CARGO PROTECTION DEVICES FOR RAILWAY CARS, METHOD FOR PRODUCTION, AND AUTORACK RAILWAY CAR

BACKGROUND OF INVENTION
1. Field of the Invention

The present invention relates to cargo protection devices useful for railway cars carrying cargo, and more particularly to protectors in the form of bumpers or guards for autorack railway vehicles that are used to transport automobiles, methods for their production, and railway autorack cars.

2. Brief Description of the Related Art

Railway cars are often used to carry cargo. There are specially designed railway cars that are used to transport automobiles, such as, for example, cars, trucks, vans, SUV's. The autorack railway cars typically have vertical sidewalls and may have multiple levels, such as two or three stacked levels that can contain vehicles, the levels depending on the rail clearances and the heights of the vehicles being transported. A number of vehicles may be transported in one railway car, from as few as two, to ten or more, and there are guidelines for loading vehicles. In some instances, the railroads purchase the rack structures, and the rack structures are installed on a flatcar of the railroad converting the flat car to an autorack car. In other instances, the autorack railway car may be a self-contained car having a structure of levels. In most cases, the autorack cars will typically have exposed support posts that are vertically disposed at intervals along each lateral side of the car. The autorack railway cars generally have screens on each side thereof which are the sidewalls. The screens have a plurality of holes provided therein for air and light, and are designed to protect against objects and debris that could otherwise damage the automobiles in transit.

The posts or struts that support the walls of an autorack railway car present a potential danger to the automobiles therein. Often, automobiles are loaded onto an autorack by a human driver who drives them onto the platform or level within the railway car (typically on a ramp leading to the autorack cargo entrance). In order to do this, the driver must open the door to exit the vehicle. This can present a problem should the door swing too far and contact the autorack sidewall or more likely the side post. Even where a driver is careful and does not open the door into a sidewall or post, in other situations, the automobile vehicle door may become dislodged and open during transport. In any situation where a door contacts the post or other structure of the autorack, there is usually damage, and repair costs can be substantial as the vehicles typically are new vehicles. While the new automobiles being transported usually have a protective wrap covering their exterior surfaces, the wrap does not protect the vehicle from engagement with the autorack interior structures.

A number of attempts to protect the automobile cargo traveling in an autorack railway car have been made. Some prior devices may be time-consuming to install and can be expensive to mount. Since typically a large number of autorack railway cars are configured at once, any delays in configuring them has the potential to hold-up loading operations, or require advanced efforts to install the protections. Some prior art devices may provide some protections, but still fail to protect some areas of the autorack railway car, leaving some structure exposed (such as a post or sidewall) and likely to cause damage to an automobile should an automobile door inadvertently contact the autorack structure sidewall or support. In addition, the existing door edge protection systems typically are placed in what are considered to be optimal locations to protect against as many different car door profiles as possible. While this type of general placement attempts to accommodate a number of door profiles, the prior art devices have been known to prove inadequate for some vehicles where an outermost contact point of the vehicle door is at an unprotected location and beyond the protections offered by the current devices.

Some examples of prior art devices and attempts to provide protections include US Patent application US 2002/067970 A1, which discloses a “Door Edge Protection System for Conventional Autorack Railcars”; U.S. Pat. No. 5,311,823 which discloses a “Bumper Seal For Auto Rack Car”; U.S. Pat. No. 5,762,001 which discloses a “Door Edge Protector”; and U.S. Pat. No. 5,527,139 which discloses a “Vehicle Door Protection System.

A need exists for devices and methods that can provide protection for automobiles being carried in an autorack railway car and which may be readily attached to and removed from an autorack railway car, and can be adjusted or positioned over the railway car structures.

SUMMARY OF THE INVENTION

Protectors and protector systems that are removably installable on a railway vehicle are provided. The protectors and protector systems are designed for use in a railway vehicle, and more particularly, in an autorack railway vehicle or rail car that has been configured with one or more levels and sidewalls to form an interior designed to receive and transport automobiles. The inventive protectors and protector system include mounts, and mounting hardware may be used to secure the protector in place. According to some embodiments, the mount may be provided as part of the protector. For example, according to some embodiments, the protector mount may comprise a fastener that is integrally provided as part of the protector, and allows the protector to be fastened to a structure of the railway car or autorack interior without the need for further fastening hardware or specialized tools. According to some alternate embodiments, the protectors may be secured to the autorack interior structures using separate fasteners (including commercially available fasteners). The separate commercial fasteners may be used alternatively or in addition to the integral fasteners of the protector. According to some embodiments, installation may be carried out with separate fasteners that attach the protector or portions of the protector to the sidewall or other structure of the autorack, fasteners that are pre-attached or integrally provided as part of the protector, or combinations of fastener types.

Preferred embodiments of the present protectors and protector systems allow removal and/or repositioning of the protector and components to provide protection at a suitable or desired location, allowing tailoring of the system and protectors to desired locations or relative heights.

Embodiments of the protectors are constructed from a material that if contacted by an automobile will not abrade or damage the door, paint finish, or other structure of the automobile. Preferred embodiments are constructed from a plastic material, and may be molded or extruded. Other suitable non-abrading materials may be used to construct the protector. Protectors also are suitably rigid, but yet have some resilience, so that the underlying structure of the autorack that the protector covers, such as, for example, a post or screen wall, will not be able to damage the vehicle, or, any potential damage will be minimized.

