Aerator pad assembly for railway hopper cars

Information

  • Patent Grant
  • 6393997
  • Patent Number
    6,393,997
  • Date Filed
    Friday, March 17, 2000
    24 years ago
  • Date Issued
    Tuesday, May 28, 2002
    22 years ago
Abstract
An aerator pad assembly having an aeration pad with a number of cutouts forming a shaped perimeter, is provided. The aeration pad may include a number of supports providing which provide air flow paths between the aeration pad and an associated aeration panel. A gasket may be disposed about the shaped perimeter, the gasket having a plurality of protuberances with fastener openings included, and the protuberances preferably cooperate with the cutouts to form a generally continuous interface between them. In one embodiment, a notched opening within the gasket is provided at the generally continuous interface with the shaped perimeter at least partially occupying a portion of the notched opening. In a particular embodiment, the gasket may be molded onto the aeration pad. In another embodiment, an adhesive material may be provided to form the attachment. In yet another embodiment, stitches of thread may attach the gasket and the aeration pad. A sealant material may also be provided at the generally continuous interface to seal voids between the gasket and the pad.
Description




TECHNICAL FIELD OF THE INVENTION




The present invention relates generally to permeable membrane sealing apparatus and, more particularly, to an aerator pad assembly for railway hopper cars.




BACKGROUND OF THE INVENTION




Closed railway hopper cars with pneumatic systems for unloading are used for the transportation of powdered and granular products. For cars with positive pressure pneumatic systems, air may be supplied from an external source to pressurize the interior of the car body and simultaneously fluidize the dry, bulk product carried within the car to enable it to be conveyed in a fluidized state through product transfer conduits from the car to a collection facility. Air pressure within the hopper car during unloading is typically maintained at approximately fifteen pounds per square inch gauge pressure.




Aerator tub assemblies are often installed adjacent to a discharge opening for each hopper of a railway hopper car. The aerator tub assemblies sometimes incorporate aerator pad assemblies, including an aeration fabric and elastomeric gasket. Fasteners used to secure the aerator pad assembly generally require openings in the aerator pad assembly for proper installation. These openings often provide a path for air to escape from the pressurized hopper car. Consequently, the air pressure within the hopper car is often reduced and/or performance of the discharge system may be diminished.




SUMMARY OF THE INVENTION




In accordance with the teachings of the present invention, disadvantages and problems associated with fabrication, assembly and use of aerator pad assemblies have been substantially reduced or eliminated.




One embodiment of the present invention provides an aerator pad assembly having an aeration pad with a perimeter and a number of cutouts. The aeration pad may include a number of reinforcing supports providing additional strength and durability. A gasket may be disposed about the perimeter, the gasket having a plurality of protuberances with fastener openings disposed therethrough, and the protuberances preferably cooperate with the cutouts to form a continuous interface therebetween. In one embodiment, a notched opening within the gasket is provided at a generally continuous interface with the perimeter of the aerator pad at least partially occupying a portion of the notched opening.




In a particular embodiment, the gasket may be molded onto the aeration pad. In another embodiment, an adhesive material may be used to bond or attach the gasket with the aeration pad. In yet another embodiment, stitches of thread may attach the gasket and the aeration fabric pad. A sealant material may also be provided at the generally continuous interface to seal any voids between the gasket and the aeration pad.




Technical advantages of the present invention include an aerator pad assembly which reduces or eliminates leak paths between components of a railway hopper car. Another technical advantage includes increasing the strength of the aeration pad by placing the reinforcing supports thereon. Yet another technical advantage includes the increased length of the generally continuous interface provided by the perimeter of the aeration pad, which facilitates a stronger bond between the fabric or material used to form the aeration pad and the associated gasket. Still another technical advantage includes the various sizes and configurations of aerator pad assemblies available within the teachings of the present invention, allowing a wide variety of uses, for example pneumatic and filtration systems.











