This invention relates to replaceable heads for end posts and to methods of repairing end posts for use between axially adjacent rails. More particularly, but not exclusively the invention relates to repairs of end posts for example between axially adjacent rails in railway systems. An embodiment of the invention relates to methods for repairing end posts in glued joints, insulated block joints or any other rail joint where the end post cannot be freed or is difficult to free. More particularly, but not exclusively, the invention relates to glued electricity insulating block joints. The invention also relates to end posts and to methods of manufacturing end posts.

Electrically insulating end posts are in use extensively throughout the rail network and electrically separate one track section from another. Each railway line is part of an electrical circuit for signalling purposes, the circuit being completed by the wheels of either a train or carriage. The completion of this circuit gives notification to a signal box that a train is in the sector.

It is imperative that the end posts are in place to prevent any wrong information being given to the signalling section. However, the heads of the end posts become worn away by continuous use as the wheels of the trains roll over them. Once the head starts to wear away, the rail begins to deform. When this happens, it is important that the end post is repaired quickly, otherwise the rail will be deformed to an extent that a lip of metal will span the gap between the two rails, thereby leading to the completion of the electrical circuit and the transmission of incorrect information to the signalling section. The result is then a slowing down of the rail system.

In order to repair such a damaged joint, it is necessary to stop rail traffic to effect either a total replacement of the rail joint, or a repair. This is a time consuming and expensive process.

According to one aspect of this invention there is provided a method of repairing an end post having a first portion arranged between adjacent ends of

two rails, wherein a second portion of the end post is damaged or worn, the method comprising providing a replacement element to replace the second portion and securing the replacement element to the first portion of the end post in situ.

The aforesaid second portion may be at least a part of the head portion of the end post. The method may comprise forming a bore in the first portion for insertion of the insertion member. Alternatively, the first portion may already define a bore into which the insertion member can be inserted. In one embodiment, the bore may extend wholly through the first portion. In another embodiment, the bore may be a blind bore.

The step of forming the bore may comprise providing a guide member. The guide member may be arranged over the main portion and may define a guide aperture. A bore forming member may be provided, and the guide aperture in the guide member may guide the bore forming member onto the first portion.

The guide member may engage at least one of the rails. Securing means may be provided to secure the guide member to the, or each, rail. The securing means may comprise one or more engagement screws for engaging at least one of the rails.

The bore forming member may comprise a drill member insertable through the aperture in the guide member to engage the first portion and form the bore.

A sealant may be provided on the replacement element to prevent moisture being trapped on the interface and forming an electrical circuit. The sealant may be a silicone and/or polyurethane sealant, or any other material capable of forming a seal.

The method may comprise trimming the replacement head member to conform to the size and shape of the rails, conveniently when the head member is secured to the first portion. The first portion may comprise a main portion.

Before securing the replacement element to the first portion, the upper surface of the damaged first portion may be cleared to ensure that generally plainer surface for the engagement of the replacement element therewith.

According to another aspect of this invention, there is provided a guide member for guiding a drill during a method as described above, the guide member comprising a guide portion and opposed downwardly extending side members for engaging at opposite sides of a rail.

Preferably, the guide portion defines a guide aperture for guiding a drill therethrough.

The guide member may be engageable with at least one of the rails. Securing means may be provided to secure the guide member to the/or each rail. The securing means may comprise one or more engagement screws for engaging at least one of the rails.

According to another aspect of this invention there is provided a replacement element for use in the method described above, the replacement element comprising a replacement member to replace the portion worn away and an insertion member extending therefrom.

Preferably, the insertion member can be inserted into a bore into the first portion of an end post.

Preferably, the replacement member comprises a head member to replace the head portion worn away and may also include an insertion member for insertion into the first portion.

According to a further aspect of this invention there is provided an end post comprising first and second portions an insertion member provided on the second portion, wherein the insertion member is insertable into the first portion, and the first portion being configured to enable a passage to be defined therein to receive the insertion member, the passage being enclosed within the first portion.

In one embodiment, the first portion defines the aforesaid passage. Preferably, the passage is open at one end, more preferably at both ends.

In the preferred embodiment, the end post has opposite front and rear faces for engagement with axially adjacent rails, the front and rear faces comprising wall members extending over the passage. Thus, the wall members prevent movement of the insertion member out of the passage through the front and rear faces. The end post may comprise a relatively narrow waist portion extending between relatively wide head and lower members.

