient bent portion 56 of the second flange 52 exerts a force against the solid stick composition. An alternate embodiment of this aspect of the invention is shown in Figure 7D where the length of the first and/or second slot is shorter.

[0054] For comparison, Figure 7 A shows the insert of a standard prior art applicator which does not have a slot in the first or second flanges.

[0055] An insert of a further embodiment of the present invention is shown in Figure 7C. The insert 60 comprises an elongate base 62. The elongate base 62 has a first elongate edge 64 and a second elongate edge 66, and a first end 68 and a second end 70. A first flange 72 is affixed along a length of the first elongate edge 64. A second flange 82 is affixed along a length of the second elongate edge 66. An end plate (not shown) is affixed to the second end 70 of the elongate base 62, an adjacent end of the first flange 72 and an adjacent end of the second flange 82. The first flange 72, the second flange 82 and the end plate extend outwards from the elongate base 62 in a same direction. The second flange defines one or more second slots 84 through a thickness of the second flange 82 and extending from an edge of the second flange 82 opposite the elongate base 62 and along a width of the second flange 82 to form a resilient bent portion 86 of the second flange 82. The resilient bent portion 86 of the second flange 82 is bendable away from a plane defined by the second flange 52. For example, the resilient bent portion 86 of the second flange 82 may be bendable in a plane that is perpendicular to a surface 80 defined by the elongate base 62. When the solid stick composition is placed within the insert, the resilient bent portion 86 of the second flange 82 exerts a force against the solid stick composition.

[0056] Like the one or more first slots on the first flange, the one or more second slots on the second flange are through a thickness of the second flange and may extend from: (i) an end of the second flange opposite the end plate and along a length of the second flange, (ii) an edge of the second flange opposite the elongate base and along a width of the second flange, (iii) a combination of i) and ii), or (iv) an end of the second flange opposite the end plate along a length of the second flange and continuous to a slot extending from an edge of the second flange adjacent the second elongate edge of the elongate base, to form a resilient bent portion of the second flange, examples of which are shown in Figure 5. The resilient bent portion of the second flange is bendable away from a plane defined by the second flange. For example, the resilient bent portion of the second flange may be bendable in a plane that is perpendicular to a surface defined by the elongate base. When the solid stick composition is placed within the insert, the resilient bent portion of the second flange exerts a force against the solid stick composition, reducing the level of vibration and noise, thereby increasing the field-life of the hardware.

[0057] The one or more first slots and the one or more second slots may have the same shape and position of the first and second flanges, respectively, or they may be different. Furthermore, an insert that comprises two flanges may only have one slotted flange and comprises one resilient bent portion of the flange, while the other flange remains intact.

[0058] The bend of the resilient bent portion of the first, the second, or both the first and the second flange creates a deflection. Figures 8A and 8B illustrate this deflection for two bent flanges. Figure 8A is a front view of an insert where the insert corresponds to the insert shown in Figure 7B or 7D. The flanges of the insert are parallel to the adjacent walls of the housing. Figure 8B is a front view of an insert where the insert corresponds to the insert shown in Figure 7C. The bend of the resilient bent portion of the first flange and the resilient bent portion of the second flange each define a deflection relative to an edge defined by the elongate base. When a solid stick composition is placed within the insert, both of the resilient bent portions exert a force against the solid stick composition which reduces or dampens the vibrations of the solid stick composition when in use. As noted above, only one of the two flanges may be slotted, and the insert may comprise one resilient bent portion of the flange, with the other flange remaining intact.

[0059] In addition to the embodiments described above, the elongate base may also be slotted in an analogous manner as described for the flange, and the elongate base bent to exert a force against a solid stick composition when a solid stick composition is placed within the insert of the applicator.

[0060] The inserts as described herein fit into a housing. The housing defines an internal cavity operatively configured to receive the insert, the resilient bent portion of the first flange being angled towards the internal cavity. The housing may be called a tube. The housing may be fabricated from a polymer having a suitable tensile strength, or compression strength. Non limiting examples of a polymer include high density polyethylene (HDPE), or Nylon®. Alternatively, the housing may be fabricated from aluminum, steel or fiber reinforced plastic (FRP). US 2003/0101897 and WO 2006/027859 (which are incorporated herein by reference) provide non-limiting examples of solid stick applicators that may be used to receive an insert as described herein, for application of friction modifying compositions to steel surfaces.