BRIEF DESCRIPTION OF THE DRAWINGS




For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following brief descriptions, taken in conjunction with the accompanying drawings and detailed description, wherein like reference numerals represent like parts, in which:





FIG. 1

is a schematic drawing, with portions broken away, showing a side view of a railway hopper car, incorporating aspects of the present invention;





FIG. 2

is a schematic drawing, with portions broken away, showing a partial end view of an aerator tub assembly suitable for use with the railway hopper car of

FIG. 1

;





FIG. 3

is a schematic drawing, with portions broken away, showing a cross-sectional top view of components of the railway hopper car of

FIG. 1

;





FIG. 4

is a schematic drawing, illustrating a cross-sectional view taken along line


4





4


of

FIG. 3

;





FIG. 5

is a schematic drawing illustrating a cross-sectional view taken along line


5





5


of

FIG. 3

;





FIG. 6

is a schematic drawing illustrating a cross-sectional view taken along line


6





6


of

FIG. 3

;





FIG. 7

is a schematic drawing, with portions broken away, showing an alternative configuration of an aerator panel, suitable for use within the teachings of the present invention;





FIG. 8

is a schematic drawing showing an aerator pad assembly incorporating aspects of the present invention;





FIG. 9

is a schematic drawing showing portions of the aerator pad assembly of

FIG. 8

;





FIG. 10

is a schematic drawing showing a cross-section taken along line


10





10


of

FIG. 9

;





FIG. 11

is a schematic drawing showing a different cross-section taken along line


11





11


of

FIG. 9

;





FIG. 12

is a schematic drawing showing an alternative embodiment of an aerator pad assembly incorporating teachings of the present invention; and





FIG. 13

is a schematic drawing showing another alternative embodiment of an aerator pad assembly incorporating teachings of the present invention.











DETAILED DESCRIPTION OF THE INVENTION




The preferred embodiments of the present invention and its advantages are best understood by referring now in more detail to

FIGS. 1-13

of the drawings, in which like numerals refer to like parts.




A railway hopper car generally indicated by the reference numeral


30


, is illustrated in

FIGS. 1 and 2

. Car


30


has a body


32


which is supported at each end on trucks


34


by bolsters


36


incorporated into end structures


38


of body


32


. Body


32


is generally symmetrical about transverse centerline TC of car


30


. A top sheet


40


and side sheets


42


, form a partially enclosed container. Side sheets


42


consist of curved plates butt-welded at junctures


43


. Similarly, top sheet


40


consists of curved plates butt-welded at junctures not explicitly shown. Car


30


is loaded via covered hatches


45


installed in top sheet


40


. Channel-shaped top cords


44


and bottom cords


46


extend along each upper and lower edges of body


32


. Crossridge frames


48


support top sheet


40


and side sheets


42


.




For the embodiment shown in

FIG. 1

, railway hopper car


30


has four hoppers


50


,


52


,


54


, and


56


. Front and rear hoppers


50


and


52


are formed in part by end slope plates


58


of car


30


, end structures


38


, transverse slope plates


60


and hopper side skirts


62


. Center hoppers


54


and


56


, which adjoin each other at transverse center line TC, are formed in part by transverse slope plates


64


and side skirts


66


. Each hopper


50


,


52


,


54


, and


56


has a rectangular discharge opening


68


at its lower end, discharge openings


68


being of similar size and shape and each being defined by a perimeter frame


70


.




Referring to

FIGS. 2-6

, an aerator tub assembly


72


may be bolted to frame


70


of each hopper


50


,


52


,


54


and


56


, and each aerator tub assembly


72


includes a top opening


73


. Top opening


73


is defined in part by a peripheral top frame


76


, coextensive with discharge opening


68


of the respective hopper. Frame


76


may be fabricated from specially formed angle sections, the legs of which are preferably attached to frame


70


. In another embodiment, aerator tub assembly


72


may be welded to frame


70


. Each aerator tub assembly


72


associated with hopper car


30


is preferably identical, and each aerator tub assembly


72


includes a plenum


75


and four aerator units


74


associated therewith.