Preferred embodiments may be constructed to meet the requirements for door edge protection systems set forth in AAR specification M-991, or exceed these requirements where minimum thresholds are provided. For example, embodiments of the protectors and protector systems, including the fastening components or features, preferably are constructed from materials that if inadvertently contacted will not damage the painted door surface of an automobile, nor transfer any color or material to the vehicle door. In addition, the protectors and systems preferably have longevity and can last for a duration of at least 10 years while remaining full functionality to provide protection. The protectors and systems also are removable, and preferred embodiments provide replaceability for conservation and reuse of materials. Embodiments may be constructed from recycled materials and may themselves be recyclable, and which preferably pose no environmental hazards, nor any harm to the health or safety of personnel installing or operating near the devices. As a further safety aspect, the protectors and systems preferably are configured without sharp edges, in order to minimize the potential to catch on clothing of personnel and/or injure personnel passing or working nearby. The present systems also allow easy repairs or replacement should that be necessary, which can be done on site, or at shop or pool loading locations. According to some embodiments, fewer components may be used to construct a variety of protectors suitable for different spans of coverage. The protectors and systems also are designed and constructed to have sufficient strength to withstand expected contact with vehicle doors and/or personnel without becoming damaged or misaligned. The protectors and systems preferably are sufficiently strong so that they can have a minimal thickness that provides protection to the vehicles, while at the same time, minimizes potential intrusion into the cargo space of the rail car where the vehicle is loaded.

The protector preferably includes one or more protective surfaces or structures which provide a barrier of protection to protect the cargo, such as a vehicle door part, from contact with the post or other item of the railway car interior structure. Some preferred embodiments of the protector may include arcuate or radiused surfaces or structures, which, when the protector is installed, will protrude away from the autorack structure providing a contacting surface that sits in front of or above the autorack structure (e.g., post or sidewall). The inventive protectors allow some resilience or rebound when the protector is engaged by a vehicle part, such as an automobile door. For example, the resilience slows down the door by absorbing some or all of the force and transferring that force to the movement of the protector surfaces to compress. According to some preferred embodiments, the protector may include at least one, and preferably a plurality of outwardly positioned segments, such as longitudinal beads that may span the protector length. In the preferred embodiments, the longitudinal beads may be separated by a wall segment or joined by another connecting portion. Preferred embodiments are illustrated with longitudinal beads being adjacently disposed, but they could be provided in one or more other directions and/or arrangements.

According to some embodiments, the protective devices are provided so that they may be configured to meet the needs for the particular autorack railway vehicle, and/or satisfy the demand for the railroad, the customer, installer, or other person or entity that needs to procure and install the protective devices. For example, according to some embodiments, the protectors comprise a configurable section or portion that may comprise, or be supplied in, different lengths. According to these embodiments, a protector section, when assembled together with one or more other protector sections, forms a protector spanning a length. The protectors are designed to accommodate the structure on or over which the protector is being applied in order to provide suitable coverage at the height installed (e.g., over the surface of a post or other structure, to cover the post width at a desired post height). The protectors may constructed to be offset to account for posts and other mounting structures so that the protector covers the face of a structure as well as sides of dimensional structures, such as posts.

According to some embodiments, a protector may include one or more segments that are attachable to one or more other portions of the protector to provide additional width and coverage of protection. The one or more sections may be attached during production of the devices, or alternatively, they can be supplied and, in some arrangements, the protectors can be configured at or prior to use or installation. The assembly of a protector may be done prior to or after shipment, and preferably are configurable and reconfigurable to address the installation needs. According to some preferred embodiments, assembly of the protectors may be done manually and without the need for tools, and do not require the use of adhesives, welds or other time-consuming construction processes.

For embodiments where the protector devices are produced from a plurality of sections, the segments or sections may be attachable using a suitable fastening means. The fastening means may for example comprise separate fasteners such as push-in type fasteners, or, alternatively, may comprise an integral attachment feature where the section or segments attach using an integral locking mechanism. According to preferred embodiments, the fastener or integral locking mechanism is releasable and may be released to detach or remove the extension segment. The integral fastener provides improvements over the prior fasteners, since, unlike separate fasters, the integral fasteners will not be dropped or lost, and facilitate installation. The additional benefit reduces environmental resources, since in addition to convenience, according to some embodiments, the separate production fasteners may be reduced or even eliminated. The cost savings, both economic and environmental, may be realized by reduced resources consumption.

According to some embodiments, where the protector is configured to be constructed from a plurality of sections or segments, one or more of the sections may be provided having a track or guide that facilitates aligning the sections together for receiving the fastener that secures the sections, or for the integral lock to engage. The guide may comprise a track, slot, or other suitable alignment element. For example, sections that are configured to be connected together may include a guide that facilitates alignment of the sections, and preferably places the connectors, such as locking tabs, apertures, or other connectors, in alignment with one another so that the sections may be readily attached. According to some preferred embodiments, a method for producing the protector includes aligning the sections together, and securing the sections. According to some embodiments, the method also includes selecting a section having a particular length that will produce a protector having a desired length.

The protectors are configured to mount on the autorack interior, such as on the sidewall, post, roof rail or other interior structure. Embodiments of the protectors may include tabs for securing the protector to the sidewall of an autorack or other mounting structure of the railway car. For example, the tabs may be provided at each end and may be configured so they are offset from the central area or protective body of the protector. The tabs preferably are provided to mount the device to the autorack screen sidewall. In an installation, for example, the offset body may be distant from the sidewall and positioned over a post that is located in front of the sidewall (i.e., where the post protrudes into the autorack interior). The protective portions of the protector may cover portions of the front of a post as well as the sides.

Methods for producing and installing a protector and protector system on a railway vehicle, such as, for example, an autorack railway vehicle, are also provided. The methods include installation of the protector by inserting a portion of the protector configured to mount to an autorack structure into an aperture of the autorack structure (e.g., such as a side-wall or screen panel which typically have openings therein). The methods also may comprise assembling the protector to a desired length by selecting and attaching a section, and also may include constructing the protectors by actuating a self-locking component to join protector sections together. According to some embodiments, this may be accomplished by sliding and/or snapping together sections.

According to preferred embodiments, the system, devices and methods are configured to facilitate assembly of the protective devices, during production or installation, or both. The devices are configured to allow connections of the strap or device ends to an intermediate portion or portions. The connections between the device sections or portions, such as the end portions and the intermediate portion (or portions) preferably are removable connections. The connection that connects the one or more intermediate portions is releasable. According to some preferred embodiments, the connected together portions may be removable and re-attachable.

Embodiments of the devices that employ a releasable connection allow for one of the connectable parts of the assembly to be replaced without the need for the entire device to be replaced (for example, where damage has occurred to one of the components, such as when the components have been assembled together).