The first portion preferably comprises the lower member and may also include the waist portion. In one embodiment, the first portion includes some of the head member.

The second portion preferably comprises at least some of the head member. The insertion member may extend from the second portion.

The insertion member may have a free end region, and the insertion member may be of a sufficient length that the free end region thereof can protrude from the second portion when the head member is arranged on the second portion.

Fastening means may be provided on the free end region to fasten the insertion member to the second portion. The fastening means may comprise a threaded fastener which may be threadably secured to the free end region of the insertion member. The free end region of the insertion member may be provided with threads to co-operate with the threads on the threaded fastener. The threaded fastener may be a nut. A thread locking adhesive may be provided on the threaded free end region to lock the threaded fastener to the threaded free end region.

According to another aspect of this invention, there is provided a method of manufacturing an end post, the method comprising providing first and second portions, wherein the second portion has an insertion member for insertion into

the first portion, and the first portion is configured to enable a passage to be formed therein to receive the insertion member, the passage being enclosed with the first portion.

Preferably, the method involves forming the passage in the first portion to receive the insertion member. Preferably, the end post has front and rear faces for engagement with the ends of the adjacent rails. The front and rear faces preferably comprise wall members extending over the passage to prevent movement of the insertion member out of the passage through the front and rear faces.

Preferably, the method involves forming the passage wholly through the first portion and may further include inserting the insertion member into the passage at one end so that a free end region of the insertion member extends out of the passage at the opposite end.

The method may further include providing fastening means on the free end region. The fastening means may comprise a threaded fastener, such as a nut. The free end region of the insertion member may be provided with corresponding threads to co-operate with the threads on the threaded fastener. The method may further involve providing a thread locking adhesive on the threads to lock the threaded fastener to the threaded free end region.

The preferred embodiment of the invention has the advantage that the head . of a glued end post can be repaired with a replacement head portion without the need to remove the end post from between the rails.

According to a further aspect of this invention there is provided an end post comprising a main body having a laterally extending end portion, and the end post further including a securing member extending from the main body, the securing member being co-operable with a corresponding securing element to secure the end post to a rail.

Preferably, the main body comprises a narrow portion extending from the end portion. The securing member may extend from the narrow portion.

Preferably, the end portion constitutes an upper or head portion of the end post, The corresponding securing element may be co-operable with the securing element such that the securing element engages the underside of the rail.

Preferably the securing element engages the underside of adjacent longitudinally extending rails.

Preferably, the end post is substantially devoid of a lower outwardly extending end portion. In one embodiment, the relatively narrow portion is of sufficient length to extend in use from the head portion to the underside of the rail.

Preferably, the main body consists only of the head portion and the narrow portion. The securing member may extend from a lower end of the narrow portion.

The securing member may comprise a shaft, which may be threaded or may have a threaded lower end region.

The corresponding securing element may comprise a threaded member capable of being threadably received on the shaft. The threaded member may comprise a nut, suitably a wing nut. The corresponding securing element may further include a washer to spread the load from the threaded member onto the underside of the rail.

Alternatively, the threaded member may comprise a nut having outwardly extending engagement members. The engaging members may be elongate. The engaging members may be rectilinear.

The threaded member may include a main part defining a threaded aperture. The engaging members may extend outwardly from the main part opposite each other.

The engagement members may extend from an end region of the main part and may extend at an acute angle to the main part.

The aperture in the main body may have a wider portion extending to a narrower portion. The narrower portion may open at the first mentioned end region.

Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:-

Fig. 1 is a sectional view of a damaged end post mounted in situ on a rail;

Fig. 2 is a sectional side view of the end post shown in Fig. 1 after a guide has been put in place;

Fig. 3 shows a sectional view of the end post shown in Fig. 2 during a further step of the method;

Fig. 4 shows a sectional view of an end post shown in Fig. 3 after a further step of the method has been completed;

Fig. 5 shows a replacement element;

Fig. 6 shows the end post in Fig. 4 with the replacement elements arranged in place;

Fig 7 shows one embodiment of an end post;

Fig 8 shows a first portion of the end post shown in Fig 7;

Fig 8A shows a view along the lines VIII - VIIl of the head shown in Fig 8;

Fig 9 shows a second portion of the end post shown in Fig 7;

Fig 9A shows a view along the lines IX - IX in Fig 9;

Fig 10 shows another embodiment of an end post;

Fig 11 shows a side view of a nut for use with the embodiment shown in

Fig 10; and

Fig 12 is a top view of the nut shown in Fig 11.