Aerator units


74


are defined in part by inner and outer side slope panels


84


and


86


and aeration panels


83


. Aeration panels


83


are coupled with side support angles


78


and


80


associated with side slope panels


84


and


86


, respectively, with a number of mechanical fasteners


150


. Aeration panels


83


are also coupled to support angle


77


of plenum


75


with additional mechanical fasteners


150


. Transverse support angles


82


are attached to branch discharge piping


92


and secured to aeration panel


83


with round head mechanical fasteners


152


which do not obstruct outlet opening


88


of discharge piping


92


.




Air inlets


120


are provided within aeration panels


83


to facilitate the introduction of pressurized air or gas into car


30


. In the illustrated embodiment, one air inlet is provided within each aeration panel


83


. As discussed in more detail with respect to

FIG. 7

, one or more aerator cone assemblies


128


may also be incorporated into aeration panel


83


, as desired, to enhance the performance of the system during unloading.




In the illustrated embodiment, panels


84


and


86


are oriented at approximately fifty-five degrees with respect to a horizontal axis (not expressly shown). The slope of panels


84


and


86


, and the elliptical cutouts


87


disposed therein allow granular and powdered products to slide down panels


84


and


86


under the force of gravity, to the outlet opening


88


located at the bottom of each aerator unit


74


. Since car


30


is symmetrical about transverse centerline TC, and aerator tub assemblies


72


function similarly, the operation of hoppers


52


and


56


will be described in detail, for illustrative purposes.




Outlet openings


88


communicate with branch discharge piping


92


to provide a conduit for unloading the contents of aerator units


74


. Branch discharge piping


92


is coupled with main discharge piping


94


, which carries the contents of hopper car


30


downstream to product discharge piping


97


. Product outlet


99


is sealed during transport and later connected to additional piping (not expressly shown) in order to transport the product to a collection facility.




As mentioned previously, car


30


may be loaded with a bulk product (not expressly shown) which is typically in a powdered or granular state. Once the final destination is reached, car


30


may be unloaded quickly and easily according to the following sequence.




Compressed air or other suitable gas is provided to railway hopper car


30


through main air supply line


110


by connecting an air source at fitting


112


. In one embodiment, a flex hose or flex connection may be accomplished at fitting


112


in order to introduce air into car


30


. In order to unload hoppers


52


and


56


, with control valve


114


in the closed position, air is introduced to main air supply line


110


. When ball valves


116


are opened, air will charge branch air supply lines


118


. Air will enter railway hopper car


30


through air inlets


120


, and the pressure within railway hopper car


30


can be increased to a predetermined level, for example, fourteen and seven tenths pounds per square inch. Once this is accomplished, butterfly valve


122


within discharge piping


92


may be opened to allow product to flow through discharge piping


92


and into main discharge piping


94


, for downstream collection. To enhance the flow of product through discharge piping


92


and


94


, control valve


114


may be opened during the discharge procedure to provide a supply of air downstream of the flow of product as hopper car


30


is unloaded. Typically a pressure differential of


2


to


3


psi is maintained between railway hopper car


30


and main discharge piping


94


. This ensures the flow of product will remain continuous during unloading. Control valve


114


may be pre-set and/or modulated to maintain this difference in pressure.




Hopper


52


may be unloaded in a similar manner, by sealing ball valves


116


and butterfly valve


122


and opening ball valves


126


and butterfly valve


124


. Similarly, hoppers


50


and


54


may be unloaded using main air supply line


111


and main discharge piping


95


.




In order for the system to operate efficiently, the interior components of railway hopper car


30


must be properly sealed, including the associated discharge piping and valves. Aerator pad assemblies


90


provide a generally fluid tight seal between components of aerator tub assemblies


72


, and facilitate the introduction of air into hopper car


30


in a clean and efficient manner. Aerator pad assemblies


90


may be installed upon each aeration panel


83


to seal the joint between respective components, and to allow the flow of fluid through aerator pad assembly


90


, without allowing the contents of car


30


to become lodged within air inlet


120


.