According to some preferred embodiments, the devices may be secured together without the need for welds, adhesive or other bonding agents and methods. The devices may be permitted to remain in the secured together condition, and released, or the secured together condition may be made permanent if desired.

For example, for manufacturing or installation, the devices may be connected together, and, according to some alternate embodiments, they may connect together using the methods and features disclosed herein, and may optionally be affixed to make a permanent connection.

Embodiments of the invention also provide an autorack railway car configured with protectors arranged to protect the automobiles transported therein from damage due to inadvertent contact with an interior structure of the autorack car (such as a post or sidewall). The protector provides a barrier between the post or sidewall and the automobile door, so that in the event a door is swung open too widely, it will contact the protector and damage will be prevented or minimized.

These and other advantages are provided by the invention. Features that are described and shown in connection with an embodiment may be used in conjunction with another embodiment.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a perspective view of a protector according to an embodiment of the invention, as viewed from the top right.

FIG. 2 is a side elevation view of the protector of FIG. 1.

FIG. 3 is a sectional view of the protector of FIG. 1, taken along the section line 3-3 of FIG. 2.

FIG. 4 is an enlarged partial view of the protector of FIG. 1, taken in the encircled area of FIG. 3.

FIG. 5 is a top plan view of the protector of FIG. 1.

FIG. 6 is an enlarged partial view of the protector of FIG. 1, taken in the encircled area of FIG. 5.

FIG. 7 is a sectional view of the protector of FIG. 1, taken along the section line 7-7 of FIG. 5.

FIG. 8 is an enlarged partial view of the protector of FIG. 1, taken in the encircled area of FIG. 7.

FIG. 9 is an enlarged partial view of the protector of FIG. 1, taken in the encircled area of FIG. 7.

FIG. 10 is a perspective view of a protector configured according to another embodiment of the invention, as viewed from the top right, showing the protector of FIG. 1, assembled with another section.

FIG. 11 is a perspective view of the protector of FIG. 10, shown in a partial assembly condition, with a section of the protector detached from another protector portion.

FIG. 12A is a top plan view of an intermediate portion of the protector of FIG. 10, shown separately from the other portions of the protector.

FIG. 12B is an elevation view looking at the end of the intermediate portion of FIG. 12A.

FIG. 12C is a perspective view of an intermediate portion of the protector shown in FIG. 10, shown separately from the other portions of the protector.

FIG. 13 is a perspective view of a protector according to another embodiment of the invention, as viewed from the top right, shown in a first condition where the first and second portions are connected.

FIG. 14 is a perspective view of the protector of FIG. 13, shown in a partial assembled condition, with a section of the protector detached from another protector portion.

FIG. 15A is a side elevation view of the protector shown in FIG. 14, shown with the section attached.

FIG. 15B is a sectional view of the protector shown in FIG. 15A, taken along the line 15B-15B of FIG. 15A.

FIG. 15C is a perspective view of an intermediate portion of the protector shown in FIG. 14, shown separately from the other portions of the protector.

FIG. 16 is a perspective view of a protector according to another embodiment of the invention, as viewed from the top right, shown in a first condition where the first and second portions are connected.

FIG. 17 is an enlarged partial view of the protector of FIG. 16, taken in the encircled area of FIG. 16.

FIG. 18 is an enlarged partial view of the protector of FIG. 16, taken in the encircled area of FIG. 16.

FIG. 19 is a side elevation view of the protector of FIG. 16.

FIG. 20 is an enlarged partial view of the protector of FIG. 16, taken in the encircled area of FIG. 19.

FIG. 21 is a partial view of the protector of FIG. 16, shown in an assembly view with a first portion of the protector shown detached from another portion of the protector, the intermediate portion seen in partial view.

FIG. 22 is an enlarged partial view of the protector portion, taken in the encircled area of FIG. 21.

FIG. 23 is a partial view of the protector embodiments of FIGS. 16 and 21, shown separately from the other portions of the protector, and representing a portion of the protector showing the end opposite of that shown in FIG. 21.

FIG. 24A is a side elevation view of the protector shown in FIG. 21.

FIG. 24B is a perspective view of an intermediate portion shown separately from the other portions of the protector of FIG. 21.

FIG. 25 is a sectional view of the protector shown in FIG. 24A, taken along the line 25-25 of FIG. 24A.

FIG. 26 is an enlarged partial view of the protector portion, taken in the encircled area of FIG. 25.

FIG. 27 is a front elevation view of a fastener.

FIG. 28 is a perspective view of the fastener of FIG. 27, as viewed from the top right.

FIG. 29A is a perspective view of an exemplary embodiment of an autorack railway car.

FIG. 29B is a perspective view showing the interior sidewall and floor of an autorack railway vehicle illustrated separate from the other wall and showing the protectors installed to cover posts.

FIG. 30 is a perspective view of an alternate embodiment of a protector.

FIG. 31 is a perspective view of an alternate embodiment of a protector, shown with the first portion separated from the second portion.

DETAILED DESCRIPTION OF THE INVENTION

Protective devices comprising of guards for use in an autorack railway vehicle to provide protection for the cargo, typically, automobiles such as cars, trucks and vans loaded into and carried therein are shown and described herein according to preferred embodiment illustrating the invention. Methods for producing the devices and for installing the devices also are provided.

Referring to FIGS. 1 to 9 there is illustrated an exemplary embodiment of a protective device according to the invention configured as the protector 110. The protector 110 is shown comprising a body 111 with a first portion 112, a second portion 113. Mounting tabs 116, 117 are shown respectively on the first portion 112 and second portion 113. The mounting tabs 116, 117 each are shown including apertures 120, 121, and 122, 123 respectively, for facilitating mounting of the protector 110 onto the autorack. A fastener (such as for example, the fastener 250 shown in see FIGS. 14, 27 and 28) may be used to secure the protector 110 to the autorack sidewall. An alignment wall 124 is provided on the tab 116 in order to prevent inadvertent rotation and potential dislodgment of the fastener from its mounting position. An alignment wall 125 similar to the wall 124 is provided on the second tab 117. According to some preferred embodiments, the fasteners (such as the fastener 250 of FIGS. 27 and 28) may be oriented with the fastener wider side installed in a direction parallel to a mounting tab 116, 117. This feature permits the fastener 250 to be co-located with the mounting tab 116, 117 and allows the mounting tab 116, 117 to have a slimmer width or profile. According to some other embodiments, the fastener 250 may be placed in a different orientation. Alternatively, the fasteners may be commercially available fasteners and/or may be configured to correspond with the tab dimensions.