Referring to Fig. 1 there is shown a sectional view of a damaged end post

10 at one end of rail 11 , at a junction between adjacent rails. The end post 10 generally has a profile which is the same size and shape as the profile of the rail 11. Only a portion of the head 11A of the rail 11 is shown. The portion 11A is visible in Fig. 1 , because the end post 10 has been damaged to expose the portion 11 A. The rail 11 is attached to the axially adjacent rail by fish plates 12A, 12B mounted on opposite sides of the two adjacent rails as would be understood by someone skilled in the art.

The end post 10 comprises a head member 14, a foot member 16 and a connecting or waist member 18. As can be seen, the head member 14 has been damaged such that the upper part of the head member 14 has been worn away, leaving a damaged lower part 14A. The foot member 16, the waist member 18 and the lower part 14A of the head member constitute a first portion, in the form of a main portion 19 of the end post 10.

As can be seen, the damaged lower part 14A of the head member 14 has a rough upper edge 20.

In order to repair the head member 14 and replace the part which has been worn away, the region 20A of the damaged head member 14 is first cleared and worn down until the edge 20 is generally straight, as shown in Fig. 3.

This can be carried out as follows. Any "lipping" of the rail is first removed by conventional techniques known in the art. A sufficient amount of the damaged

head 16 is removed to allow a drill guide 22 to be fitted over the rail ends, see Fig 2.

The drill guide 22 comprises a central member 24, part of which extends between the adjacent ends of the two rails and a pair of opposite side members 26, 28 the side members 26, 28 engage the sides of the two rails. The guide member 22 is secured in place by suitable securing means, for example two screws 30 which are screwed through a suitable aperture in the side members 26, 28 to engage the rails.

The drill guide 22 defines a lateral first through aperture 31 , and a vertical second through aperture 32. A drill bit 31 A mounted on a suitable drill (not shown) is inserted into the first through aperture 31 and is drilled through the region 2OA until the drill bit 31 A has passed completely through the region 2OA and has come out the other side.

The drill guide 22 can then be removed and both sides of the region 2OA can be cut away from the rails using, for example, a hacksaw. The hacksaw cuts are made as close to the faces of the rails as possible. The debris can then be removed. The upper surface 2OA of the remaining end post and the end faces of the rails can then be cleaned using a file. If appropriate, pressurised air can be used to remove loose debris.

The above described stage removes the damaged region of the head member 14 of the end post to a depth of, for example, 20mm. This depth can be greater than 20mm, if necessary.

Referring to Fig 3, the drill guide 22 is replaced over the remaining portion of the end post 10.

A drill bit 33, mounted on a suitable drill (not shown), can be inserted through the aperture 32. The drill guide 22 should be arranged such that the aperture 32 in the central member 24 is centrally arranged over the end post 10.

The drill bit 31 A and 33 may be a tungsten carbide tipped drill bit, or any other suitable device. The drill bit 33 is inserted through the second through aperture 32 in the central member 24 to engage the upper edge 20 of the lower part 14A of the head member 14. The drill bit 33 is operated to form a bore or passage 34 through the waist portion 18 and foot member 16 of the end post 10. This is shown in Fig. 4. As can be seen from Fig. 4, the passage 34 follows the central axis of the end post 10. However, this is not essential and may extend off the central axis, for example shown by the broken lines 34A in Fig. 4.

After the passage 34 or 34A has been formed, a second portion of the end post 10, in the form of a replacement element 36 is provided as shown in Fig. 5. The replacement element shown in Fig. 5 comprises a head member 38 and an insertion member 40. The head member 38 comprises a lower edge 42 along which a sealant 44 can be provided before the replacement element is used. The sealant 44 may be a silicone and/or polyurethane sealant, or any other suitable material capable of forming a seal.

Referring to Fig 5, the insertion member 40 is in the form of an elongate rod having a threaded lower end region 46.

The replacement element 36 is arranged such that the insertion member 40 is received through the passage 34 such that the lower end region 46 protrudes from the lower edge 48 of the end post 10. A suitable fastening member for example a nut 50 is then screwed onto the lower end region 46 of the insertion member 40. If desired, suitable thread locking adhesive can be applied to the threads on the lower end region 46 of the insertion member 40. In this way, the replacement element 36 is held in place such that the lower edge engages the upper edge 20 of the damaged head 14 of the end post 10.

