Technical Field

This disclosure relates to containers for rail cars and, more particularly, to rail car containers for bulk material and to structures to reinforce the side wall of rail car containers to improve their load carrying capability.

Background

Rail car containers have long been used to transport bulk material such as ore, coal, grain and the like. Rail car containers particularly have a pair of side walls and end walls extending upwardly from a floor. The side walls of the container must provide sufficient support for a full load of bulk material such as ore or other bulk material to be positioned within the container without causing structure fatigue or hopper buckling. A wall construction with adequate strength, a relatively low weight and limited impact on the capacity of the container would be beneficial.

Summary of the Disclosure According to one embodiment, the disclosure provides a rail car container for bulk material having a side wall, a floor, and at least one support member arranged to support the side wall, the at least one support member having a base portion that engages the floor and a body portion that extends upwardly from the base portion along at least a portion of the side wall, wherein the base portion is wider than the body portion.

According to another embodiment, the disclosure provides a rail car container for bulk material having opposed side walls and opposed end walls, each side wall arranged to be connected at opposite ends to respective end walls and each end wall arranged to be connected at opposite ends to respective side walls, wherein the rail container also comprises at least one connecting member disposed between and connecting one of the side walls to one of the ends walls. The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. Brief Description of the Figures

Fig. 1 is a top perspective view of a rail car container according to one embodiment of the disclosure;

Fig. 2 is a perspective cutaway view of the rail car container of Figure 1 showing the side wall and reinforcing structure of the rail car container in detail; Fig. 3 is a side view of a rib of one form of reinforcing structure for the rail car container of Figure 1;

Fig. 4 is a top perspective view of a rail car container according to another embodiment of the disclosure;

Figure 5 is perspective yiew in detail of a connecting member of the rail car container of Figure 4 that connects between an end wall and a side wall;

Figure 6 is a top sectional view of the connecting member of Figure 5.

Detailed Description of Embodiments

In the following detailed description, reference is made to the accompanying drawings, which form a part thereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilised, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

The present disclosure is directed generally to containers for carrying bulk material. Rail car containers have long been used to transport bulk material such as ore, coal, grain and the like. Rail car containers particularly have a pair of side walls extending upwardly from a floor. The side walls of the container must provide sufficient support for a full load of bulk material such as coal or other material to be positioned within the container without causing structure fatigue or hopper buckling. One type of rail container, referred to as a gondola, may be arranged to be unloaded from the top of the container, by rotation of the container, typically by a rotary dumper. Another type of rail container, known as a hopper, has a discharge system in the floor of the container so as to discharge the material through the bottom of the container. Hopper cars include side walls that are curved or bowed to allow for ease of gravity discharge through discharged doors positioned in the floor of the container. The present disclosure is applicable to both types of containers, but has particular application for gondola cars that include side walls which may be flat or may have corrugations formed therein to increase strength and stiffness.

Disclosed in some embodiments is a rail car container for bulk material having a side wall, a floor, and at least one support member arranged to support the side wall, the at least one support member having a base portion that engages the floor and a body portion that extends upwardly from the base portion along at least a portion of the side wall. The base portion is wider than the body portion. Accordingly, in this embodiment, stress due to bulk material loading in the rail car container is transferred through the body portion to the base portion and into the floor of the container. This results in less stress concentration in the support member and the side wall and thus a lowering of the likelihood of the side wall failing.

In some embodiments, the container is a gondola having at least one grip portion for a rotary dumper to hold and rotate the container to discharge the bulk material therefrom. In one form, the grip portion may be located towards the top of the side wall. In another form, the grip portion may be disposed adjacent the floor of the container. In other embodiments, the container is a hopper having a discharge opening disposed in the floor of the container.

The at least one support member, in some embodiments, is operative to resist outward deformation of the side wall. In some forms, the at least one support member is operative to accommodate moment induced on the support member as the side walls are biased outwards by the internal pressure induced by the bulk material. These moments are accommodate about the base of the support member(s).

In some embodiments, the at least one support member comprises a plate member. In some forms, the base portion and body portion are portions of the plate member.

In some embodiments, the plate member is of unitary thickness.

Disclosed in some embodiments, the at least one support member extends into the container from the side wall. In certain embodiments, the base portion extends further into the container than the body portion.

In some embodiments, the at least one support member extends the height of the side wall.

Disclosed in some embodiments, the at least one support member also comprises a transition portion between the body portion and base portion, the transition portion increasing in width between the body portion and the base portion.