The protector 110 may be expanded by joining an additional section or sections, also referred to herein as a portion or portions. This may be done by providing the protector 110 as a single piece and separating it, or providing a plurality of pieces, and assembling them together. Exemplary embodiments of the protectors and system are shown and described herein.

In the exemplary embodiment shown in FIGS. 1-9, the protector 110 is configured having a plurality of longitudinal wall segments, including the wall segments 112a, 112b provided on the first portion 112, and wall segments 113a, 113b, provided on the second portion 113. In the exemplary embodiment depicted, the wall segments 112a, 112b and 113a, 113b are separated by a joining area or wall 112c, 113c, respectively, and are shown raised from the respective joining wall 113a, 113b. The wall segments 112a, 112b and 113a, 113b comprise raised surface portions and are illustrated according to a preferred configuration having an arcuate or curved surfaces. The profile of the wall segments 112a, 112b is shown in FIG. 3, where the wall segments 112a, 112b are illustrated comprising longitudinal beads that are raised in relation to the wall segment 112c. According to preferred embodiments, the bead structures, such as the wall segments 112a, 112b and 113a, 113b preferably are formed by one or more walls having a thickness. According to some alternate embodiments, the bead may be formed from a solid material, such as a foam or other resilient substance. However, the preferred embodiments provide a wall thickness to reduce the amount of material used, and promote conservation. The longitudinal wall segments 112a, 112b and 113a, 113b preferably form a bend at each end of the protector 110 to provide protection from a structure that is dimensional, such as a post having a front and sides. According to a preferred embodiment, the protector 110 provides longitudinal wall segments 112a, 112b and 113a, 113b that span the front of the protector 110 and turn inward at each end of the protector 110.

The protector sections 112, 113 may be formed as separate sections, while according to some alternate embodiments the protector sections, they may be formed together, and then separated. FIGS. 10 and 11 depict the sections 112, 113 as separate units, which, for example, may be produced as separate individual components, or, according to alternate embodiments, may be produced as a unit, and then cut or separated into a first section 112 and second section 113. Embodiments of the protectors that are formed together and separated into one or more sections may have indicia indicating the location or locations where separation or separations may take place.

The protector 111 is shown in an exemplary embodiment having a bisecting line or groove 130. According to preferred embodiments, the groove 130 is provided on the underside of the protector 111 and spans transversely across the underside of the protector 111. According to a preferred embodiment, the transverse groove 130 is shown commencing at an edge 130a of the protector 110. The line or groove 130 may be visibly provided (on the top or underside surface), or 130 may represent the center section with no line or groove, depicting a location where, if separated, would form two sections (e.g., first and second sections 112, 113). According to preferred embodiments, the groove 130 is provided on the underside to facilitate cutting of the protector 111 (such as when desired to connect with an intermediate portion, for example, intermediate portion 131 shown in FIGS. 10 and 11). According to some embodiments, the indicia, such as the line or groove may comprise other suitable indicia such as perforations, or a row of apertures or fenestrations separated by material. The indicia, such as the line or groove 130, provides an indication of a location where the protector 111 may be separated or cut to form separate pieces or sections. The separation of the protector 110 may be carried out in order to configured the protector in a different length, such, as for example, by installing a section between the first and second sections 112, 113 (see, e.g., FIGS. 10 and 11, where an intermediate portion 131 is shown). The separation line or groove 130, although shown in a preferred embodiment at a central location, may be provided at a different location. The material of the protector 110 preferably permits separation of the protector (e.g., along the line or groove 130) by use of a conventional cutting tool, such as a saw, box-cutter, or other cutting implement. According to some embodiments, the protector 110 may be constructed without the separation line or groove, and the first and second sections may be provided together with a continuous surface, such that the longitudinal wall segments 112a, 112b and 113a, 113b join without a seam. The protector 110 may be used as a unit to provide protection (such as to cover a post or other structure of a rail car interior), or may be separated into a first section 112 and second section 113 for use with an intermediate portion. FIG. 30 illustrates an alternate embodiment of a protector 610 with mounting tabs 616, 617 having apertures 620 and 621 therein and the fasteners 623, 624 shown comprising a pair of flexible legs 623a, 623b, and 624a, 624b. The protector 616 has a pair of raised surface portions 626, 627, which are connected by a joining portion 625.

The embodiment of the protector 110 illustrated in FIGS. 1-9 is shown including a fastening means that provides the capability to secure an additional section, such as the intermediate portion 131 shown in FIGS. 10-12.

Referring to FIGS. 10-12, the protector 110 is shown configured in an alternate arrangement where the first portion 112 and second portion 113 are separated, which in the illustration is along the line or groove 130 shown in FIGS. 1-9. The first portion 112 forms a first connectable section and the second portion 113 forms a second connectable section. The intermediate portion 131 preferably has a first end 132 and second end 133, and includes a matingly associated connector 134, 135 at each respective end thereof 132, 133. According to the embodiment illustrated, the connectors shown on the intermediate portion 131 comprises receiving apertures 134, 135. According to preferred embodiments, the intermediate portion 130 preferably is configured to provide the raised surfaces or structures, similar to the wall segments 112a, 112b and 113a, 113b of the respective first and second portions 112, 113. According to a preferred embodiment, the intermediate portion 131 is shown comprising raised portions 136a, 136b.