The head member 38 of replacement element 36 is of a generally rectangular configuration as shown in Figs. 5 and 6 and, after its fitting onto the end post 10, the head member 38 is trimmed such that such that it conforms to the edge of the rail 11 , as shown by the broken lines 52 in Fig. 6. Alternatively,

the head member 38 of the replacement element 36 could be preformed to the desired shape of the head.

In addition to a method of repairing an end post, there is also provided an end post and a method of manufacturing the end post, as shown in Figs 7, 8 and 9.

As can be seen from Fig 7, the end post comprises a head member 102, a foot member 104 and a narrow waist member 106.

The end post 100 is manufactured in two separate parts, namely a first portion 108 as shown in Fig 8, and a second portion 109, as shown in Fig 9. The first portion 108 comprises the foot member 104, the waist member 106 and a lower region 110 of the head member 102.

The second portion 109 comprises an upper region 112 of the head member 102 and an insertion member 114 extending from the upper region 112.

As can be seen from Fig 9A, the insertion member 114 has dimensions such that its profile as shown in Fig 9A lies wholly within the profile of the upper region 112 from which the insertion member 114 extends.

A bore or passage 116 is formed lengthwise all the way through the first portion 108, for example by drilling, to receive the insertion member 114. The insertion member 114 is longer than the passage 116 and a free end region 118 of the insertion member 114 extends out of the passage as shown. Fig 8A shows a view along the lines VIII - VIII of the head member shown in Fig 8, and as can be seen the passage 116 is enclosed with the body of the second portion 108 except at the upper and lower surfaces 120, 122 of the second portion 108.

The second portion 108 has front and rear faces 124, 126 which engage the respective ends of the rails. The front and rear faces 124, 126 provide respective front and rear wall members 124A, 126A, which extend over the passage 116. This feature provides an advantage of preventing the insertion

member 114 moving out of the passage 116 through front and rear faces 124, 126.

The free end region 118 of the insertion member 114 is threaded and threadably receives thereon a nut 128 to secure the insertion member 114 and, hence, the second portion 109 to the first portion 108.

The passage 116 can be formed either during the process of manufacture of the first part 108 or after the first part has been installed in a rail system as described below.

The first part either with or without the passage 116 is arranged between two axially adjacent rails, and secured in place by suitable resin as would be understood by those skilled in the art. The adjacent rails are secured to each other by fish plates as would be understood by those skilled in the art.

If the passage 116 has not already been formed through the first part 108, for example during manufacture, the passage 116 can now be formed using the same technique as described above with reference to Fig 3.

The second part 109 is then provided and the insertion member 114 inserted into the passage 116. If desired, a sealant 130 can be provided along the lower surface 132 of the upper region 1 12 of the head member 102 to prevent water entering the interface between the upper and lower regions 112, 110 of the head member 102.

The free end region 118 of the insertion member 114 extends from the lower member 104 and is secured thereto by the nut 128. Thread locking adhesive can be applied to lock the nut 128 to the threaded lower end region 1 18.

There is thus described a simple, efficient and effective method of repairing a rail end post without the need to replace the whole end post, or take the joint apart. There is also described a new rail end post and a method of

manufacturing the rail end post. One advantage of the above described embodiments of the invention is that it increases the working life of an insulated joint and can be used either during manufacture or for the repair/modification of joints already in use.

The above described embodiments shown in the drawings provide a simple, fast and effective repair to the head of a glued end post. If a replaceable head is part of the initial manufacture, as shown in Figs 7 to 9A, the repair will simply involve undoing the nut 128, removing the damaged second portion 109 and replacing it with an undamaged one. This has serious cost saving implications to the repair of glued end joints.

If the glued end joint does not have a replaceable head, the repair method is still easier and quicker than known repair methods, as described above.

Fig 10 shows a further embodiment, in the form of an end post 210 comprising a main body 212, and a securing member 214 extending from the lower end of the main body 212.

The main body 212 comprises an upper laterally outwardly extending head portion 216 and a narrow portion 218 extending from the head portion 216. The securing member 214 extends from the lower end 220 of the narrow portion 218.