[0061] In addition to the embodiments described above, if the insert comprises one, or no, flange affixed along the edge of the elongate base, then the one or more “flange equivalent” may be located on, or attached to, an internal wall of the housing and exert a force against the solid stick composition which reduces or dampens the vibrations of the solid stick composition when in use. For example, the “flange equivalent” may be a length of spring steel having a width that approximates the width of the solid stick composition, although this width may also be less than the width of the stick. One end of the length of spring steel is attached to the internal wall of the housing using any fastening device, for example bolts, screws, a weld, or the one end may be matingly engaged with a slot located on the internal wall, and the free end of the length of spring steel (equivalent to the resilient bent portion) configured to extend into the interior of the housing so that the free end presses against the solid stick composition, pressing the solid stick against either the one flange of the insert, or against the opposite internal wall of the housing.

[0062] The solid stick composition may be a set of interlocking sticks (see W02006/116877, which is incorporated herein by reference) or a single long stick. The interlocking feature provides support to a segment of a set of interlocking sticks, which is in contact with a surface, such as a wheel flange, and prevents it from falling out of the applicator and contaminating the environment once it is worn down to a short length. US 6,136,757, US 5,308,516, and US 5,173,204 (each of which is incorporated herein by reference) describe solid stick compositions that may be used with the applicator and insert as described herein. [0063] The applicators as described herein also include a biasing member (32, Figure 2) for advancing the solid stick composition, when placed within the insert, towards the first end of the elongate base. The biasing member may be attached to either the insert or the housing. If the biasing member is attached to the insert, it may be located on the elongate base, the first flange or the second flange. The biasing member may be made of a sturdy, corrosion-resistant material, such as anodized aluminum. Examples of biasing members include a spiral torsion spring, a helical torsion spring, a constant force motor spring and a power spring.

[0064] The insert may be constructed of sheet metal. The sheet metal can be steel, stainless steel, aluminum or other similar material.

[0065] The length of the insert may vary, depending on the length of the applicator required for various applications.

[0066] In use, a solid stick composition is placed within the insert, so that the biasing member is in a biasing position, and the insert is placed in the housing, or applicator. The housing may be pre-installed on a frame (e.g. 14; Figure 1) using a bracket 12, that holds the applicator in place. Alternatively, the applicator, comprising the housing and insert, may be attached to a frame. The applicator is positioned on the frame so that the solid stick composition is in contact with a metal surface that is in sliding, slipping, rolling and sliding, or rolling and slipping contact with another metal surface. The biasing member pushes the solid stick out of the housing and against the metal surface thereby applying the composition of the solid stick to the metal surface. The resilient bent portion of the first, the second, or both the first and the second flanges press against the solid stick within the insert or housing thereby reducing vibration of the stick that is generated when the stick is rubbing against the metal surface. As a result of using an insert comprising one, two, or more resilient bent portions of the first, the second, or both the first and the second flanges, there is reduced breakage of the solid stick, reduced wear, stress or breakage of the insert and housing, or both reduced breakage of the solid stick and reduced wear, stress or breakage of the insert and housing, thereby increasing the field life of the solid stick, the insert, the housing or a combination thereof.

[0067] As used herein, the terms “comprising”, “having”, “including”, and “containing”, and grammatical variations thereof, are inclusive or open-ended and do not exclude additional, un recited elements and/or method steps. The term “consisting essentially of’ when used herein in connection with an apparatus, composition, use or method, denotes that additional elements, method steps or both additional elements and method steps may be present, but that these additions do not materially affect the manner in which the recited composition, method or use functions. The term “consisting of” when used herein in connection with an apparatus, composition, use or method, excludes the presence of additional elements and/or method steps.

[0068] Any element expressed in the singular form also encompasses its plural form. Any element expressed in the plural form also encompasses its singular form. The use of the word “a” or “an” when used herein in conjunction with the term “comprising” may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one”, and “one or more than one”. Directional terms such as “top”, “bottom”, “upwards”, “downwards”, “vertically”, and “laterally” are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article is to be positioned during use, or to be mounted in an assembly or relative to an environment.

[0069] As used herein, the term “about” when followed by a recited value means plus or minus 10% of the recited value.

EXAMPLES:

Lab Design for Testing Vibrations of Solid Stick Composition Applicators

[0070] A custom lab design apparatus for testing vibrations of solid stick composition applicators was assembled to measure self-excited vibrations in the solid stick composition and applicator assembly. During use these vibrations occur frequently, and typically comprise a non-linear character.