Each connector 134, 135 is configured to connect with the first portion 112 and second portion 113, respectively. As illustrated in accordance with an exemplary embodiment, the body portions 112, 113 have self-locking connectors 137, 138 that are matingly configured to connect with the respective connectors, which comprise the apertures 134, 135 provided on the intermediate portion 131. The intermediate portion 131 is depicted as a single portion, but according to some other embodiments, although not shown, may be configured from a plurality of portions that connect together to provide different lengths for the protector 110. The intermediate portion 131 is shown separately in FIG. 12 having the apertures or recesses 134, 135 provided at each end, 132, 133. An intermediate portion 131 may be provided in different lengths, which when assembled together with the first section 112 and second section 113, provides a protector with a length of the combined sections 112, 113, 131.

According to an exemplary embodiment illustrated, the respective connectors 137, 138 provided on the first and second portions 112, 113, are shown comprising respective legs 140, 141, which are disposed in a respective opening 142, 143, and preferably are flexibly provided. The intermediate portion 131 has matingly associated connectors 134, 135 that connect with the legs 140, 141, respectively, to secure the intermediate portion 131 to the first and second sections 112, 113. The connectors 134, 135 of the intermediate portion 131 are illustrated according to a preferred embodiment comprising apertures or recesses that are matingly configured to receive respective bosses 150, 151 provided on each of the respective legs 140, 141 of the first and second sections 112, 113. Preferably, each leg 140, 141 has an attachment point 154, 155 and a free end, 156, 157. The legs 140, 141 are designed to flex so that the respective bosses 150, 151 are received in the respective apertures 134, 135 of the intermediate portion 131.

Flanges 160, 161 are provided on the first portion 112, and flanges 162, 163 are provided on the second portion 113. The respective flange pairs 160, 161 and 162, 163 are configured as guides that comprise channels or slots 164, 165 and 166, 167 to guide the edges 131a, 131b of the intermediate portion 131 into position within a first section 112 and/or second section 113 to facilitate engagement of the locking feature. Preferably, the sections may be slidably connectable, by aligning the edges of one protector portion with guide slots or channels, and sliding the protectors to engage the connector. For example, according to one embodiment, the intermediate portion 131 may slidably connect with the first portion 112, by aligning and sliding the intermediate portion edges 131a, 131b within the channels or slots 164, 165 of the first portion 112, and sliding one or both portions together to engage the connectors, such as the first portion locking leg 140 and intermediate portion connector, such as the aperture 134 (see FIG. 11). Conversely, the assembled protector 110 having the intermediate portion 131 also may be disassembled to remove and/or replace the intermediate portion 131, with a section of a different length. For example, once the initial protector has been separated into two separate portions (the first portion 112 and second portion 113), as shown, for example, in the illustration of FIG. 10, a connector, such as an intermediate portion, similar to the section 131, may be used to reattach the two sections (where the replacement intermediate portion 131 is shorter so that when attached, the protector length is or approximates the original length of the protector 110 (in the FIG. 1 condition) prior to the first and second sections 112, 113 being separated). For example, according to some preferred embodiments, the protectors shown and described herein, such as the protector 110, for example, may be produced by any suitable method, including, without limitation, extrusion, thermo-forming, and/or injection molding, or combinations of these methods. According to a further embodiment, as illustrated in FIG. 31, the protector first portion 112 is shown connecting to a second portion 113′, via the respective connector 137 provided on the first 112, which is shown comprising a leg 140 disposed in the opening 142, and preferably is flexibly provided. The second portion 113′ is configured similar to the second portion 113 shown in FIG. 10 but includes an extended or elongated body section comprised of the raised portions 113a′, 113b′. The mounting end of the second portion 113′ includes a mounting tab 117′ with apertures 122′, 123′. At the end opposite the mounting end is a leading end 113g′ having an connector aperture 113d′ (similar to the intermediate portion aperture 134 shown in FIG. 11). The configuration of the second portion 113′ allows the elongated body containing the raised portions 113a′, 113b′ to be provided having a variety of lengths, including for example, the same or different lengths (e.g., longer or shorter, or the same as the length of the first portion 112), allowing the first portion 112 to be combined and connected to the second section 113′ to form a protector. Similar to the intermediate portion 131 that connects with the first portion 112 and second portion 113 (as illustrated in FIGS. 10 and 11), the second portion 113′ shown in FIG. 31 preferably includes edges 113e′, 113f′ that are designed to be received within the guide slots 164, 165 of the first portion 112. The first portion 112 is preferably releasably connectable to and detachable from the second portion 113′. According to alternate embodiments and configurations, the first portion 112 and second portion 113′ may connect with an intermediate portion that connects to the first connector 137 and second connector, shown configured as the connector aperture 113d″. Although shown on the first portion, the guide slots may be provided on another portion that connects with the first portion, such as on the intermediate portion, and the first portion may have lateral edges that are received within the guide slots. The guides and channels that allow the sliding locking of the protector portions may be provided in different locations, such as for example, in a location apart from the lateral edge. The numbers of guide slots and channels also may vary, as there may be more or less than the two shown. Additionally or alternatively, the guide may be configured as a single guide or have alternate configurations. Additionally, or alternatively, a guide may comprise one or more slots, tracks or other suitable alignment elements. The guide facilitates alignment of the sections that are configured to be connected together, and preferably places the connectors, such as locking tabs, apertures, or other connectors, in alignment with one another so that the sections may be readily attached.

Referring to FIGS. 13-15C, another embodiment of a protector 210 is illustrated. The protector 210 is shown having a body 211 with a first portion 212 and second portion 213. FIG. 14 shows the first portion 212 and second portion 213 separated, with an intermediate portion 214 spanning between the first portion 212 and second portion 213. A separation groove or line 230 is shown, and preferably the line or groove 230 is provided on the underside of the protector. According to a preferred embodiment, the intermediate portion 214 preferably has raised surface portions 214a, 214b which align with respective raised portions 212a, 212b and 213a, 213b. A joining wall 214c is shown connecting the raised portions 214a, 214b. The intermediate portion 214, shown separately in FIG. 15C, has apertures 234, 235 and 236, 237 disposed respectively, at each end thereof. The first section 212 includes apertures 244, 245 and the second section includes apertures 246, 247. As shown in FIG. 14, the first section 212 and second section 213 connect with an intermediate portion or section 214 to form the protector 210 having an elongated length. The protector 210 is shown in a first condition in FIG. 13, where the first portion 212 and second portion 213 are connected, and in a second condition in FIG. 14 where the first portion 212 and second portion 213 are separated. The apertures 234, 235 and 236, 237 of the intermediate portion 214 align with the apertures 244, 245 and 246, 247 of the respective first and second sections 212, 213. A suitable connector connects the first and second portions 212, 213 with the intermediate portion 214. According to an exemplary embodiment, fasteners 250 are shown passing through the aligned apertures to connect the portions together.

