[0001] The present invention claims priority under 35 U.S.C. 1 19 to U.S. Prov. Pat. App. No. 61/932,062, titled "Support Surface Deck Grating Apparatus for Auto-Rack Railcars, Systems and Methods of Using the Same," filed January 27, 2014, which is expressly incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present invention relates to a support surface grating apparatus for use in auto-rack railcars. Specifically, the present invention provides a grating apparatus having a plurality of laterally-disposed bars and a plurality of longitudinally-disposed bars interweaved in a grid pattern. Systems and methods of using the same are further provided.

BACKGROUND

[0003] Auto-rack railcars are used to transport automobiles and other vehicles over long distances utilizing the railroad system, allowing hundreds of vehicles to be transported from one location to another on a single train. Specifically, an auto-rack railroad car generally is compartmentalized, having at least one level, but in many cases two or three levels, where automobiles or other vehicles may be parked for transport of the same. Typically, to protect the vehicles transported, auto-rack railroad cars typically have mesh-type or perforated side panels and a roof thereover. Doors for loading and unloading of vehicles are typically found on opposite ends thereof. FIG. 1 illustrates a pair of auto-rack railcars having three levels for transporting vehicles therein.

[0004] Moreover, the levels on which the vehicles sit are typically support decks containing a means for securing the vehicles to the decks. An example of a deck for this purpose is a metal floor grating system, and the vehicles' wheels typically rest on the grating. The grating typically consists of a plurality of laterally-disposed and longitudinally-disposed metal bars that are spot welded at the bars' intersections. Chock apparatuses may then be utilized to hold the wheels of the vehicles in place on the grating. The chock apparatuses may typically be secured to either or both of the laterally-disposed and longitudinally-disposed metal bars by one or more teeth or other engaging means extending from the chock apparatuses. Thus, the chock apparatuses may be rigidly secured on the grating and engaging tires of the vehicles to prevent unwanted movement of the vehicles during transport of the same.

[0005] The grating, as noted above, is typically made of a plurality of a laterally-disposed metal bars and a plurality of longitudinally-disposed metal bars forming a grid pattern. The metal bars are typically of a thickness and strength necessary to hold vehicles therein when disposed in a grid pattern to form the grating. Indeed, in one prior art embodiment, the longitudinally-disposed metal bars are straight, and are disposed beneath the laterally-disposed metal bars and form a support surface to hold vehicles and wheel chocks, as illustrated in FIG. 2. In another prior art embodiment, the longitudinally-disposed metal bars form a wave pattern having a plurality of repeating peaks and troughs, with a plurality of straight laterally-disposed metal bars sitting in the troughs of the longitudinally-disposed metal bars, as illustrated in FIG. 3. In either embodiment, the longitudinally-disposed metal bars must be welded to the laterally-disposed metal bars at their intersections to form the rigid grid pattern. Without the welding of the metal bars together, the grid pattern would not be sustained, and the metal bars would detach one from the other. Certainly, without welds, the metal bars would not stay together to be utilized as a support surface for vehicles when utilized in an auto-rack railcar.

[0006] Welding, however, introduces many points of weakness in the grating that may fail when bearing a load, such as a plurality of vehicles during transport thereof. Welding is a fabrication or sculptural process that joins materials, such as metals, by causing coalescence. Specifically, in mesh welding, this is often done by melting the workpieces to form a pool of molten material (the weld pool) that cools to become a joint. In the present case, the intersection of the metal bars is subject to a brief period of melting where the metal bars meet, cooling to form the joint where the two metal bars intersect.

[0007] Many distinct factors influence the strength of welds and the material around them, including the welding method, the amount and concentration of energy input, the weldability of the base material, and flux material, the design of the joint, and the interactions between all these factors. Oftentimes, welds that hold the metal bars together on an auto-rack railcar are subject to extreme temperature fluctuations and elements as vehicles are transported through extreme climates and weather conditions, such as between sub-zero temperatures and extreme heat. Expansion and contraction of the metal bars as well as the joints may cause failure of the welds. In addition, during transport and use as a support surface for vehicles, the grating may be subject to heavy loads that can also strain the joints, causing failure of the same over time.