[0071] The lab design included a bracket for holding the applicator, an applicator comprising a housing and an insert, a solid stick composition placed within the insert, a shaker, a mock wheel connected to the shaker where the solid stick composition is placed against a side of the mock wheel, and accelerometers to measure vibrations in response to shaking by the shaker. The mock wheel, which was a solid mass, was connected to one end of a flexible rod, which had coupled flexural and torsional oscillatory modes. The accelerometers were placed on the mock wheel, the solid stick composition and opening of the housing. The shaker was an electrodynamic shaker which produced vertical vibration. [0072] Variables tested were frequency of the shaker, and amplitude (or power) of the shaker. The frequency and amplitude ranges when the insert designs were sensitive to excitation were determined. For example, excitation effects were observed at excitation voltages above 800 mV up to 1200 mV (the limit that was tested). The different insert designs were then tested within these ranges and the effects of excitation at 1000 mV are described as an example.

[0073] It was found that under excitation by a frequency sweep from 30 Hz to 40 Hz, the vertical oscillations of the mock wheel produced motion in many directions in the solid stick composition of the applicator, especially in the lateral direction. This lateral motion of the solid stick composition resulted in the solid stick hitting against the walls of the insert and housing.

[0074] In prior art applicators, the lateral motion of the solid stick composition is not resisted up to a certain amplitude, because of a pre-existing clearance in the lateral direction between the one or two flanges of the insert and the solid stick composition. This clearance may be desirable for functional reasons, for example, to permit loading of the solid stick into the insert, or to permit movement of the solid stick within the insert as a result of the biasing member pressing against the stick. Movement of the solid stick composition within the insert is also hindered by the presence of a wheel flange.

[0075] Modifications to the insert, as described herein, resulted in applicators with enhanced performance with respect to stability of the solid stick, insert and housing, without sacrificing the functionality of the solid stick, insert or housing.

[0076] Four different insert designs comprising one flange, each manufactured from the same material and having the same dimensions, were tested, using the apparatus described above, and vibration in three directions, vertical, lateral and axial, as a function of vertical shaking frequency was measured. The results are shown in Figure 9. The top row shows data from the accelerometers positioned on the solid stick, and the bottom row shows data from the accelerometers on the housing. The four inserts tested were:

“Standard or Regular insert” (·): a prior art insert with no bent flange (see Figure 4A);

“Standard bend, or Regular curved, insert” ( _■ ): a prior art insert with a first flange defining one first slot through a thickness of the first flange and extending from an end of the first flange opposite the end plate and extending 40% to 65% along a length of the first flange (as shown in Figure 4B);

“Short bend” insert (¨): an insert with a first flange defining one first slot through a thickness of the first flange and extending from an end of the first flange opposite the end plate and 1% to 35% along a length of the first flange (as shown in Figure 4D); and

“Top bend” insert (*): an insert with a first flange defining one first slot through a thickness of the first flange and extending from an edge of the first flange opposite the elongate base and 25% to 75% along a width of the first flange, the slot being 15% to 65% along a length of the first flange (as shown in Figure 4C).

[0077] As shown in Figure 9, all three inserts comprising a bent flange (lower lines in each panel of Figure 9), exhibited lower vibrations when measured at the solid stick and housing, than the prior art insert design (“Standard Insert” - ·; upper line in each panel of Figure 9). While the three insert designs comprising bent flanges displayed reduced vibrations compared with the Standard or Regular insert, the modified insert designs according to the invention described herein (the Top bend,*, and Short bend inserts, ¨, bottom two lines in each panel of Figure 9) experienced lower vibrations across a range of frequencies when compared to the prior art Standard bend (Regular) insert (■; middle line in each panel of Figure 9; comprising a slot length of greater than 40% the length of the flange).

[0078] These results demonstrate that inserts comprising one bent flange as described herein that comprise a slot length of 1-35%, or any amount therebetween, the length of the flange, or 25-75%, or any amount therebetween, the width of the flange, are useful in reducing vibration of a solid stick when the solid stick is placed within an insert, and in reducing vibration of a housing when loaded with the modified insert comprising the solid stick. Furthermore, inserts comprising more than one bent flange, for example two bent flanges, as described herein are also useful in reducing vibration of a solid stick when the solid stick is placed within an insert, and in reducing vibration of a housing when loaded with the modified insert comprising the solid stick.