Similar to the protector 110, the protector 210 includes mounting tabs 216, 217. Each mounting tab 216, 217 is shown including respective apertures 220, 221, and 222, 223, for facilitating mounting of the protector 210 onto the autorack by passing a fastener (such as the fastener 250) through the apertures 216, 217. The intermediate portion 214 may be supplied in different lengths to provide variations for the protector 210, so the protector 210 may be assembled, reconfigured, or produced to have the desired length.

The design of the protectors 110, 210, 310 permits standardized end pieces, such as the first portion 112, 212, 312 and second portion 113, 213, 313 to be provided as the end sections and have different protector overall length based on the length of an installed intermediate portion 131, 214, 314. The production of the protectors 110, 210, 310 preferably is facilitated by the design configuration where the end pieces are assembled together with the intermediate portion.

According to some embodiments, the protectors shown and described herein are self-mounting, and include mounting elements provided as part of the protector. In an exemplary embodiment, snap-legs are provided on each tab for facilitating press-fit or snap-fit installation to a panel wall of the autorack, such as, for example, by inserting the mounting elements into the apertures in the autorack screen sidewall. An exemplary embodiment showing the self-mounting feature is depicted in FIGS. 16-26, provided on the protector 310. Each mounting tab 316, 317 includes a fastener 321, 322, each fastener 321, 322 shown comprising a pair of flexible legs 321a, 321b, and 322a, 322b, respectively, with locking ends shown comprising barbed ends 321c, 321d and 322c, 322d, respectively, for mounting the protector 310 to the autorack sidewall. The autorack sidewall preferably includes a plurality of apertures therein allowing placement of the protector to be mounted at a variety of locations. Although the self-mounting feature is shown in connection with the embodiment depicted in FIGS. 16-26, the self-mounting feature may be provided in other protector embodiments, such as the protectors 110 and 210. The flexible leg pair 321a, 321b preferably are spaced apart so that they may converge during insertion into a receiving aperture of an autorack sidewall, and are biased so that once inserted, the legs return back to their separated position to provide a stop that retains the tab 316 and protector 310 on the autorack. Similarly, the second mounting tab 317 also is shown with the flexible leg pair 322a, 322b for securing the second tab 317 to the autorack wall. The distance along the leg where the locking end or barb is located preferably is sufficient to permit the passage through the sidewall thickness (of the wall to which the protector is being mounted), and to retain the protector, so that once the leg end is no longer restricted by the opening's boundary, the legs spread apart setting the locking ends. The protector 310 is also removably mountable from the autorack in the event it needs to be removed, repositioned or reused. The protector 310 may be removed after being mounted by releasing the leg pairs 321a, 321b and 322a, 322b. As shown in FIG. 18, fenestrations 365, 366 are provided in the tab 316 on opposite sides of where the leg pair 321a, 321b is located. The fenestrations 365, 366 provide access to the legs 321a, 321b to release them from engagement with a structure. For example, a tool, such as the jaws or nose ends of pliers (not shown) may be inserted into the fenestrations 365, 366 and brought together (clamped) to move the legs 321a, 321b toward each other to allow the locking ends 321c, 321d of the legs to pass through the structure to which the protector is mounted (e.g., such as the aperture of a sidewall or structure of the autorack railway car). Similarly, fenestrations preferably are provided in conjunction with the other self-mounting fasteners, such as the legs 322a, 322b of the mounting tab 317, where fenestrations 367, 368 are shown adjacent to and on opposite sides of the legs 322a, 322b (FIG. 19). Alternatively, the locking ends may be released from behind the wall (if there is suitable access), or by inserting a tool or pliers under the tab if there is sufficient access.

According to some preferred embodiments, protective devices according to the invention may be configured with a self-mounting fastener (such as the fasteners 321, 322), or alternatively, or additionally, may include both one or more self-mounting fasteners and another fastening or mounting feature, such as an aperture designed to receive a fastener (see e.g., fastener 250 shown in FIGS. 14, 15B, 27 and 28). As shown in conjunction with the protector embodiments illustrated in FIGS. 16-26, the apertures 361, 362 are provided, respectively, in the mounting tabs 316, 317. The apertures also may be provided in other protector embodiments, and preferably in the mounting tabs and/or intermediate portions.

An alternate configuration of a protector 310 is shown to secure the intermediate portion 314 to the respective first and second portions 312, 313. The first and second portions 312, 313 are shown in a separated configuration in FIGS. 21-24. The protector 310 may be provided in separate portions 312, 313, or alternatively, may be provided as a single item where the first and second portions 312, 313 are connected, and may be separated. For example, to facilitate separation, when desired or needed, a center line or groove 330a may be provided in the body 311, similar to the line or groove 130 appearing in FIG. 1, shown in FIG. 19 commencing at an edge 330a of the protector 310. The groove 330a preferably is provided on the underside of the protector 310 at a location or locations that divide the protector into the first and second sections. The respective first and second portions 312, 313 are shown having self-connecting fasteners 341, 342, 343, 344 provided on the first portion 312, and self-connecting fasteners 345, 346, 347, 348 provided on the second portion 313. According to some embodiments at least one connecting fastener is provided to connect each of the first portion 312, and second portion 313 to an end of the intermediate portion 314. In the exemplary embodiment depicted, the protector 310 is shown comprising a plurality of longitudinally disposed elongated beads 312a, 312b and 313a, 313b, respectively on the first portion 312 and second portion 313. In the exemplary embodiment shown, self-connecting fasteners 341, 342 are provided in the first bead 312a, and self-connecting fasteners 343, 344 are provided in the second bead 312b. As shown in FIGS. 21, 23, 24B, 25 and 26, the intermediate portion 314 is provided with apertures 351, 352, 353, 354, that are aligned with the respective self-connecting fasteners 341, 342, 343, 344 (FIG. 21). The self-connecting fasteners 341, 342, 343, 344, shown configured as snap legs, may be press-fit into the respective apertures 351, 352, 353, 354 of the intermediate portion 314 to connect the first portion 312 to the intermediate portion 314. Similarly, the second portion 313 includes self-connecting fasteners 345, 346, 347, 348 that connect to the apertures 355, 356, 357, 358 at the end of the intermediate portion 314 (FIG. 24B). Preferred embodiments also may include a release mechanism to release the self-connecting fasteners for removal of the protector from a mounting structure. According to some alternate embodiments, a release mechanism also may be provided or for disassembly of the protector sections from one another.