[0008] Spot welding each intersection where the longitudinally-disposed metal bars meet the laterally-disposed metal bars may require significant amounts of time, manpower and material to accomplish, increasing the time required and costs of manufacturing the gratings.

[0009] A need, therefore exists for an improved support surface deck grating apparatus for supporting vehicles in an auto-rack railcar. Specifically, a need exists for an improved support surface deck grating apparatus for supporting vehicles in an auto-rack railcar that provides sufficient load-bearing qualities to support the vehicles for long periods of time without failure of the same. [0010] In addition, a need exists for an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar without subjecting the grating to potential failure points. Specifically, a need exists for an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar without relying on welds to hold the metal bars together. More specifically, a need exists for an improved support surface deck grating apparatus reducing or eliminating welding of the same.

[001 1] Moreover, a need exists for an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar that may readily withstand extreme temperature conditions, such as extreme cold and extreme heat, without causing failure of the same.

[0012] Still further, a need exists for an improved support surface deck grating apparatus that is simple, relatively inexpensive and quick to manufacture.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a support surface grating apparatus for use in auto-rack railcars. Specifically, the present invention provides a grating apparatus having a plurality of laterally-disposed rods and a plurality of longitudinally-disposed bars interweaved in a grid pattern. Systems and methods of using the same are further provided.

[0014] To this end, in an embodiment of the present invention, a support surface grating apparatus is provided. The grating apparatus comprises a plurality of longitudinally-disposed metal bars, each of said longitudinally-disposed metal bars having a repeating pattern of a straight portion and a trough; and a plurality of laterally-disposed metal bars, each of said laterally disposed metal bars having a second repeating pattern of a straight portion and a trough, wherein the trough of a longitudinally-disposed metal bar intersects a straight portion of a laterally-disposed metal bar, and a trough of a laterally-disposed metal bar intersects a straight portion of a longitudinally-disposed metal bar, forming an interwoven grid pattern.

[0015] It is, therefore, an advantage and objective of the present invention to provide an improved support surface deck grating apparatus for supporting vehicles in an auto-rack railcar.

[0016] Specifically, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus for supporting vehicles in an auto-rack railcar that provides sufficient load-bearing qualities to support the vehicles for long periods of time without failure of the same.

[0017] In addition, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar without subjecting the grating to potential failure points.

[0018] Specifically, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar without relying on welds to hold the metal bars together.

[0019] More specifically, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus reducing or eliminating welding of the same.

[0020] Moreover, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus for bearing vehicles in an auto-rack railcar that may readily withstand extreme temperature conditions, such as extreme cold and extreme heat, without causing failure of the same.

[0021] Still further, it is an advantage and objective of the present invention to provide an improved support surface deck grating apparatus that is simple, relatively inexpensive and quick to manufacture.

[0022] Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0024] FIG. 1 illustrates prior art auto-rack railcars.

[0025] FIG. 2 illustrates a prior art support surface grating having a plurality of straight longitudinal and lateral metal bars welded together to form a grid for holding vehicles and wheel chocks thereon.

[0026] FIG. 3 illustrates a prior art support surface grating having a plurality of longitudinal metal bars in a wave pattern and a plurality of straight lateral metal bars sitting in the troughs of the longitudinal bars and welded thereto.

[0027] FIG. 4 illustrates a perspective view of a support surface grating apparatus in an embodiment of the present invention.

[0028] FIG. 5 illustrates a close-up perspective view of support surface grating apparatus in an embodiment of the present invention.

[0029] FIG. 6 illustrates a close-up perspective view of a support surface grating apparatus hingedly attached to a support frame in an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0030] The present invention relates to a support surface grating apparatus for use in auto-rack railcars. Specifically, the present invention provides a grating apparatus having a plurality of laterally-disposed bars and a plurality of longitudinally-disposed bars interweaved in a grid pattern. Systems and methods of using the same are further provided.