The end post 210 is intended to be fitted between the ends of two longitudinally adjacent rail sections. As would be appreciated by the person skilled in the art the rail has an upper flange, and the head portion 216 has a configuration that corresponds in size and shape to the profile of the upper flange of the rail.

The rail also has a lower flange 250, as shown in broken lines in Fig 10. A web portion of the rail extends between the upper flange and the lower flange 250. The narrow portion 218 of the end post 210 has a configuration that corresponds in size and shape to the profile of the web portion of the rail.

The embodiment shown is substantially devoid of any lower laterally outwardly extending lower portion that corresponds in size and shape to the profile of the lower flange 250 of the rail.

In order to secure the end post 210 to the rail, a corresponding securing element 224 is provided to co-operatively engage the securing member 214 and engage undersides of the two longitudinally adjacent rails thereby holding the end post between the adjacent ends of the two rails.

In the embodiment shown, the securing member 214 extending from the lower end 220 of the narrow portion 218 comprises a threaded shaft 222. The corresponding securing element 224 comprises a threaded member in the form of a wing nut 226, although it will be appreciated that the threaded member could be any other suitable threaded member, such as a hexagonal nut. A washer 228 can be provided to spread the load from the wing nut and to engage the under side of both rails.

The end post 210 is mounted in position by inserting the main body 212 with the narrow portion downwardly into the gap between the ends of the two longitudinally adjacent rails. The main body is inserted downwardly from the top of the rail. The narrow portion 218 passes between the fishplates securing the two adjacent rails together. The threaded shaft 222 protrudes from the underside of the rails. The washer 228 is passed over the shaft 222. The wing nut is threadably mounted on the shaft 222 and screwed onto the shaft 222 thereby pulling the main body 212 downwardly until the head portion 216 engages the fishplates. The wing nut 226 is then tightened such that the washer engages the two adjacent rails thereby securing the end post 210 in position.

In Figs 11 and 12 there is shown an alternative securing element to the securing element 224 shown in Fig 10. The securing element in Figs 11 and 12 is generally designated 250. It is in the. form of a nut and comprises a main part

252 which is of a cuboid configuration and defines an aperture or through bore

254. The through bore 254 has a wide portion 256 extending to a narrow portion

258. It will, of course be appreciated that the main part 252 can be of any other suitable configuration, such as cylindrical.

The main part 252 has a first end region 260 and an opposite second end region 262, defining a plane.

A pair of elongate engagement members 264,266 extend outwardly from the main part 252 at the first end region 260. The elongate engagement members 264, 266 are arranged opposite each other and each has a first end 268 at which it is attached to the main part 252 and an opposite second end 270.

As can be seen each of the second ends 270 has a planar end face 272 which is generally coplanar with the plane defined by the second end region 262 of the main part 252.

The elongate engagement members 264, 266 extend from the main part 252 at an acute angle α thereto, which is in the region of 30 ^s .

In use, the securing element 250 is screwed onto the threaded securing member 214 of the end post 210. The securing element 250 is arranged such that the wider portion 256 of the aperture at the second end 262 is received first over the threaded securing member 214. Thus, when the securing element 250 is tightened onto the securing member 214, the end faces 272 of the engagement members 264, 266 engage the underside of the adjacent rails.

Various modifications can be made without departing from the scope of the invention. For example, a different fastening means maybe used to secure the end of the insertion member 40 to the main portion 19 of the end post 10. Alternatively, the end post may be configured such that the passages or bores 34, 116 do not extend wholly through the main portion and are blind bores. Thus, the insertion member 40 does not protrude from the lower edge of the end post. In such situations, it would not be necessary to drill the bore 34, 116 such that it extends to the lower edge, and in order to secure the replacement element 36 to

the main portion 19 to the end post 10, a suitable adhesive, such as a cyanoacrylate adhesive could be used.

In a further modification, it may be necessary to replace the head of an end post which has, in its turn, already been repaired. In such a situation, it would not be necessary to drill the bore 34, since one would already have been formed. In order to remove the previously installed replacement element 36, the head member 38 is simply removed, by undoing the nut and pulling out the head member 38, thereby pulling the insertion member 40 with it. A new replacement element 36 can then be installed as described above.

In a further modification, the replacement element could be a lower part of the end post such that the insertion member is inserted upwardly from below into a bore or passage in an upper part of the end post.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.