In some embodiments, the transition portion has an inward edge that is curved. Although it is to be appreciated that in other embodiments, the inward edge of the transition portion may be substantially linear or comprised of a plurality of linear portions. In some embodiments, the side wall of the rail car container may be substantially flat. But in other embodiments, the side wall has at least one ridge. In these embodiments, the at least one support member may have at least one recess formed therein to accommodate the at least one ridge of the side wall. In some forms, the recess is formed in the body portion of the at least one support member.

In some embodiments, the at least one support member may be formed separately from the side wall and attached thereto by for example welding. However, in other embodiments, the at least one support member may be integrally formed with the side wall. Disclosed in some embodiments, the floor comprises a central sill extending parallel with respect to the side wall and at least one cross-member extending between the side wall and the central sill.

In some embodiments, the cross-member is located underneath and supports the at least one support member. In some embodiments, the cross-member forms part of the floor of the container and the base portion of the at least one support member engages the cross- member.

Disclosed in some embodiments, the container comprises a plurality of the support members, disposed along the side wall. Also lisclosed in some embodiments, the container comprises opposed side walls and a plurality of the support members, respective ones of the support members being arranged to support each side wall.

Disclosed in some embodiments, the container comprises opposed end walls connected to opposed ends of the side wall, each side wall arranged to be connected at opposite ends to respective end walls and each end wall arranged to be connected at opposite ends to respective side walls, wherein the rail container also comprises at least one connecting member disposed between and connecting one of the side walls to one of the ends walls.

In some embodiments, the at least one connecting member provides strength and stiffness to the joint between the side wall and the end wall. In some

5 embodiments, the at least one connecting member eases manufacture of the rail car container by providing an intermediary member between the side wall and the end wall which they can be more readily connected to, by welding for example, than to each other.

In some embodiments, the connecting member comprises first and second i o engaging surfaces, the side wall engaging and connected to the first engaging surface and the end wall engaging and connected to the second engaging surface.

In some embodiments, the first and second engaging surfaces are disposed at 90° to each other.

In some embodiments, the first and second engaging surfaces extend from the

15 bottom to the top of the container.

Disclosed in some embodiments, the connecting member is hollow. In particular embodiments, the connecting member comprises a first panel and an opposed second panel, the first and second panels interconnecting the first and second engaging surfaces at respective sides thereof. In some embodiments, the first

20 panel is wider than the second panel.

Disclosed in some embodiments, the connecting member forms a chamfered corner of the container.

Disclosed in some embodiments, at least one of the side wall and the end wall connected by the connecting member has a surface feature formed therein. The 25 surface feature may be a ridge formed in the side wall arid/or end wall that extends the length of the side wall or end wall. Disclosed in some embodiments, the container comprises a connecting member connecting each of the side walls to each of the end walls respectively.

Referring to Figures, some illustrative embodiments of rail car containers, are reinforced by structures that are relatively low weight and include low material usage during manufacture. In particular Figure 1 shows a rail car container 10 according to one embodiment of the disclosure. The rail car container 10 comprises a first side wall 11 extending upwardly from a floor 12. In the illustrative form, the side wall may be made from a single sheet (such as sheet steel), or may be made from multiple sheets which may be fixed together by welding, mechanical fasteners or the like. The surface of the side wall may be generally smooth or may be profiled to include strengthening formations, such as corrugations or ridges as shown. The container 10 also comprises a second opposite side wall 13 which in the illustrated form is of the same design and opposite end walls 14, 15 that connect to each of the side walls 11, 13 at respective opposite ends. In the illustrated form, the end walls have the same profile as the wide walls.

The rail container as illustrated is as a gondola for tipping or rotating discharge of material. The floor 12 comprises a plurality of cross members 16 (sometimes referred to as "transoms" or "bolsters") extending laterally across the floor, and a central beam (or sill) 17 that extends longitudinally along the container 10 between the end walls and parallel to the side walls. The centre sill 17 forms a main structural component of the container and the cross members 16 extending between the side walls 11, 13 and are supported centrally on the centre sill 17. The cross members 15 provide some stiffening to the floor of the container and as such have a structural function. In operation, there is significant loading imposed on the side walls 11, 13 in particular and also to some extent on the end walls 14, 15 when the container is carrying bulk material. The material tends to force the walls outwards, thereby causing the walls to bulge or otherwise deform. To improve the performance of the walls to accommodate these loads, the container 10 includes at least one support member 20 which strengthens the side walls.