[0031] Now referring to the figures, wherein like numerals refer to like parts, FIG. 4 illustrates a perspective view of a support surface grating apparatus 10 in an embodiment of the present invention. The grating apparatus 10 comprises a plurality of longitudinally-disposed metal bars and laterally-disposed metal bars that forms a grid pattern 12. The grating apparatus 10 may be utilized as a support surface on an auto-rack railcar to provide a support surface to bear a plurality of vehicles thereon, whether on a first deck, second deck or third deck thereof, and to allow one or more wheel chocks to engage the same. The grating apparatus is made of, preferably, steel and has sufficient strength to support a plurality of vehicles thereon for transport over large distances for significant periods of time. Moreover, the grating apparatus 10 may have a support frame 14 disposed on at least one side thereof for holding the same within an auto-rack railcar, as described in more detail below.

[0032] A close-up perspective view of the grid pattern 12 is illustrated in FIG. 5. The grid pattern 12 comprises a plurality of longitudinally-disposed metal bars 20 and a plurality of laterally-disposed metal bars 22 interwoven together to form the grid pattern 12. Each of the longitudinally-disposed metal bars 20 comprises a repeating pattern of a trough 24 and a straight portion 26. Likewise, each of the laterally-disposed metal bars 22 comprises a repeating pattern of a trough 28 and a straight portion 30. As illustrated in FIG. 5, the straight portions 26 of the longitudinally-disposed metal bars 20 intersect and sit in the troughs 28 of the laterally-disposed metal bars 22. Likewise, the straight portions 30 of the laterally-disposed metal bars 22 intersect and sit in the troughs 24 of the longitudinally-disposed metal bars 20.

[0033] Thus, each of the longitudinally-disposed metal bars 20 alternately weaves under and over the laterally-disposed metal bars 22. Likewise, each of the laterally-disposed metal bars 22 alternately weaves under and over the longitudinally-disposed metal bars 20. The interweaving of the longitudinally-disposed metal bars 20 and the laterally-disposed metal bars 22 provides a surprisingly strong and robust grid pattern 12 to hold and support a plurality of vehicles thereon.

[0034] An advantage of the grid pattern 12 disclosed herein is that the plurality of metal bars is truly meshed together, wherein each holds the others in place in concert together. Thus, welding the metal bars together in the same manner as necessary in prior art gratings is not necessary in the present invention as the metal bars will hold themselves together without significant movement of the same. Moreover, without welds, points of weakness are not introduced to the metal bars. However, it should be noted that spot welds may still be provided in various intersections of the longitudinal and lateral metal bars, disclosed herein, for added support, and/or to ensure that metal bars maintain their relative positions. However, the welds are not necessary to ensure that the metal grid pattern maintains its shape or grid pattern as is necessary in the prior art.

[0035] FIG. 6 illustrates a close-up perspective view of the grid pattern 12 engaging and hingedly attached to the support frame 14, in an embodiment of the present invention. Specifically, each of the laterally-disposed metal bars 22 may terminate under a final longitudinally-disposed metal bar 40, which may preferably be straight to engage the support frame 14, as disclosed herein. Specifically, the straight final longitudinal metal bar 40 may be disposed within a bracket 42 that may clamp over the final longitudinal metal bar 40 but allow the grating to rotate upwardly and act as a hinge for the same. The clamp 42 may have spaces 44 to allow free rotation of the grating upwardly, allowing clearance of the lateral metal bars 22 when rotated, as is known by those of ordinary skill in the art.

[0036] Thus, the grid pattern 12 may rotate upwardly allowing access beneath the grating apparatus 10 when necessary, or for installation and/or replacement of the same. The support frame 14 may be bolted and/or welded inside an auto-rack railcar and may effectively hold the grating apparatus 10 in place therein.

[0037] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to "the invention" are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.