Full Wheel Design for Testing Vibrations of Solid Stick Composition Applicators

[0079] A custom full wheel apparatus for testing vibrations of solid stick composition applicators was made. The full wheel design included a freight wheel inside a wheel guide, a proximity sensor, an applicator comprising a housing and an insert, a solid stick composition placed within the insert and accelerometers placed on the housing of the applicator and on the solid stick composition. A set-up for the full wheel design, with the solid stick composition in contact with the wheel, is shown in Figure 10.

[0080] Variables influencing vibration were tested. These variables included speed and direction of the wheel, temperature of the wheel, applicator angle and vertical position, wet or dry conditions on the wheel, and external bracket excitation power (to mimic a train bogie). An analysis was conducted to determine which of these variables resulted in the most vibrational sensitivity in the applicator. Various inserts as described herein were tested using only the significantly sensitive variables.

[0081] The inserts tested were the same as those tested using the lab design apparatus (discussed above comprising one first flange) and the results are shown in Figure 11.

[0082] Figure 11 shows a series of graphs of vibration as a function of rotation speed of the wheel as measured for the solid stick composition (referred to as the “Stick”; upper row in Figure 11) and the housing of the applicator (referred to as the “Tube”; lower row of Figure 11), in the vertical, lateral and axial directions.

[0083] All three inserts comprising a bent flange experienced less vibration than the insert without a bent flange (Standard, or Regular, Insert “·”; top line in each panel of Figure 11). Using the full wheel testing apparatus, the Top bend insert (“*”, bottom line in each of the panels of Figure 11) experienced the least vibration. The Short bend insert (V) experienced less vibration than the Standard bend, or “Regular curved” insert (“·”) when measured at the solid stick in the axial and vertical directions, and similar vibration in the lateral direction (middle lines on each panel in the top row of Figure 11). At higher speed (600 rpm) the solid stick within the modified insert designs according to the invention described herein comprising a slot length of 1-35%, or any amount therebetween, the length of the flange, or 25-75%, or any amount therebetween, the width of the flange (the Top bend,”*”, and Short bend inserts,”·»”, bottom two lines in the top panel of Figure 11) exhibited lower vibrations when compared to the prior art Standard bend (Regular) insert (“·”; Figure 11 ; comprising a slot length of greater than 40% the length of the flange). When measured at the applicator (“Tube”, lower row, Figure 11), the overall vibration measurements were less than those observed when measured at the stick, and the top bend insert (“*”, bottom line in each of the bottom panels of Figure 11) again exhibited the least vibration.

Static Stiffness Analysis

[0084] In order to confirm the results observed above, the stiffness of the single flange inserts described above was modeled in ABAQUS, based on a point load application of force on an edge of the first flange. The normalized results of this static stiffness analysis are shown in Table 1. Both the Short bend insert and the Top bend insert were stiffer than the Standard bend or Regular curved insert. Thus, in various embodiments disclosed herein, the flanges of the inserts are at least twice as stiff compared to flanges of prior art inserts having a slot extending 40% to 65% along a length of the flange. This increased stiffness of the resilient bent portion of the flange reduces the vibrations transferred to other components of the system, for example, the solid stick composition, applicator and applicator hardware. For example, the inserts described herein may have flanges that are at least 2 times, 2.5 times or 3 times more stiff compared to flanges of prior art inserts having a slot extending 40% to 65% along a length of the flange.

[0085] Table 1. Results of Static Stiffness Analysis

[0086] Thus, it was shown that solid stick composition applicators comprising an insert having one flange with resilient bent portions as described herein that exert a force against the solid stick composition can reduce or dampen the vibrations of the solid stick composition, the applicator and its associated hardware. Furthermore, inserts comprising more than one bent flange, for example two bent flanges, as described herein are also useful in reducing vibration of a solid stick when the solid stick is placed within an insert, and in reducing vibration of a housing when loaded with the modified insert comprising the solid stick.

[0087] It is contemplated that any part of any aspect or embodiment discussed in this specification can be implemented or combined with any part of any other aspect or embodiment discussed in this specification. While particular embodiments have been described in the foregoing, it is to be understood that other embodiments are possible and are intended to be included herein. It will be clear to any person skilled in the art that modification of and adjustment to the foregoing embodiments, not shown, is possible.