In the illustrated embodiment in Figures 1-4, the container has five such support members 20 disposed along and spaced from one another along each of the side walls 11, 13. It is to be appreciated that the number and spacing of the support members may vary from what is shown and will depend on the design loading on the side wall and the inherent strength of that wall. The support members need to be adequately fixed relative to their respective side wall so as to resist outward bowing of that side wall. This fixing may be by welding or may be by mechanical fixing such as by mechanical fasteners or the like. In another embodiment, the support members may be integrally formed with their respective side wall. In the illustrative form, the support members are disposed on the interior of the container. However, it is to be appreciated that they could be externally mounted.

Each support member 20 comprises a base portion 21 that engages one of the cross members 16 that forms the floor 12 of the container and a body portion 22 that extends upwardly from the base portion along the inner surface of its respective side wall, generally to the top of the side wall as shown in the illustrative embodiment. The base portion 21 is fixed to one of the cross members 16, typically by welding, but it may also be fastened using other means including mechanical fasteners. The base portion 21 is wider than the body portion 22 which means that when stress due to bulk material loading in the rail car container is transferred through the body portion to the base portion and into the floor of the container, the wider base portion 21 provides the support member 20 with sufficient strength and stiffness to

accommodate and transfer these stresses. In particular the support members are well designed to accommodate moments induced by the bulk material in the container which tend to try to rotate the support members outwardly relative to the floorl2. Each support member 20 also comprises a transition portion 23 that widens between the body portion 22 and the base portion 21, defining a curved inner edge 24. The transition portion 23 enables a smooth transition between the body portion 22 and the base portion 21 so that loading is more evenly distributed through the support member 20 and avoids undue stress concentration within parts of the member.

In the illustrated embodiment, each support member 20, including the base member 21, the body portion 22 and the transition portion 23, is in the form of a plate member of generally unitary thickness. Advantageously, the plate member provides the required strength and stiffness to support the side wall whilst being light weight, small, easy and cost effective to manufacture. However, in other embodiment, the support member could be in other forms that provide a base member that is wider than the body portion. For example, the support member could comprise a hollow or open section having a flared lower portion that comprises a base portion. The support member 20 also comprises recesses or cut-out portions 30 formed in an outer edge of the of the body portion 22. The recesses 30 are provided so that support member fits around and accommodates ridges 31 formed in the side wall 11 for strengthening of that side wall. It is to be understood that the support member 20 may have more or less recesses as shown in Figures 1-3. In other embodiments, the side wall may be flat and the support member has no recesses.

Referring now to Figures 4-6, the rail car container 10 is shown having connecting members 40 that are disposed between and connect each of the side walls 11, 13 to each of the end walls 14, 15. Although, in other embodiments, the rail car container may be provided with connecting members between some or only one of the side walls and one of the end walls. Each connecting member 40 comprises a generally trapezoidal shaped hollow member comprising first and second panels 41, 42 that are interconnected and spaced apart by side panels that provide engaging surfaces 43, 44 for one of the side walls and one of the end walls of the container 10 to engage and connect. The first panel 41 is wider than the second panel 42 which confers the trapezoidal shape on the connecting member 40. The shape of the connecting member 40 results in the container 10 having chamfered corners.

The engaging surfaces 43, 44 of each connecting member are disposed at generally 90" to each other. They present surfaces that are perpendicular to the longitudinal extent of the side and end walls respectively. Advantageously, the engaging surfaces 43, 44 provide a surface against which the side and end walls can abut respectively, whatever their shape. In this abutting configuration, the side and end walls can be readily joined by welding for example to the connecting member 40 and thus to each other (via the connecting member). In for example the illustrative embodiment of Figures 4-6, the side and end walls are provided with corrugations or ridges for strengthening and stiffening of the walls. With this shaping of the walls, they would ordinarily be very difficult to join at the corners of the container 10. However, by employing the connecting members 40, joining of the walls and thus construction of the container 10 is greatly eased. In addition, the connecting members 40 strengthen and stiffen the corners of the container 10.

In the claims which follow and in the preceding summary of the invention except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", that is, the features as above may be associated with further features in various embodiments of the invention.

Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure. For example the number and arrangement of the positioning and spacing of the ribs and supports may vary. Also in alternate forms, the ribs may be integrated into the side walls such as for example made integrally with the sheet by profiling of the sheets or by forming an integrated strengthening formation at a join between adjacent sheet panels forming the sheet.

Accordingly, the present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

From the foregoing, it will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope and spirit of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope and spirit being indicated by the following claims.