According to some embodiments, an optional feature may include fenestrations that provide access to the legs in order to release the legs from their engaging positions, in the event that sections of the protector 310 are desired or needed to be disassembled from each other (or reconfigured). Embodiments provide access openings near the fastening post that may be used to facilitate removal of the device or device portion. For example, a device portion may be disassembled by pinching the fasteners together to disable and/or release the snap fit.

Embodiments of the invention also include a railcar configured with one or more levels to receive automobiles therein, and transport automobiles via the rails. The railcar is fitted with the protectors shown and described herein, such as the protectors 110, 210, 310, 610. The railcars that transport automobiles are often referred to as autorack railway cars, or just simply autoracks, and typically are flat cars that have sidewalls and roof covers installed on them to protect the cargo in the interior space. The railcar also has one or more wheelsets, one or more decks for the automobiles (e.g., single level, bi-level, or tri-level). Automobiles are loaded into the autorack railway car (typically they are driven in) and the autorack transports the automobiles on the railway to a destination. The sidewalls of the autorack car are formed from a panel, such as a screen having apertures therein to which the protectors 110, 210, 310, 610 may be mounted. The autorack car includes a plurality of supporting posts that provide structure to the railway car, and which also support the sidewalls. The railcar interior structure is formed by a plurality of upstanding posts extending from the railcar frame. The railcar has sidewalls and a roof that protect the contents by blocking out debris and some weather elements. The upstanding posts are located on opposite lateral sides of the railcar and the sidewalls are also located on opposite lateral sides. An interior space for receiving the vehicles, and where the one or more decks are located, is provided between the lateral sides of the railway car, with the posts being disposed on each lateral side of the interior space, and sidewalls also being disposed on each lateral side of the interior space. The roof preferably covers the interior space. The protective guards of the invention discussed herein, are installed on the railcar interior to provide protection for automobiles to be transported. The protective guards are mounted to cover portions of the posts, sidewalls and/or other interior structures (rails or beams), and preferably are installed at pre-determined heights and positions to provide a barrier to unexpected contact with an automobile (e.g., such as a door swinging open). According to preferred embodiments, the protectors are mounted by attaching them to the sidewalls.

An exemplary embodiment of a railcar 500, configured as an autorack car is depicted in FIGS. 29A and 29B. The railcar 500 is shown to represent an autorack railway car. The railcar 500 is shown in FIG. 29B without the wheelsets, and without coupling apparatus which are standard components of a railcar that are commercially available and known, and shows the exposed interior portion and a base or floor (which is a single floor shown, while an autorack may have multiple levels, such as two or three levels, depending on the vehicle cargo being transported. In addition, the railcar interior is shown for illustrative purposes, and the heights, levels and positioning of the protection devices and shown in exemplary placements, and depending on the number of levels, post locations, and relative spacing and heights from the floor level and/or the anticipated location of the door swing, could be different than the locations shown. Protective devices 110 are shown installed on the autorack railcar 500, with 110′ and 110″ representing protectors having different lengths to provide suitable protection at the desired placement level or position. Placements of the protective devices 110, 110′ and 110″ may not represent the actual level or levels of the height position of the protection devices when installed in the autorack, but rather give examples or approximations of the levels where protection may be installed and shows the versatility of the protectors and system of the invention to provide protection at a number of suitable locations and positions. The railcar includes a base that serves as a floor or bed 501 and has a pair of upstanding end posts 502, 503, and, in the embodiment depicted, includes a plurality of upstanding intermediate support posts, for example the posts 504, 505. A second or third elevated floor also may be provided (though not shown). A sidewall 506 is shown, and may be configured from a plurality of panels 507, 508, 509 that are mounted to the posts, such as the posts 502, 503, 504, 505, and, in some embodiments also the base 501. The sidewall panels 507, 508, 509 preferably are screen panels, also known as side screens, that have a series or plurality of apertures therein 511. As discussed herein, the protectors of the invention, such as the protectors 110, 210, 310, 610, and 110′, 110″ (see FIG. 29B), mount to the autorack car 500, and preferably secure to the sidewalls 506, such as to the sidewall panels 507, 508, 509, and more particularly to the apertures 511 shown provided at a number of locations on the panels 507, 508, 509. The protective guards or protectors, such as 110, 210, 310, 610 and 110′, 110″, may be installed on the panels 507, 508, 509, and are shown covering a portion of the posts 504, 505 to provide protection from inadvertent contact by cargo, such as an automobile door. Other types of protective guards 550 also are shown in the autorack configuration to provide protection along the sidewall 506.

The protective devices 110, 210, 310 may be installed by securing the respective mounting tabs 116, 117; 216, 217; 316, 317 to the sidewall apertures 511. As shown in FIG. 29B, the protective devices 110, 110′ preferably are installed to span the width of the post 504, 505, and the protectors 110′, 110″ are shown provided to cover a portion of a frame structure. A suitable sized protector 110, 110′, 110″ (or 210, 310, 610) is configured and/or selected and installed to span the appropriate distance to provide coverage across the post or frame portion. In FIG. 29B, different widths of protectors are shown installed, demonstrating the versatility of the invention. In addition, the protectors of the invention may be used in conjunction with other types of protectors, such as side screen protectors as well as roof rail protectors.