As illustrated in

FIGS. 4-6

, aerator pad assembly


90


occupies the area between aeration panel


83


and respective support angles


78


,


80


,


77


and


82


. A gasket


98


associated with aerator pad assembly


90


, to be discussed in more detail with reference to

FIG. 9

, forms a fluid tight seal between aeration panel


83


and support angles


78


,


80


,


77


and


82


. Aerator pad assembly


90


is held in place in part by fasteners


150


and


152


, and partially due to the compression between aerator pad assembly


90


and support angles


77


,


78


,


80


and


82


.




Referring to

FIG. 7

, one or more aerator cone assemblies


128


may be provided within aeration panels


83


or units


70


to distribute the air flow through air inlets


120


more effectively and promote fluidization of product within hopper car


30


. Flow cones as manufactured by SureSeal and Solimar are suitable for use within the teachings of the present invention. Additional information regarding Solimar's Flowcone is available in U.S. Pat. No. 4,662,543. It will be recognized by those skilled in the art that the size, number, shape and configuration of air inlets and/or aerator cone assemblies associated with aeration panel


83


may be significantly modified within the teachings of the present invention.




Referring now to

FIGS. 8-11

, aerator pad assembly


90


includes an aeration pad


96


which is preferably formed from material or fabric which will allow pressurized fluid to pass therethrough, but block solid materials, including the product within railway hopper car


30


cannot pass therethrough. Aeration pad


96


covers the interior portion of aerator pad assembly


90


. Aeration pad


96


may be formed from fabric specifically selected with a woven density appropriate to prevent granular or powdered product which may be carried in hopper car


30


from passing therethrough. Other materials and fabrics are suitable for use in forming aeration pad


96


, provided the specific fluid contained within supply lines


118


may pass through, and the product within car


30


will not.




A gasket


98


is preferably disposed about the perimeter of aeration pad


96


to provide suitable surfaces for forming a fluid tight seal between aerator panel


83


and corresponding surfaces of support angles


77


,


78


,


80


and


82


. In the illustrated embodiment, elastomeric material used to form gasket


98


is preferably selected to allow suitable compression to form an airtight seal between metal components of aerator tub assembly


72


at a pressure in excess of fifteen pounds per square inch. For example, gasket


98


may be formed from a white, FDA approved food-grade polymer with a durometer of


50


-


60


. Other suitable compressible materials are available to form gasket


98


. For some applications, gasket


98


may be designed for pressure in excess of fifteen pounds per square inch and a fluidizing agent other than air may be utilized.




Aeration pad


96


at least partially occupies a portion of notched opening


106


of gasket


98


. Notched opening


106


allows aeration pad


96


to be “tucked” into gasket


98


forming an overlap therebetween. The size of notched opening


106


may be altered for various configurations. For instance, notched opening


106


may be provided with a wider and/or deeper dimension when a stronger bond is required. Depending upon the particular fastening technique used to join gasket


98


and aeration fabric pad


96


, adhesives, joint fillers, and/or sealants may be introduced into notched opening


106


to strengthen the bond, and prevent the formation of leak paths.




Aeration pad


96


includes perimeter


100


with a number of generally semicircular cutouts


102


contained therein. Cutouts


102


are sized and configured to ensure that aeration pad


96


does not intersect any portion of fastener openings


131


. Cutouts


102


form a gasket material/fabric interface with a number of protuberances


104


, formed within gasket


98


, extending therefrom. In the illustrated embodiment, cutouts


102


are a generally semicircular configuration. Various other configurations for cutouts


106


are available for use within the teachings of the present invention, provided aeration pad contact with fastener opening


131


is avoided.




The semicircular configuration of cutouts


106


increases the overall length of perimeter


100


of aeration pad


96


which provides a greater interface between gasket


98


and aeration pad


96


. Depending upon the fastening technique used to couple gasket


98


and aeration pad


96


, this may provide an advantage for the strength of the connection, and also minimize the vulnerability to leaks. For instance, if gasket


98


and aeration pad


96


are sewn together, this configuration provides a longer seam for stitching, which increases the strength of the bond. Similarly, if an adhesive material is used, the semicircular configuration provides a greater surface area to apply adhesive, thereby forming a stronger bond.




Protuberances


104


in gasket


98


provide a location for fastener openings


131


to avoid overlap of aeration pad


96


and fastener openings


131


. In this manner, any fasteners, including mechanical fasteners


150


and


152


, may be placed through openings


131


without penetrating or damaging the integrity of aeration pad


96


. This eliminates any potential leak path which could form through which pressurized air would escape if aeration pad


96


joined fastener opening


131


directly. Accordingly, the designed interface between any aeration fabric which incorporates a boundary gasket will not allow the leakage of air at this interface to any area outside car


30


. This facilitates the formation of a pressure vessel defined by components of car


30


. The teachings of the present invention eliminate any leakage of air on either side of the gasket surface including a direction transverse through the fabric and out through fastener holes.




In one embodiment, gasket


98


may be molded directly onto aeration pad


96


to form a single integral aerator pad assembly


90


. Alternatively, gasket


98


may be extruded and secured to aeration pad


96


. Many methods of securing aeration pad


96


with gasket


98


may be utilized within the teachings of the present invention. In one embodiment, an adhesive material (not expressly shown) may be placed within notched opening


106


to secure aeration pad


96


with gasket


98


. In another embodiment, one or more threads may be sewn through gasket


98


and aeration pad


96


to hold fabric


96


in place. In yet another embodiment, a sealant material may be applied to the interface of the aeration fabric and the gasket to fill and seal any voids present therebetween. The sealant material may be utilized in combination with any of the aeration pad and gasket fastening techniques.




An alternative embodiment of an aerator pad assembly incorporating teachings of the present invention is illustrated in FIG.


12


. Aerator pad


190


is generally circular in shape and includes aeration pad


192


with gasket


194


molded thereto. Fastener opening


195


are provided for attaching aerator pad assembly


190


to components of a railway hopper car. Aeration pad


192


is preferably molded to gasket


194


such that aeration pad


192


does not overlap fastener opening


195


.




There are many additional benefits to be derived from the teachings of the present invention. The molding process may be used to form a gasket on and into the fibers of the fabric or material used to form the associated aeration pad, thereby making the gasket an integral part of the aeration pad. Accordingly, the perimeter of the aeration pad may be shaped into nearly any configuration as desired for a particular application. Furthermore, the present invention allows the elimination of aeration pads in areas where mechanical fasteners and/or fastener openings are provided. By segregating the aeration pad and the fastener holes, leakage from transverse air movement through the aeration pad is minimized or eliminated. The molding process also removes the need to fasten the gasket and the aeration pad together.




Although the illustrated embodiment incorporates cutouts


102


in aeration pad


96


to accommodate fastener openings


131


, cutouts


102


are not required. Similarly, protuberances


104


, formed at the interface with cutouts


102


are not specifically required within the teachings of the present invention. If the width of gasket


98


is sufficient to completely surround fastener opening


131


, and aeration pad


96


does not contact fastener opening


131


, then potential leak paths are reduced and the efficiency of the seal between components is enhanced.




Another embodiment of aerator pad assembly


290


is illustrated in FIG.


13


. Aerator pad assembly


290


includes aeration pad


196


and gasket


198


disposed therearound. Fastener openings


231


are provided for attaching aerator pad assembly


290


between components of a railway hopper car. Aerator pad assembly


290


incorporates reinforcing supports upon aeration pad


196


. A central support


240


is provided near the center of aeration pad


196


. Additional perimeter supports


245


are provided at various locations upon aeration pad


196


. Supports


240


and


245


cooperate with each other to provide air flow paths under aeration pad


198


and prevent it from fully contacting aeration panel


83


. Radial lines are included in

FIG. 13

to illustrate one possible layout for supports


240


and


245


. It will be recognized by those skilled in the art that many other configurations of supports


240


and


245


are available for use within the teachings of the present invention. For example, the size and location of all supports


240


and


245


may be varied significantly.