The protectors provide a barrier between the automobile and the interior rail car structures. The protectors may be installed to cover a post, and provide a protective surface or structure between the post and an automobile in order to limit damage caused by an automobile door that may swing out and instead contact the protector. According to preferred embodiments, the autorack is configured with a plurality of protectors which are disposed at heights suitable to protect the automobiles from direct contact with a post by providing a protective barrier between the automobile door and the post. According to preferred embodiments, the protector has a resilient surface that is designed to absorb shock and forces to prevent damage to the paint finish and/or structure of an automobile, such as the automobile door that is swung open toward a sidewall or post. The autorack may include protectors that have different lengths (which, for example, may be mounted horizontally or diagonally across a post), so that the width of the post at the height above the floor or floor level at which protection is required can be accommodated. The protectors are configured with an intermediate portion to provide a suitable length to cover the post width. The system and methods of assembly and installation provide suitable protection at the desired locations in the autorack interior. The protectors are assembled and/or installed with an intermediate portion length that is suitable to cover the post width, and allow mounting of the protector (such as with the tabs at each protector end). According to some implementations and embodiments, protector sections may be produced separately. According to some other implementations, the protectors may be produced by having one or more protector sections formed together, and then separating the formed together protector sections into two or more sections. For example, as shown in connection with embodiments depicted herein, the first and second protector portions may be formed or otherwise produced together, and then separated if desired or as needed. This allows the protector to be used with the first and second portions forming each side or half of the protector. It also allows for the protector to be separated, through cutting or other separation technique into separate protector portions, so that one or more additional sections, such as an intermediate protector section may be connected with the first and second sections. The methods include separating the protector into sections, such as a first section and second section, and connecting the first and second sections to an intermediate portion to provide a desired length for the resultant protector. The intermediate portion and first and second protector portions include a connection for connecting the protector sections, which may be integral connectors, or separate connectors, such as fasteners. The protectors may be provided already assembled with the intermediate portion, or may be provided in a kit form to be assembled, or may be provided in the form where separation is optional, in the event desired or needed. The intermediate portions may be provided in different lengths as desirable to provide suitable protection for the span of the post or post frames being covered. In addition, although the beads are shown spanning the longer dimension of the protector, and intermediate portion, the beads may be provided in a different orientation, such as vertically oriented or in some other orientation. According to some embodiments, the intermediate portion may be provided as a plurality of intermediate portions, where two or more intermediate portions connect to each other, and/or to a first portion and/or a second portion, and may also connect utilizing the connectors shown and described herein. In addition, although the first portion and second portion are shown according to some embodiments formed by a single piece, and separated to form the first protector and second protector (such as the first portion 112 and second portion 113), according to some alternate embodiments and implementations, the protector portions may be formed independent of each other, as separate pieces. The protectors referred to herein may comprise a single portion or section, or may be comprised of a plurality of sections or portions in assembled together or unassembled conditions.

According to some alternate embodiments, protectors of the invention may comprise a body with mounting tabs disposed at each end thereof. The body may take any of the configurations shown and described herein, or may have alternate configurations that provide a protective surface structure that covers an autorack sidewall or support structure such as a post, that may readily self-mount using any of the self-mounting locking features shown and described herein. According to some embodiments, the mounting tabs preferably may be configured to include an integral fastening feature, such as, for example, the snap-legs shown and described herein. The protector may comprise a single structure with mounting tabs at each end, or alternatively, the protector may comprise a plurality of sections, such as two end portions connecting with an intermediate portion. According to some alternate embodiments, the connection between the end portions and the intermediate portion may be made using adhesive, welds, pins that are inserted into receiving apertures and are heat welded, or other suitable connecting mechanism. In these alternate embodiments, the mounting tabs include self-mounting fasteners, and preferably, the snap-legs shown and described herein in connection with the protectors shown in FIGS. 16-26, and the mounting tabs 316, 317. The embodiments illustrated with the snap-fit connectors connecting the intermediate portion to the first and second portions, although shown with the snap-legs provided on each mounting tab, according to alternate embodiments, may be configured with the apertures in the mounting tabs (such as those shown in the tabs 216, 217), or another suitable fastening element. The protectors that utilize the fasteners 250 (shown in FIGS. 27 and 28), according to alternate embodiments, may be configured with integral connectors or fasteners, such as the snap-fit legs shown and described herein in connection with embodiments disclosed.

The protectors shown and described preferably are constructed from a suitable material which may be a polymer having resistance to heat, cold and extreme weather conditions, as well as corrosion and UV radiation. The protector integral fastening features preferably are suitably strong to resist breakage when compressed together during mounting and released and held within the structure to which the protector is mounted, and also are resistant to heat, cold and extreme weather conditions, as well as corrosion and UV radiation. Some embodiments of the protectors may be formed from one or more sections, and include self-mounting fasteners that allow the protector to be mounted without the need for separate fasteners. The self-mounting protectors include protectors that have a single body section, as well as protectors that are formed by separate components that are assembled together (e.g., using welds, adhesives, fasteners or another connection). The protectors shown and described herein may be injection molded, and/or extruded, or produced using a combination of extrusion and injection molding. According to some embodiments, protector intermediate portions may be formed by extrusions, which may be separate extrusions or an extrusion that is separated into a plurality of intermediate portions. The first and second portions, whether formed together or separately, may be produced by any suitable manner. Preferred methods for the production and assembly of the protectors are disclosed herein. Features shown and described in connection with an embodiment may be implemented in other embodiments.

It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. Numerous other changes, substitutions, variations, alterations and modifications may be ascertained by those skilled in the art and it is intended that the present invention encompass all such changes, substitutions, variations, alterations and modifications as falling within the spirit and scope of the appended claims.

	Number	Date	Country
Parent	18528578	Dec 2023	US
Child	18611803		US

CARGO PROTECTION DEVICES FOR RAILWAY CARS, METHOD FOR PRODUCTION, AND AUTORACK RAILWAY CAR

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CROSS-REFERENCE TO RELATED APPLICATIONS

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