In another embodiment, one or more supports may be provided in the form of “strips” rather than the spot application shown. Furthermore, supports


240


and


245


may be provided in various materials. The illustrated embodiment incorporates an elastomeric material similar to gasket


98


, to form supports


240


and


245


. Other potential materials include strips of aeration pad.




The teachings of the present invention are equally applicable to many applications, including an aerator pad assembly for a railway hopper car. Many filtration devices requiring fluid flow therethrough will benefit from the aerator pad assembly of the present invention. This includes many liquid and gas filtration devices and pneumatic vehicle outlets wherein a gasket-type seal is desired between components.




Although the present invention has been described by several embodiments, various changes and modifications may be suggested to one skilled in the art. It is intended that the present invention encompasses such changes and modifications as fall within the scope of the present appended claims.



Claims
  • 1. An aerator pad assembly, comprising:an aeration pad with a plurality of cutouts forming a shaped perimeter of the pad; a gasket disposed about the shaped perimeter, the gasket having a plurality of protuberances with fastener openings disposed therethrough, the protuberances sized to cooperate with the cutouts to form a generally continuous interface between the gasket and the pad; a notched opening within the gasket at the generally continuous interface; and the shaped perimeter of the aeration pad at least partially occupying a portion of the notched opening.
  • 2. The aerator pad assembly of claim 1, wherein the gasket is molded onto the pad.
  • 3. The aerator pad assembly of claim 1, wherein the gasket and the pad are attached by an adhesive material.
  • 4. The aerator pad assembly of claim 1, wherein the gasket and the pad are attached by stitches of thread.
  • 5. The aerator pad assembly of claim 1, further comprising a sealant material applied to the generally continuous interface of the gasket and the pad to seal voids between the gasket and the pad.
  • 6. The aerator pad assembly of claim 1, wherein the cutouts are generally semicircular in shape.
  • 7. The aerator pad assembly of claim 1, wherein the gasket is formed from an elastomeric material.
  • 8. The aerator pad assembly of claim 1, wherein the gasket is disposed between components of a railway hopper car to form a fluid tight seal therebetween.
  • 9. The aerator pad assembly of claim 1, further comprising a plurality of reinforcing supports attached to the pad.
  • 10. A railway hopper car having a plurality of hoppers with a pneumatic discharge system attached to each hopper, comprising:an aerator pad assembly; an aeration pad; a gasket molded onto a perimeter of the pad; and the gasket having a plurality of fastener openings disposed therethrough with the openings located outside the perimeter of the pad.
  • 11. The aerator pad assembly of claim 10, further comprising a sealant material applied to the perimeter of the pad to seal any voids between the gasket and the pad.
  • 12. The aerator pad assembly of claim 10, further comprising a plurality of reinforcing supports attached to the pad.
  • 13. The aerator pad assembly of claim 10, wherein the gasket is formed in part from a white, FDA approved, food grade polymer.
  • 14. The aerator pad assembly of claim 10, wherein the gasket has a durometer of approximately 50-60.
  • 15. A method for manufacturing an aerator pad assembly, comprising:forming an aeration pad with a plurality of cutouts which define in part a shaped perimeter of the pad; and forming an elastomeric gasket corresponding generally with the shaped perimeter of the gasket and having a plurality of protuberances which cooperate with the cutouts to form a generally continuous interface between the gasket and the aeration pad; and forming a plurality of fastener openings disposed in and extending through respective protuberances.
  • 16. The method of claim 15 further comprising attaching the gasket to the pad with an adhesive material.
  • 17. The method of claim 15 further comprising stitching the gasket to the pad using thread.
  • 18. The method of claim 15 further comprising applying sealant material to the shaped perimeter to seal voids between the gasket and the pad.
  • 19. The method of claim 15 further comprising molding an elastomeric pad formed from a white, FDA approved, food grade polymer.
  • 20. The method of claim 15 further comprising molding a gasket having a durometer of approximately 50-60.
RELATED PATENT APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/125,371, filed Mar. 18, 1999, and entitled “Aerator Pad Assembly for Railway Hopper Cars”.

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Number Date Country
60/125371 Mar 1999 US